GTS 2

NMDC LIMITED
3.0 MTPY STEEL PLANT AT NAGARNAR
GENERAL TECHNICAL SPECIFICATION

(GTS)
VOL-II
MECON LIMITED
RANCHI - 834002
No. MEC/GTS/11/R2/Q6QZ/REV 2 MAR’ 2010

VOL - II
VOLUME CONTENTS
CHAPTER
DESCRIPTION
NO.
06 Material Handling Equipment
07 Civil Works
08 Air Conditioning & Ventilation
09 Painting
10 Fire Fighting
11 Architecture
12 Information Technology
13 Preferred Make
14 Hydraulics
15 Erection
NMDC LIMITED

FOR
MATERIAL HANDLING AND EQUIPMENT
(GS – 06)
MECON LIMITED
RANCHI - 834002

General Technical Specification
3.0 mtpy steel plant at Nagarnar
LIST OF CONTENTS FOR GS-06
SNo Chapter Chapter No No of Pages
1. CONVEYORS GS - 01 21
2. CRUSHER GS – 02 7
3. SCREEN GS – 03 7
4. VIBRO FEEDER GS – 04 3
5. VIBRATORY GRIZZLY FEEDER GS – 05 5
6. GATES (ALL EXCEPT DIVERTOR GATES) GS – 06 5
7. DIVERTOR GATES GS – 07 4
8. WEIGH HOPPER GS – 08 4
9. BELT WEIGH SCALE GS – 09 4
10. VIBRATION ISOLATION SYSTEM GS – 10 4
11. TRAVELLING TRIPPER & BUNKER SEALING GS – 11 5
ILMS – SUSPENDED MAGNETIC SEPARATOR & GS – 12
12. 9
METAL DETECTOR
13. CHARGING HATCH GS – 13 3
14. CRANES, HOISTS ETC. GS – 14 27
15. ELEVATOR GS – 15 14
16. TRANSFER CAR GS - 16 8
17. FORK LIFT TRUCK - ELECTRICAL GS – 17 5
18. FORK LIFT TRUCK - DIESEL GS – 18 6
VULCANISING M/C & MOBILE BELT-CHANGING GS – 19
19. 2
WINCH
20. PADDLE FEEDERS GS – 20 7
Chapter 06 Material handling equipment Page 1 of 152

© 2010 MECON Limited All rights reserved
GS – 01, CONVEYORS:
01.00 CONVEYOR SYSTEM & RELATED EQUIPMENT
01.01 Scope
1. The scope of work of the Tenderer shall include design, engineering, manufacture,
fabrication, assembly, testing and inspection, packing, dispatch, transportation,, delivery to
Purchaser’s site, unloading, handling and storage at site, erection supervision, testing,
inspection, commissioning, guarantee testing and handing over to the client including all
electrics and standard accessories of the following components for all the conveyors
indicated in the enclosed drawings.
i) Motors
ii) Gear boxes
iii) Couplings
iv) Pulleys with bearing blocks – head, tail, snub, bend and take-up
v) Conveyor belting
vi) Idlers – carrying, return, impact, self-aligning and transition
vii) Idler frames
viii) Belt cleaning devices
ix) Hold back devices
x) Brakes
xi) Pull-cord switches with cord
xii) Belt sway switches
xiii) Rotary level / position limit switches
xiv) Optical Sensors for detecting longitudinal rupture
xv) Pulse encoder, wherever required
xvi) Zero-speed switches
xvii) Chute jamming devices
xviii) Level indicators, wherever required
xix) Take up pulley frame with take up guides, weight etc.
xx) Bend pulley frame
xxi) Head pulley frame
xxii) Tail pulley frame
xxiii) Drive base frame
xxiv) Chutes with liners
xxv) Guards – tail pulley, bend pulley, coupling
xxvi) Discharge hood up to 500 mm below the discharge pulley platform / deflector
plate, wherever required
xxvii) Screw take – up, wherever required
xxviii) Skirt Boards with liners
xxix) Belt Weigh Scale – wherever required
xxx) Magnetic Separators/ ILMS wherever required
xxxi) Metal detectors wherever envisaged
xxxii) Sampling devices wherever envisaged
xxxiii) Hand-lamps for hood/ chute inspection
2. The scope of the Tenderer shall be deemed to include all such items which although are not
specifically mentioned in the specification, but are needed to make the equipment complete
in all respect for its safe, reliable, efficient and trouble free operation.

3. The scope of supply and services of the Tenderer shall include the following:
a) Mechanical
− Each equipment shall be complete in all respect including, its drive units, cables,
safety switches, structural, mechanical and other standard accessories.
− Provision of necessary fixtures, supporting angles and brackets required for mounting
and supporting the equipment.
b) Electrical
− LT AC motors and brakes with rectifier panels (in case DC brakes are envisaged) as
required for the equipment.
− Switches as necessary for interlocking and control and safe operation of equipment.
− Complete flexible cable festoon arrangement with protective chain, cable guide &
rollers, junction boxes etc. required for shuttle conveyors / carriages including power
& control flexible cables and their termination up to junction boxes. Junction boxes
for power and control supply shall be separate and shall be supplied by the Tenderer.
Any other mounted electrics that may be required for satisfactory operation and
maintenance of equipment supplied by Tenderer.
01.02 Design Basis & Hierarchy of Specifications
The equipment shall be designed as per design criteria given below:

Hierarchy of Specifications
a) Technical Specification
b) General Technical Specification (GTS)
c) Indian Standard (IS) and IPSS
c) Indian Electricity Rules & statutory requirements of Central Govt. and
State Govt.
Equipment complying with other recognised Standards such as IEC, BS, VDE, and IEEE
will also be considered if it ensures performance equivalent to or superior to Indian
Standards.
The components and materials used and the equipment supplied shall conform to high
standards of design, engineering and workmanship and shall be suitable for efficient
operation and reliable service in steel plant conditions.
Design Basis
Material characteristics (Tentative – Final in Technical Specification)
Material Size Bulk Density

Coal (indigenous) 0-100mm 0.8t/m3
Coal (Imported) 0-25mm 0.8t/m3
Iron Ore Lump 0- 30mm 2.0t/m3
Iron Ore Fines 0-10mm 2.2t/m3
Limestone, Dolomite 0-50mm 1.6t/m3
Mn Ore, Quartzite 0-75mm 1.6t/m3
Coke (Uncut) 0-300mm 0.5t/m3

Coke sized 0-80mm 0.5t/m3
Sinter 0-60mm 1.8t/m3
Sinter Mix 0-10mm 1.8t/m3
Calcined Dolomite, Limestone 25-50mm 1.2t/m3
Ferro – Alloy 0-30mm 3.0-5.0t/m3
− Utilisation of cross sectional area - 80 % of theoretical cross sectional area

indicated in IS 11592-2000 (for computation of belt speed)
− Design capacity of belt conveyors- 20% more than rated capacity to be

considered while calculating motor power and selecting belt speed and belt
width.
− Motor kW shall be selected with a minimum 10% margin over calculated

brake horse power (Power required at input shaft of gearbox)
− Troughing angle - 35o
− Friction factor (for kW calculation) of belt conveyors- 0.03
− Friction factor between belt and drive pulley : 0.275
− Belting
a) Top-cover thickness - 6 mm (min)
b) Bottom-cover thickness - 3mm
c) Actual Running tension < 80% of allowable belt tension
d) Starting tension <120% of allowable belt tension
e) Bottom and top cover thickness shall be 8/4mm for all conveyors
with length less than 25m.
f) Additional breaker ply shall be provided for belt feeders below
Wagon Tipplers.
g) Counterweight shall be chosen based on minimum 80% of full
load starting.
h) Actual running tension shall be calculated based on
counterweight provided.
− Idlers (Carrying, Self Aligning Carrying)

139.7mm Outer Diameter with 4.5mm (Nominal) shell thickness (for belt
with upto 800mm)
152.4 mm Outer Diameter with 4.85 mm (Nominal) shell thickness (for
belt with above 800mm)
− Idlers (Return, Self Aligning Return)
Two Roll V type 10˚ for 1400mm and 1600mm wide belts
Flat for conveyors upto 1200mm.
Diameter as per carrying Idler
− Idlers (Impact)
190mm Outer Diameter (for belt with upto 800mm)
205 mm Outer Diameter (for belt with above 800mm)
− Carrying idler spacing -1000 mm. Spacing in the convex curve position of
conveyor shall be limited to half the normal spacing of carrying idlers.
− Return idler spacing - 3000 mm

Flat type for belt width below 1400mm
− One set inverted ‘V’ type idler for belt widths above 1000mm and conveyor
lengths above 40m
− Training Idler spacing

a) Carrying side - 15 m
b) Return side - 30 m
− Impact idler spacing - 500 mm or less - (min. 6 Nos.)
− Impact pads shall be provided for material size of 100mm or more and also
below Wagon Tippler’s belt feeders and wherever material is received from
Stackers/ Reclaimers.
− Deck plate - 3.15 mm thick wherever specified
− Drive pulley –12 mm thk. vulcanized natural rubber lagging, minimum

durometer hardness of 55o shore A scale. Pulley Shell thickness16 mm
minimum.
− Tail/ Bend/take-up pulley – 10 mm thk vulcanized natural rubber lagging,

minimum druometer hardness of 45 o shore A scale, and shell thickness 12
mm minimum.
− Pulley face width - As per IS 8531-1986, Reaffirmed in 1993.
− Pulley Shaft – major shaft diameter upto 160mm- Rolled steel, class - 4 as per
IS 1875-1992 /EN9. More than 160mm- Forged steel, class-4 normalised as
per IS:2004-1992/EN9 Forged and nomalised
− Bearing / Pillow blocks

a) Material - Below 140mm dia cast iron Grade FG-260 & for
dia of 140mm and above cast steel
b) Bearing - Self aligning spherical roller bearing
c) Life - 40,000 working hrs min
d) Construction - Horizontal split type (one end fixed and the other
end expn. type)
e) 4 – bolt connection, preferably for all pulleys and compulsory for
drive pulleys
f) Only preferred sizes for bearing as per IPSS shall be chosen for
minimizing inventory
− Reducer
a) Service rating of 1.8 times the calculated shaft kW and thermal

capacity of gear box shall be better or 1.25 times that of motor
b) Casing Material - fabricated or cast steel
c) KW rating shall be not less than 1.25 times the motor kW. Higher
value of `a’ or `c'will be considered
d) No worm gear / open gears unless otherwise mentioned for gates

etc.
− Optical sensors shall be provided on belts with lengths above 300m to detect
longitudinal cutting of belts.
− Brakes
DC Electromagnetic type brakes shall be provided for all conveyors with a
coasting time equal to or more than 6s
− Sprag Roller type hold back device – integral with gear-box shall be provided
on all inclined conveyors to prevent roll back. Rating minimum 1.5 times the
maximum calculated torque.
− Take up
Screw take-up (with protected thread) up to 40 m conveyor length. Automatic
take up travels as per I.S. for conveyor length more than 40m. Horizontal take
up trolley shall be provided provided in tail pulley or in intermediate portion
shall be provided where vertical gravity is not possible. Counterweights shall
be metallic type.
− High speed coupling - gear coupling/ resilient coupling for drives less than 30
kW and Traction type Fluid coupling for drives of 30 kW upto 100 kW. Delay
filled chamber type traction fluid coupling for 100kw to 200kW (LT Motor)
Scoop type fluid coupling for all HT motors. Scoop coupling hydraulic fluid
shall be air cooled through radiator and fan and water cooling is not
permitted.
− Low speed coupling - gear or resilient.
− External scrapers
One number Multi sprung blade type (Secondary) & one number single blade
PU liner (Primary) with elastomount. All material scraped shall fall into main
chute.
Blade material for Multi sprung blade type – metallic blade with tungsten
carbide tips.
− Internal scraper
V shaped, mounted on carrier assemblies with elasto-mount and non metallic

polyurethane blade (min 10 thk.).
− Belt sway switch - At both ends and at 50 m interval (Approx.), min 1 pair for
each conveyor
− Belt slip and snap switch - away from the drive (1 No.)
− Pull cord switch - at 30 m interval on both sides for each conveyor, starting at
40m away from the drive end, minimum two pairs in each conveyor.
01.03 Belt Conveyor system
1. General

All equipment shall be designed, manufactured, supplied, erected, tested and

commissioned in accordance with relevant Indian Standards and International Standard
wherever applicable, in addition to the requirement mentioned herein.
The Supplier shall make his own calculation in respect of belt speed, motor kilowatt, belt
tension etc. of belt conveyors to ensure satisfactory performance of the conveyor
components and system as a whole. The drive motor selected shall not be of lesser kW
than what is indicated and the belting chosen shall not be of inferior quality than what is
specified. The starting torque of drive motor and the high speed coupling shall be so
chosen as to allow soft start condition.
Adequate no. of locating pins and match marking shall be provided for easy assembly and
dismantling.
Standardisation of components and assemblies shall be carried out to the maximum

possible extent to ensure interchangeability.
All equipment shall be designed such that all components are easily accessible for
inspection, repair and maintenance.
Profile of conveyors shall be such that it is lifted at the earliest to at least +6m of gallery
bottom level (above GL) and continues horizontally so that long conveyors do not block
access for trucks/ cranes etc.
All galleries shall be fully covered type unless otherwise is specifically asked for.
Clear walkway width for all single galleries shall be 750mm on one side and 1200mm on
other side, unless otherwise specified.
Clear walkway width for galleries housing multiple conveyor shall be 750mm on extremes
and 1000mm between two conveyors for belt width upto 1000mm and 1200mm for belt
width above 1000mm.
Antiskid bars shall be provided in gallery walkway portion with a slope of 6 to 12 degrees
and steps above 12 degree inclination.
Gallery shall be provided with a clear height of 2200mm above walkway, excluding
service lines and cable trays if positioned horizontally.
Seal plate shall be provided at bottom of all the galleries throughout the length of gallery.
Emergency escapes for over head galleries shall be provided with cross over where length
of conveyor galleries is more than 100m.
Underground Junction Houses shall be provided with sump pits sump pumps suitable for
draining out underground water to nearest drain. Tunnel shall be provided with drains on
both side and shall be covered with gratings and slope to evacuate seepage/ rain water to
drains.
Penthouse shall be provided where the tunnel comes out at ground level.
Height of gallery and tunnels shall have 2200mm clear height excluding cable trays,
service lines.

2. Conveyor Belting
Belting shall be designed for heavy duty condition and shall be suitable for 24 effective
working hour’s operations per day and 365 working days per year. It shall be suitable for
installation over conveyor system having 35o troughing angle and shall be suitable for
operation at an ambient temperature of 50oC. It shall have sufficient resistant against
exposure to open sunlight so that its qualities do not deteriorate while working in open
sun. It also may have to work in rain and / or in conditions where relative humidity goes
upto 100%.
The fabric for belting shall be of Nylon. The belting shall be pre-stretched, straight ply,
skin coated with open ends. It shall have sufficient strength to give required tension at 10
safety factor and 80% tension utilisation. All belts shall be joined by vulcanized splicing.
The belt shall have sufficient lateral flexibility so that it suits the troughing angle
requirements even when it is empty. The belt shall have sufficient longitudinal flexibility
so that it can easily flex around different pulleys of the conveyor system. The belt shall
have sufficient impact resistance to withstand impact at the loading points. The rubber
cover used in the top and bottom cover of the belting shall be of M-24 grade (Fire
resistant grade T1 for belts handling hot sinter, hot coke and coal). The edge shall be of
cut edge construction.
On the carrying surface, at interval of maximum 12 meters, the belting shall be marked as
follows:
a) Manufacturer’s name and trade mark, if any.

b) Fabric designation as NN
c) Belt designation i.e. KN/m
d) Code of rubber cover i.e. M-24 (T1 for hot Coke & Sinter and coal)
e) Last two digits of year of manufacturing.
Belt roll shall be packed in wooden drums. This packing should enable easy unreeling of
the belting. On the body of the wooden drum the direction of belt and location of end of
the belting should be indicated so that belting can be properly placed while unreeling.
The design, construction, testing and performance of the belting shall comply with all
applicable codes and as per IS, IPSS and International Standards.
Before dispatch, the finished material shall be subject to inspection by the

Purchaser/MECON. The inspection shall be carried out in the presence of
Purchaser/MECON, in terms of up to date engineering practice and relevant IPSS, IS and
International Standards in this respect, for which all facilities shall be provided by the
Contractor at his cost. This shall interalia, include the following:
a) Full thickness belt test
i) Breaking load, Kg/sq. cm for wrap and weft.

ii) Elongation under reference laod (%).
iii) Elongation at break (%).
b) Rubber cover test (Top/Bottom)

i) Tensile strength of cover , Kg/sq. cm

ii) Elongation at break (%)
iii) Adhesion between ply to ply and between covers and ply.
iv) Abrasion loss of rubber cover
c) Physical dimension check
d) Flexibility Test
All relevant type test certificates shall have to be produced during inspection and along
with supply for necessary verification and approval.
3. Conveyor Pulleys
All pulleys shall be of welded steel construction, stress relieved before boring and
machining and statically balanced. Solid end discs shall be designed and provided to give
maximum strength. Pulleys shall be designed as per relevant Indian Standard where
applicable. Pulleys shall be connected to the shaft through keyless friction grip
connections for all drive pulleys unless otherwise agreed. For all other pulleys, either
keyless friction grip connections or keyed connections may be used.
Drive pulley shafts shall be designed for running tensions with a dynamic loading factor
of 1.5 both in bending moment and torque transmitted. The maximum shaft deflection
shall be limited to L/1200 where L is bearing center distance and maximum deflection
shall be limited to 5’. Other pulleys shall be designed based on running tensions.
Shell thickness of the pulley shall be suitable for taking bending loads on the pulley. This
shall not be less than 16mm for drive pulley and 12 mm for tail and other pulleys. Pulleys’
shell below Magnetic separator shall be of non – magnetic stainless steel material with
min. 16 thk.
Drive pulleys shall be covered with minimum 12mm thick diamond rubber lagging. Tail,
bend and take-up pulleys shall be covered with minimum 10 mm thick plain rubber
lagging. The depth and width of the grooves in the lagging shall be 6 mm spaced at 30mm
interval. The eccentricity of pulley shell shall not be more then + 0.5% of the diameter
prior to lagging. Drive pulleys shall be machined at steel faces prior to lagging. Shore
hardness of rubber for drive pulleys shall be not less than 55 deg A and for other pulleys
shall be not less than 45 deg A. All pulleys shall be statically balanced to minimize the
vibration during running.
Rolled steel may be used for pulley shafts of diameter up to 160 mm. Forged steel shall be
used for shafts above 160 mm diameter.
Pulley shafts shall be supported on self-aligning double row spherical roller bearings with
adequate sealing and external lubrication arrangement in plummer blocks. One bearing for
each shaft shall be fixed to prevent any movement of the shaft assembly and the other
bearing shall be floating to have free axial movement. All lubricating nipples shall be
readily accessible without removing the guards.
Welding on the pulley shell shall be tested radio graphically or by ultrasonic method.
Pulley shafts shall be ultrasonically tested. Checking of out of roundness and static
balancing tests shall be carried out before dispatch of the pulleys.

4. Idlers
Three roll inline troughing idlers of equal length shall be used throughout. The angle of
inclination of side rollers to horizontal shall be 35o. Troughing as well as return idlers
shall be of reputed make and manufactured out of heavy duty ERW tubes as per
IS:9296-1983. Idlers shall be of “drop-in-slot” type. Minimum diameter of idlers shall
correspond to the value indicated under “Design Basis” under Chapter 04. Idlers below
magnetic separator shall be of non – magnetic stainless steel.
The eccentricity (diametrical run out) of troughing and return idlers shall not exceed + 0.8
mm. Minimum shell thickness of idler tube shall be 4.85 mm (Nominal dia). All idlers
shall be fitted with either heavy duty deep groove ball bearings or seize resistant ball
bearings. The bearings shall be held positively on the shafts. Multi-labyrinth seals shall be
used for retention of grease. All bearings shall be greased and sealed for life against
ingress of dust, water and escape of grease. All bearings shall be rated for minimum
40,000 working hours. Bearing housing of idler shall be made of pressed steel of CRCA
sheet press fitted and preferably be welded with idler tube.
Self-aligning troughing and return idlers with vertical guide rollers shall be of above
specified construction. All self-aligning idlers shall be provided with grease lubricated
anti-friction bearings at pivot points. All grease fittings shall be of the button head type or
equivalent and shall be accessible from the walkway side of the conveyor by piping. The
grease tubing shall be made of aluminum. The grease fittings shall have adequate
protection against dust collection.
Impact cushioned idlers shall be of above specified construction. The rings or disc for
impact idler shall be made of rubber. The minimum number of impact idlers at each
loading point shall be six. The first impact idler shall be placed approx. 150 mm behind
the loading point. Conveyor with multiple loading points shall also be provided with
impact idlers at each loading points.
Transition idlers of above specified construction shall be used adjacent to head and tail
drums to permit proper support of loaded belt near the head and tail pulleys without
excessive stress and stretch of the belt edges. The transition idlers shall be installed in
steps of 10o, 20o toughing angles.
Training idlers shall not be used close to belt-weighing scales.
Idler shaft shall be made of class -4, IS-1875 or EN-8, BS-970 or bright bar of equivalent
grade suitable for the duty requirement. Idler frame shall be made of rolled/ formed steel
with provision for securely bolting to the stringers of the conveyor frame. All fixing bolts
shall have spring washers.
Clearance, gap etc. for the carrying and return idlers shall conform to the relevant IS/IPSS
Standard to extent possible. The fixing arrangement of carrying and return idlers shall be
such as to permit adjustment of idler sets for the purpose of belt training. Allowance for
such adjustment shall be provided on both sides of the conveyor and the play shall not be
less than 10 mm on either side.
Pressure pulleys /live shaft idlers shall be provided wherever there is change in belt
profile i.e. after snub pulley, tail pulley.

All conveyor shall be provided with one no self cleaning idlers on return side near head
end. Reversible conveyors shall be provided with self cleaning idlers on both sides.
One set of inverted ‘V’ type idlers shall be provided on the return side.
Minimum Idler shaft diameter shall be as following:
Carrying / SACI : 20mm upto 1000mm BW

25mm for 1000mm to 1200BW
30 mm above 1200mm
Return /SARI : Same as carrying idlers
Impact Idlers : 30 mm upto 1000mm BW

35 mm for 1000mm to 1200mm
40 mm beyond 1200mm
The preceding and succeeding set of idlers from belt weigh station shall be of machined
type with out of roundness limited to ± 0.2mm.
All idler rollers shall be painted with 2 coats of red oxide primer and 2 coats of enamel
finish paint.
Following tests shall be carried at random on the assembled idler roller in the presence of
Purchaser / MECON:
a) Friction factor test

b) Idler running test at high speed.
c) Test for dust proof
d) Test for water proof
e) Quality test.
f) Alignment and co-axiality test.
5. Belt Cleaners
a) External belt cleaners
Two numbers of External belt cleaners shall be provided at the discharge pulley at each of
the conveyors including tripper pulley. The Primary scrapper shall be of Single blade PU
type and the secondary scrapper shall be Multi sprung blade type with metallic blades (in
segments) with tungsten carbide tips.
Polyurethene deflector skirts shall be provided below the tips to prevent materials build
up on the unit. The multi-blade cleaners shall be mounted on an elastomount system to
facilitate automatic blade adjustment on wear. The inclination of the blades should be
such as to effect efficient scrapping of the belt. The spring action of the individual
metallic blades should ensure constant contact with belt during operation and suitable
sprung deflection of contact with uneven surface of the belt. The blades shall be in
segments for ease of replacement and mounting on the head pulley frame. All material
scrapped should fall inside the discharge chute directly.
Reversible conveyors shall be provided with primary and secondary scrapper at both ends.

b) Internal scraper
`V'shaped internal scraper shall be provided on the upper side of the return belt near the
tail end, fitted with wear resistant non-metallic scraper blade to remove spilled materials
on the belt. The blade shall be adjustable after the wear. Reversible conveyors shall be
provided with diagonal scrapper on both ends.
6. Gear Boxes
Conveyors shall be driven through totally enclosed oil-cooled reduction gearing having
anti-friction bearings with oil seals at shaft projection. These shall be suitable for
continuous operation at full load and shall be suitable for shock loads. Wherever required,
oil temperature rise over ambient shall be restricted by 50o C (Max.). Worm gear/ open
gear or chain drive shall not be used. The reducers shall be selected with a service rating
of 1.8 times the calculated mechanical kW. The transmission efficiency of the gearing
shall not be less than 0.98 per stage. The material of gears, profile and geometry shall
ensure high power/weight ratio with low volume. Gears and pinions shall preferably be
solid forged. Where forging is not possible, forged steel gear rims shall be fitted on steel
centers to withstand shock loads. All reducers shall have permanent magnet plugs,
breather cap and oil level indicator.
7. Couplings
Flexible couplings shall be used between motor and gear-box and geared couplings shall
be used between gear-box and drive pulley. The hub and sleeves of the geared coupling
shall be of forged C-40 steel and bolts shall be of alloy steel. The hub teeth shall be of
triple vary crown design. Traction type fluid coupling shall be used between motor and
gear-box for drives from 30 kW to 100 KW, delayed fill chamber couplings shall be used
for drives from 100KW to 200KW and air cooled type scoop couplings for HT motors, in
combination with flexible connecting coupling. All coupling bolts shall be replaceable
without shifting of drive components.
8. Hold Back and Brakes with panel
All inclined conveyors shall be provided with suitable roller type hold back devices (other
than brakes) to prevent belt from running back in case of conveyor stoppage due to power
failure or otherwise. Holdback rating shall be minimum 1.5 times the maximum calculated
torque.
A.C Thruster type imported brakes shall be provided on all conveyors after calculating the
coasting time. Brake shall have min 1.5 times the max. calculated torque rating. Brakes
shall be mounted on input shaft end of gear box.
9. Take Up
All conveyors up to 40 meter in length shall have screw take - ups having protected
threads. Take-up travel shall be minimum 500mm. The screw of the screw take-up shall
be of square thread type and stainless steel construction with brass nut.
Automatic counterweight gravity take up shall be provided for conveyors above 40 meters
in length. Vertical gravity take up shall be provided wherever feasible. Horizontal gravity
takeup with takeup trolley and takeup tower shall be considered for conveyors where

VGTU is not feasible. Take-up travel shall be as per IS:4774 (part-I) and it shall be
complete with pulley carriage suitable for guide structure, sand pit and enclosures for the
pit. Counter-weight for Take up shall be cast iron metallic blocks.
10. Discharge Hood
Hood shall be made of 6mm thick mild steel plate for portion above the pulley frame. The
hood shall be in segments bolted to each other for ease of maintenance. The hood shall
cover discharge opening for the chute as well as pulley. Rubber curtain and guard shall be
provided at the entry of belt in the discharge hood. No direct impact of material on hood
wall shall be allowed. Baffle plates shall be designed in such a manner that discharge
material fall centrally on belt / hopper. Baffle plates shall be lines with 40thk natural
rubber having shore hardness-55 deg. suitable to take care of impact. Easily adjustable
baffle plates with liners shall be provided in the hood to control trajectory of materials,
whenever necessary.
The length of hood/chute shall be selected such that the first impact of material occurs
minimum 200mm below discharge pulley center line. Hinged inspection door shall also be
provided in the hood with hand lamp facility. The door shall preferably be located within
a height of 1200 mm from the floor or shall be provided with a platform. Adequate
openings with rubber curtain shall be provided in the hood for withdrawal and adjustment
of belt scrapers.
11. Chutes
All transfer points shall be provided with non choking chutes made of minimum 10 mm
thick mild steel plates with liners in all inside faces and shall be constructed in small
segments for easy dismantling.
Hinged type sealed inspection doors and flanged poking holes with bolt cover shall be
provided at suitable height and location. The size of the door shall allow replacement of
liners without any dismantling.
Chutes shall be designed such that impact of the material on the conveyor is minimum.
They shall be designed to ensure continuous flow of material to the centre of the belt with
minimum spillage, noise and dust emission.
Chute shall be designed such that the spillage from snub pulley and scrapped material
from belt scrappers fall inside the chute. The chute length at discharge area shall be such
that the first impact of the material trajectory is minimum 200mm below the discharge
pulley line. Minimum valley angle of the chute shall be 55 deg. to the horizontal.
Minimum angle of slope of chute plate shall be 60 deg. The valley angle and slope angle
shall be suitably increased for handling wet or sticky material.
Adjustable stone box shall be provided at discharge end of chute for arresting the free fall
of material and to form a natural bed of material for protecting the parent plate. Chutes
shall be oriented as far as possible so as to ensure discharge of material in the direction of
travel of receiving belt.
All chutes shall be provided with replaceable liners on all inside surfaces as follows:
- Coal : 6thk SS-409M

- Coke : : 20thk UHMWPE (6 thk SS 409M for hot coke

zone)
- Lump Ore : 40 thick Steel Backed Rubber
- Limestone dolmite 20 thk UHMWPE
- Blend Mix 20 thk UHMWPE
- Sinter : 20 thick SAILMA/SAILHARD
- Mixed Material 20 thk UHMWPE
12. Guards
Guards on the conveyor shall comply with the relevant IS/IPSS Standard. The guards shall
be of expanded metal conforming to IS: 412 (latest)
Safety guards shall be provided for all couplings, brakes etc. of the conveyor drive and
screwed on the above base frame.
13. Conveyor Frames
Conveyor frames shall be made of joists and/or channels suitably stiffened and braced.
The spacing of supports shall not exceed 3000 mm. Frames shall be connected to floor
beams/civil foundation of junction house by bolting. Conveyor stringers and short posts
shall be of minimum ISMC-125. For impact zones short post shall be of beam section of
minimum size ISMC 200. Short- posts shall be properly strengthened and adequately
braced to take lateral & longitudinal forces.
Short-post centers shall be as per relevant IPSS and as follows:
- 900mm for 500 BW

- 1050mm for 650 BW
- 1200mm for 800 BW
- 1400mm for 1000 BW
- 1610mm for 1200 BW
- 1810mm for 1400 BW
- 2060mm for 1600 BW
- 2300mm for 1800 BW
- 2550mm for 2000 BW
Short post within underground premises/ tunnel shall be installed on 150mm high
pedestals.
14. Deck Plates
Deck plates of minimum 3.15 mm thickness shall be provided throughout the length of
shuttle conveyor to avoid spillage of materials from the carrying side of belt on to the
return side. For other conveyors, loading zones (at least 15m), conveyor portion within
junction houses, 15m at discharge zone and at road/ rail crossings etc. shall have deck
plates.
15. Skirt Boards
Skirt boards of minimum 5000 mm length shall be provided at the loading points of all
conveyors. Dust-suppression system (DFDS / high pressure mist) shall be provided at all
transfer points. The skirt height shall be 600 mm (min.) and the skirt length after loading
shall be 1500mm (min) for fixing of nozzles and dust settlement. Wherever the loading

points are nearer to each other, the skirt board shall be made continuous between them.
Minimum length of skirt boards from the beginning of loading area in the chute shall be
2500 mm in the direction of belt travel. Skirt shall be totally covered where dust
extraction system is envisaged or when handling dry fine materials (-10 mm). The
thickness of skirt plate shall be minimum 10 mm. The top cover plate where provided
shall be minimum 3 mm thick. Skirt plates shall be provided with SAILMA/SAILHARD
liners 10 thk. (min.).
The arrangement for fixing rubber curtain and rubber on skirt boards shall be such as to
ensure quick adjustment. The thickness of rubber curtains shall be minimum 10 mm. Skirt
board sealing with PU block shall be considered.
16. Drive Base Frame
The drive unit consisting of motor, gear-box, coupling and brakes along with protective
guards shall have a common base frame and shall be fabricated form heavy structural
sections and plates. Suitable bracings should be provided wherever necessary on the drive
unit base frame and structure to make it rigid. Proper arrangements shall be provided with
gear-boxes and motors to maintain correct alignment with finish pads for mounting. The
drive base frames shall be bolted to the structural floor beams/civil foundation of junction
houses.
17. Reversible Shuttle Conveyors
Refer TS drawing showing the general arrangement of reversible shuttle conveyors.

Shuttle conveyors shall have independent drive for travel motion through electric motor
and bevel helical gearbox. Stringer frame for the conveyor shall be in segments
independently supported on wheels and connected together through hinged pins. Screw
take - up arrangements for the belt conveyors shall be positioned at one of the hinged
joints to avoid shifting of discharge pulley location in the discharge hood.
Double flanged parallel tread wheels shall run on flat bottomed rails of minimum 60
lbs/yd (or 60mm square bar) and shall have min hardness of 350 BHN. Cleaners shall be
provided to sweep the rail from spilled material. Anti-friction bearings shall be used
throughout. The travel drive shall be so designed that no part of equipment shall project
below rail level.
The belt conveyor shall be driven through motor and bevel-helical gear box. All other
stipulation for conveyor component as detailed above shall be applicable for the shuttle
conveyor.
The minimum clear distance between two adjacent shuttle / reversible shuttle conveyors
shall be 1000mm at any given position of the same.
Power supply shall be given through flexible trailing cable system. Separate tier shall be
used for power and control cables.
Position indicators shall be provided as per requirement of control logic. Roller lever type
auto – reset type travel / over travel limit switch at both ends shall be provided before rail
stop and end buffers.
Shuttle conveyors shall have a travel speed of 20m/min.

18. Belt Feeders
Belt Feeder shall be rugged construction having heavy duty flat belt, life sealed impact
idlers. Inlet opening to the feeder shall be equipped with a manually adjustable vertical
slide gate to adjust the depth of material in the feeder. The load area shall be skirted on
three sides. The width of belt shall be so chosen that material shall not rub with the side
skirt. Belt feeders shall have a normal drive and shall be driven with a variable speed
drive if specifically mentioned. Belt scrapers shall be provided to clean carrying as well as
return side of the belt. The maximum speed of belt feeders shall be limited to 0.5m/s. The
drive and tail frames, short post etc. shall be in partitions and bolted to each other to
facilitate mounting/removal of endless belt from sides.
19. Pull Cord Switches (Addressable type)
Pull cord switches shall be provided for emergency stoppage of conveyor. The first switch
shall be about 4000 mm away from the driving drum and subsequently at not more than 30
m interval. The pull wires shall run along the entire length of each conveyor on both sides.
Where mobile trippers are used on conveyors, the pull wires shall run along the hand-
railings on conveyor walkways. All pull cord switches shall have individual local
indication lamps to indicate when operated. Minimum 2 pairs of pull cord switches shall
be provided on each conveyor / feeder irrespective of its length.
20. Belt Sway Switches (Addressable type)
Belt sway switches shall be provided on each conveyor for protection against excessive
sway of the belt. A pair of switch shall be installed near the head end and a pair near the
tail end and a pair of switch shall be installed at 50m interval thereafter. A pair of these
switches shall also be provided before the belt weighing scales. Minimum 1 pair of belt
sway switches shall be provided on each conveyor / feeder irrespective of its length.
21. Belt Slip Switches
Belt slip switches shall be provided for each conveyor to stop the drive in case of
excessive slippage of belt or over speeding. Provision shall be made such that preceding
conveyor does not start unless the running conveyor picks up 80% of the rated speed.
22. Chute Jamming Detectors
Chute jamming detectors shall be provided on each chute. The detectors shall be so
located or protected that they do not come in contact with regular flow of material. The
detector shall, also, be protected against deposit of fine particles causing false alarm or
stoppage of the conveyors. The position of each detector shall be decided based on the
braking time of the delivery conveyor at rated capacity and the holding capacity of the
chute.
23. Motors
Totally enclosed fan cooled squirrel cage motors shall generally be used for all the above
mentioned equipment unless mentioned otherwise for speed control. Where power
requirement is more than 200 KW, HT motors shall be considered. Refer Electrical GTS
for further details.

01.04 Erection Norms
Erection of all equipment shall be carried out as per manufacturer'

s recommendation.
Manufacturer's standards and recommendations for tolerances in assembly and erection

shall be submitted to the Purchaser before actual erection of equipment.
Unless specified otherwise by equipment manufacturers, equipment shall be installed

within the tolerances indicated below:
a) Supporting structures for drive : In height 3.0 mm

pulleys, tensioning drum, In horizontal plane - 1/1000 of
intermediate frame, electric motor, length in mm
gearbox & idler supporting
structure.
b) Driving pulley : 1/1000 of length of pulley in
vertical plane.
c) Axis of conveyor & center line of : 10 mm in horizontal plane
drum.
d) Tension pulley : + 2 mm in vertical plane
+ 2 mm in horizontal plane
e) Idler arrangement : + 2 mm in vertical plane
+ 2.5 mm in horizontal plane
f) Rail mounted equipment like : 2 mm /m of rail
trippers, shuttle conveyor 5 mm/ 25 m of rail
etc. in longitudinal direction of the 15 mm Max.
same rail
g) Rail gauge : + 5 mm
h) Difference in rail level with : + 1 % of rail gauge for rigid
respect to one another base +2% of rail gauge for flexible
base
i) Difference in height of connecting : < 3 mm
rails at joints
j) Horizontal gap between rails at : < 3 mm
joints
k) Location of end stopper (in plan) : + 1% of gauge but max 20 mm.
with respect to one another
l) Deviation of rail in plan with :

+ 10 mm but shall not exceed + 1
respect to true line mm in 2 m length
m) Tilt of rail in horizontal : + 8% of rail head plane width
n) Deviation in conveyor centre line : 2 mm for 1 m length , 5 mm for 2
m length but 15 mm max for
total length
p) Absolute bearing vibration velocity r.m.s. for rotating machines (to be
measured by vibration measurement instrument )
i) Up to 15 kw : Less than 0.7 mm/sec
ii) Up to 300 kw : Less than 1.1 mm/sec
01.05 Performance Tests & Guarantee Parameters
I. After the equipment are completely erected at Purchaser’s site, each item/ equipment
will be thoroughly inspected for correctness and completeness of the installation and
they shall be subjected to final tests as to performance and guarantee to be carried
out in the presence of Contractor and the Purchaser / MECON to demonstrate that the
performance of the equipment conforms to relevant standards and specifications and
meet the requirements as given in this specification. The tests/ checks to be conducted
shall be generally as under :
II. For each equipment, the load test shall be conducted in stages. The equipment shall be run
for 8 to 10 hours continuously (cumulatively) at no load, 25%, 50%, 75%, 100% of
the rated capacities or at rate mutually agreed upon between Contractor and Purchaser
/ MECON. The intervening period shall be available for making adjustments and
arrangements by the Contractor as may be required.
III. All the specified speeds of the equipment shall be measured under full load conditions.
IV. Proper operation of all positional limit switches for shuttle conveyor and all safety
switches for cable reeling drums, limit and safety switches/ alarm for conveyors like
pull cord switch, zero speed switch, belt sway switch etc. shall be demonstrated by the
Contractor in the presence of Purchaser / MECON.
V. During operations of the equipment at no load and at full load, performance of all the
drives shall be checked in respect of current drawn by the motors, temperature rise,
vibrations, gear box noise and its heating, bearing heating etc. consumption of power and
various consumptions like lubricants etc. shall also be measured and compared with the
respective rated values.
VI. Any other observations/ tests felt necessary for judging the performance of the
machines and mutually agreed between Contractor and Purchaser shall be carried out.
VII. If during the test runs, there is an interruption exceeding 2 hours due to any cause other
than power failure or shortage of input materials for which the Purchaser is
responsible, the test run shall be discontinued and fresh date shall be decided mutually
by both the parties.
VIII. The equipment shall be considered to have performed satisfactorily when
i) Rated capacity of equipment is demonstrated with all its drives and accessories
functioning properly over a minimum period of eight (8) hours.
ii) It runs successfully for a continuous period of 15 days (18 hours per day) at the
rated capacity, or at rates possible due to availability of material.
iv) Successful reversing of reversible shuttle conveyors (if any) on load.
01.06 Drawings / Document / Information to be furnished by Tenderer
The number of copies of drawings/ data and other documents shall be as per General
Technical Specification (GTS).
1 List of drawings /data to be submitted along with tender
a) General arrangement drawing of conveyors/ shuttle conveyors etc. showing overall

dimension, profile, idler spacing, take-up arrangement, motor kW, drive arrangement etc.

along with chutes, scrapper, skirt boards, switches, wheel load, wheel spacing, wheel
diameters, travel drive, power supply arrangement for travel drive etc.
b) General Arrangement of conveyor-equipment showing overall dimensions and weight as

well as GA of motor with its component list.
c) Supplier'
s name for conveyor components (like idlers, pulleys, motors, and gearbox)
catalogues for these items shall be furnished.
d) List of commissioning spares proposed by the Tenderer.
e) List of recommended spares for two years maintenance of plant and equipment along with
itemised price.
f) Duly filled up questionnaire given below.
g) List of imported components in the equipment, if any.
2 List of drawings to be submitted for approval (by successful Tenderer)
Following design data, calculations and drawings shall be submitted by the Successful
Tenderer to the Purchaser / MECON in stages for approval.
- Design basis reports

- Profile drawing / general arrangement of conveyor with all Technical parameters
- Arrangement drawing of all Junction Houses, Bunker Buildings, Crusher/ Screening
Houses etc. clearly showing all equipment within with clearance dimensions, center
dimension etc.
- All the drawings/ data listed in clause above, giving all the details, loads/ power
requirement etc.
- Calculation/ Selection of motor kW, gear box, brakes coupling and pulley selection of
belt conveyors, shuttle conveyor and belt feeders, mobile tripper.
- Technical parameters of belt conveyor, belt feeders and shuttle conveyor in a
tabulated form.
- Schedule of idlers, belting, pulleys, drive components such as motor, gear box, high
speed coupling, brake etc. including details of belt weigh scale, magnetic separator,
sampler etc. as applicable.
- In addition to the above, the Purchaser/ Consultant reserve the right to insist on
submission of calculations/ drawings/ data for any mechanical, structural or electrical
equipment/ component as required.
3 Drawing/data/calculation for reference (by successful Tenderer)
- Load data and foundation pedestal plan for head end, tail end, drive base frame etc.,
specially where the Junction House/ building is provided by another supplier/
purchaser.
- Wheel load diagram for shuttle conveyors.
- Any other load data/information required by Purchaser / MECON for design of

building/ structures.
- All drawings and documents approved by Purchaser/MECON as per GTS.
- Procedure for testing and commissioning. This shall also be furnished in soft copy.
- Spare part list and drawings
- Catalogues/literatures
- Operation and maintenance manual.
- Final test certificates
- As built drawings
- Ordering specifications for operating consumables/ supplies
01.07 Questionnaire (To be filled by by Tenderer)
The Tenderer shall also furnish the following questionnaire and submit with his offer. This
data shall form a part of the contract with Successful Tenderer.
• General
01 Name and address of the Tenderer :
02 Previous experience of the Tenderer :
03 List of similar equipment supplied :
04 Whether the Tenderer has any technical :

Collaboration with any other company/
organisation for his equipment.
05 If answer to question .04 is yes, furnish :

the following details.
a) Name and address of the

collaborator
b) Nature of the collaboration in
detail
c) Previous experience of the
collaborator
06 List of drgs./ literatures enclosed with :

the offer.
Questionnaire for conveyors
i) Conveyor no. :
ii) Carrying capacity (t/h) :
(Rated/ Design)
iii) Centre to centre horizontal :
distance (m)
iv) Belt width (mm) :
v) Belt speed (m/s) :
vi) Total weight of conveyor (kg) :
vii) Pulley details :
Followings to be indicated for head, bend, snub, tail, take-up pulleys separately :

a) Make :
b) Pulley diameter (mm) :
c) Face width (mm) :
d) Shell thickness (mm) :
e) Bearing
- Make :
- Expected life (hrs) :
f) Weight (kg) :
viii) Belting
a) Designation
b) Cover thickness
c) Cover Grade
ix) Brakes
a) Type
b) Torque rating
c) Brake drum dia
x) Idlers :
The following to be indicated for carrying, cushion, return, SACI, SARI and
transition idlers:
a) Type (in-line / off set) :

b) Diameter (mm) :
c) Shell thickness (mm) :
d) Tube specification :
(ERW / Seamless)
e) Max. roll eccentricity (mm) :
f) Troughing angle :
g) Bearing Dia :
h) Weight (kg) :
xi) Motors
a) KW rating :
b) RPM :
c) Type :
xii) Gear Boxes for belt drive and carriage travel

a) Make :
b) Type :
c) Reduction ratio :
d) Mech kW rating (kg-m) :
e) Overall efficiency :
f) Wt. of Gear box (kg) :
g) Hold Back considered
h) Type of hold back
xiii) Couplings
a) Make, type and rating of high :
speed couplings

b) Make, type and rating of :

low speed couplings
c) Weight (kg) :
xiv) Take-up type & travel :
xv) Belt cleaners – Make, type & Quantity :

− Weight (kg) :
xvi) Pull chord switches :

(no. of pairs )
xvii) Belt sway switches (no. of pairs ) :
xviii) Zero Speed Switches :

xix) Brakes
a) No. and location :
b) Brake drum diameter (mm) :
c) Torque rating (kg-m) :
xx) Skirts
a) Length &type of skirt :
(conveyorwise)
b) Type of liner & its thickness :
c) Sealing and lock provided : Yes / No
d) If sealing & lock provided :
then type & material details
xxi) Impact pads
a) Make of impact pads
b) Length considered
c) No of rows considered
d) Total width of pad
e) Material of pads and thickness
f) Coefficient of friction

GS – 02, CRUSHERS:
02.00 SCOPE OF WORK
1. The scope of work of the Tenderer shall consist of design, engineering, manufacture,
inspection, assembly shop testing, painting at manufacturer's shop as well as at site after
erection, packing, loading and transportation, supply at site, erection, testing and
commissioning of crushers & vibration isolation system (if required, refer chapter GS – 10
of this GTS).
The crusher shall be complete with individual drive, hydraulic system (wherever
applicable), lubrication/ greasing arrangement and the control, wiring, panels, local
control box etc. as per specification.
2. Complete erection and commissioning of crusher and vibration isolation system including
prestressing of vibration isolation elements, placing of elements in position, checking
clearances in the shuttering of the RCC top deck, releasing of prestress in spring elements
and making final adjustments and alignments after machine installation etc. including all
grouting as required.
3. All fixing bolts& nuts including foundation bolts, brackets, supporting structures shall be
included in the scope of supply of Tenderer.
4. All civil works, grouting of foundation bolts chipping, making holes or pockets, if any
required for fixing crushers base plate, inserts etc and finishing work after chipping shall
be in the scope of the Tenderer.
5. Spares for two years trouble free operation of each equipment. Lists of such spares along
with item wise prices shall be furnished.
6. Required quantity of initial fill of oil, grease, lubricants, hydraulic fluid etc. and other
consumable which are necessary for cleaning / flushing including erecting, testing and
commissioning the crushers.
7. Necessary tools and tackles for each crusher required for maintenance, testing or
inspection of the crusher or any of the installations on it List of such spares shall be
furnished along with the quotation.
8. All miscellaneous items and spares required for commissioning of the crushers. The list of
such spares shall be furnished along with the quotation.
9. Supply of insurance spares along with their list for each equipment.
10. All electrics/ electrical equipment as indicated under relevant clauses.
11. Statutory approval wherever required shall be taken by the Supplier for the equipment
being supplied by them from relevant state/ central authorities.
12. The equipment supply shall be complete in all respect including its structural, mechanical
and electrical components and standard accessories such as hydraulic system for cage
door opening, Roll Grinding attachment for Roll Crusher, Vibration isolation system of
spring with damping pad for swing hammer reversible impactor/ Ring Granulator etc.

All items essential for the desired operation of the equipment, whether specifically
mentioned in this specification or not, shall be included in the scope of work the Tenderer.
13. The scope of work shall stand supplemented by such details as are given in this
specification/ tender specification drawing, Instruction to the Tenderer, general conditions
of contract or any other part of the tender document.
02.01 TECHNICAL SPECIFICATION

For all types of crushers design capacity shall be considered as 120% of rated capacity for
selection of drives.
02.01.01 Roll Crusher
• The Roll Crushers shall be of robust construction and suitable for ease of maintenance.
The housing shall be of welded construction with individually driven counter rotary
crushing roll arrangement housed in a M.S. fabricated body. The frame shall be equipped
with renewable, abrasion resistant liner plates of adequate thickness
• The diameter of rolls shall be selected such that the occasional oversize material does not
slip.
• The gap between the crusher rolls shall be adjustable and the rolls mounted on hydraulic
actuator operated support.
• One roll shall be fixed and other floating roll shall be hydraulically positioned to increase
the gap automatically in case of any unwarranted presence of hard material like tramp,
scale, stone etc. After the passage of the hard material the gap shall automatically come
back to its original gap.
• Automatic gap adjustment of roll shells shall be provided.
• Roll shell shall be of replaceable type and made of chrome molly alloy steel.
• Hydraulic cage door opening without dismantling of feed chute to be provided for ease of
maintenance.
• Automatic roll grinding system shall be provided for turning each crusher top & bottom
rolls.
• The shaft shall be supported on antifriction bearings.
• Direct drive through fluid coupling and gear box / V - belt shall be provided for driving
the rolls.
• Centralised grease lubrication system shall be provided.
• Product analysis curve shall be provided justifying the selection of proper crusher.
• The crushers shall be designed so as to eliminate vibration when machine is running. The
crusher shall be mounted on vibration isolation system with continuous vibration
monitoring system, bearing RTD etc.

02.01.02 Swing Hammer Reversible Impactor
• The swing hammer reversible impactors shall be of robust construction and suitable for
ease of maintenance. The housing shall be of welded construction. The frame shall be
equipped with renewable, abrasion resistant liner plates of adequate thickness. The
hammers of the impactor shall be fitted to the disc mounted on the rotor shaft and inner
surface of impactor shall be provided with replaceable breaker plates. Life of hammer
shall be min. four lakh tonnes of material crushed. The crusher shall be provided with
arrangement for setting the required product size by suitable means.
• The casing shall be split type and able to be easily opened hydraulically for inspection and
maintenance. Casing shall be able to be opened without dismantling the feed chute.
monitoring, bearing RTD etc.
• Suitable wear resistant lining of operating life minimum 2 years shall be provided in the
housing.
• Material for the beater heads & grinding gibs shall be annealed chrome molly steel.
• Power transmission to the crusher shall be complete with V -belt drive, which includes
motor, sheaves, drive sheaves, fluid coupling, belts and guards, motor base, pedestal
bearings, hydraulics & other necessary items. The hammer shall be reversible.
• All bearings shall be provided with adequate dust seals & the bearing shall preferably be
of spherical / taper roller type. Protection hood shall be provided for coupling.
• All the parts shall be easily accessible for maintenance and repair. Inspection door shall
be provided wherever needed. The drive unit shall ensure smooth starting & running.
Extra insulations shall be used to limit the noise level.
02.01.03 Rod Mill
• Rod mills shall be provided for secondary crushing/ grinding. The rod mills shall be of
robust construction with provision of feeding the material from end. It shall be of welded
construction complete with drive arrangement through motor, fluid coupling, gear box,
brake and open girth gear. The shell shall be made of mild steel lined with suitable
replaceable liners with sub-lining so that noise level does not exceed 85 db. The shell
shall be provided with manhole & openings for the end peripheral discharge.
The Tenderer shall guarantee that the noise level will be limited to 85 db at a distance of
1.5 meter from the machine.
• The rod mills shall be of rugged design. The wearing out parts of the crusher shall be
easily replaceable. The crusher shall preferably be designed such that it is protected
against damage due to entry of foreign material. Alternatively, additional system shall be
provided to prevent the entry of such foreign material into the rod mill.
The design of rod mill shall be such that wear of crushing components can be easily
compensated and the same will not affect or upset either the product sizing or its capacity.
The Tenderer shall ensure the availability of replaceable wear parts. The rod mill shall be
provided with the inching device with separate drive.
• The rod mill shall be designed or occasional oversize material. There shall be no variation
in output quality of due to presence of oversize.
• The rods shall be high carbon steel/equivalent which shall have a tendency to break rather
than warp when worn out.
• The mill length and diameter shall be chosen such that the rods cannot turn around and
jam against the shell.
• The rotational speed shall be chosen such that there is minimum generation of fines.
• Automatic centralised lubrication system shall be provided for main supporting bearing
and automatic spray for gear drive unit, ring gear, metering grease pump for the trunion
bearings with labyrinth, seals & pinion shaft bearings. Necessary piping with couplings
and connections are also included in the scope of work. Necessary instruments, valve etc.
mounted on a panel shall be provided.
• 360 degree sectionalized guard of steel plate for ring gear and pinion shall be provided
with inspection door and felt seals on both sides of the ring gear. The guards shall also be
equipped with clean out and drain openings.
02.01.04 Ring Granulator
• The crusher shall have a frame adequately designed for the service intended with large
quick opening inspection doors, fitted with dust tight seals. The frame shall be equipped
with renewable, abrasion resistant liner plates of adequate thickness.
• The cage shall be supported on top by a heavy hinged shaft and it shall be provided with
means for adjustment to control output size and also to compensate for wear and tear of
screen plates and crushing rings. The breaker plates and screen plates provided shall be of
abrasion-resistant renewable type manganese steel conforming to IS: 276:1992 grade-III.
The opening of the screen plate shall be so designed as to allow free flow of crushed
material even with the maximum percentage of moisture specified. The crusher cage shall
be adjustable with hydraulic cylinders.
• The rotor assembly shall consist of forged and heat treated alloy steel shaft and abrasion
resistant manganese steel, suspension disc which shall be keyed to the shaft. Suspension
bar support adequately designed rings. The crusher rings shall be made of work
hardening type manganese steel conforming to IS-276 grade-III, 1992.
• The crusher shall be provided with a tramp iron trap (deflector plate and access door), to
prevent uncrushable material from being brought back into the crushing cycle.
• The crusher bearings shall be spherical roller type with provision for grease or oil
lubrication. In case of oil lubrication, supply of oil pump along with pipes, temperature &
pressure gauges & control panel to be included in the scope.
• The drive unit shall be complete with motor, fluid coupling and all other accessories.

• Crusher casing shall be provided with hinged inspection doors of minimum 300 x 200
mm on top. There shall be arrangement to lift the top half of crusher for inspection/
maintenance.
monitoring, bearing RTD etc.
02.02 Drawings / Document / Information to be furnished.
1. List of drawings /data to be submitted along with tender
a. Tender shall be accompanied by general arrangement drawings for crushers, auxilliaries &
vibration isolation system showing to scale the elevation, side view and plan along with
information such as clearances, arrangement and disposition of all drives and other
equipment installed on the crusher. Crusher weight, wt. of heaviest single piece, motor
kw, drive arrangement, control system write up and important technical features of the
crusher offered and the load data of individual crushers, auxilliaries & vibration isolation.
b. Tender shall be accompanied with details of spring & damping pad arrangement with all
literature/ catalogues.
c. List of commissioning spares proposed by the Tenderer.
d. List of operational spares recommended for two year normal operation, insurance spares
and list of tools and tackles to be supplied with the equipment.
e. Duly filled up questionnaire given below.
f. List of imported component in the equipment.
g. Data sheet for noise protection.
2. List of drawings to be submitted for approval
a) Drawings listed hereinafter shall be submitted to the Purchaser/his consultant in stages for
approval, starting within one month of issue of letter of intent and prior to the
commencement of fabrication.
The load data/ drawing must be submitted within one month of issue of letter of intent.
b) General arrangement drgs drawn to the scale and containing all information’s as described
elsewhere along with civil load data for individual equipment.
d) Assembly drawings of individual drives
e) Technical characteristics of crushers in a tabulated form, characteristic curves.
f) In addition to the above, the Purchaser/ consultant reserves the right to insist on the
submission of calculation and/or drawings for any mechanical, structural and electrical
components as required.

g) Submission of detailed design calculations, analysis (static and dynamic) and drawings for
Purchasers acceptance and approval. All documents and drawings shall be supplied in
copies and two reproducible. All calculation shall be submitted in sets.
3. Drawings / data/ calculations for reference
01 Civil load data drgs for Crushers

02 Hydraulic circuit drgs for Crushers and for each system, lubrication arrangement etc.
03 Parts list, bill of materials and material specification.
04 Major sub assembly drgs of drives.
05 G.A of grinding attachment for roll crushers.
06 G.A of greasing systems for crushers.
07 Hydraulic circuit for door opening and hydraulic circuit for roll gap setting for roll crusher
08 Oil lubrication system for Rod mills.
09 Grease spraying system for Rod mills.
10 G.A of lubrication system for Rod mills, swing hammer reversible impactor & roll
crushers.
11 P & I diagram for Rod Mills, swing hammer reversible impactor and roll crushers.
12 a) Furnishing methodology of providing shuttering for the deck structure and its
removal, installation of springs and dampers isolation system.
b) Furnishing installation and maintenance manual indicating all erection sequences
and details of maintenance of equipments, procedure etc. necessary for
installation, maintenance of vibration isolation system and the detail specification
of various spares required for 5 years operation of the plant.
c) Furnishing bill of materials of various elements such as springs, visco dampers
with their rating, stiffness etc.
d) Furnishing detailed specification of the vibration isolation system and various
items indicated in the supply and standard national or international code to which
they conform to.
13 Drawings of all wearing out parts.
14 List of special tools & tackles.
4. Contract drawings and documents to be furnished along with the supply:
i/ Erection drawings, erection specification & erection instructions

ii/ Instruction for storage and reconservation including those for electrical,
instrumentation and communication items
iii/ Performance data
iv/ Test charts and inspection certificates in bound volume
v/ Operation & maintenance manuals
vi/ Safety manuals
vii/ List of spares for 2 year'
s normal operation/maintenance
viii/ Manufacturing drawings and bill of materials for all spares and wearing parts
(excluding those for proprietary items)
ix/ Ordering specs. including catalogues and details for all spares (including
properietory items) along with spare lists.
x/ Ordering specifications for operating consumables/supplies
xi/ All as built drawings, in bound volumes incorporating approved changes if any
made during erection and commissioning, shall be supplied progressively within
two months of commissioning of the (all drawings are to be furnished even if
there is no change) equipment.
xii/ Classified list of drawings in A4 size.

02.03 Questionnaire to be filled by Tenderer.
The Tenderer shall also furnish the following questionnaire and submit with his offer.
This data shall form a part of the contract with Successful Tenderer.
01. Name and address of the Tenderer :
02. Previous experience of the Tenderer :
03. List of similar equipment supplied :

along with user’s certificate
04. Is it the Tenderer' s intention, if awarded :

the contract, to comply fully in all respects
with Purchaser’s specifications covering
the work? If not, he shall state specific
exception in details.
05. Location / Nos. off
06. Designation
07. Capacity through.
08. Material (input & product) details.
09. Drive details & rating (kW, rpm etc.)

for all components like motor, coupling etc.
10. Material of construction for various parts
11. Liner material used, type, thickness, fixing arrangement.
12. Product size adjustment methodology
13. Control details
14. Gross weight of equipment (t) and weight of individuals parts
15. Weight of heaviest part
16. Foundation load data
17. Duty
18. Special features if any
19. Any other information as the tenderer thinks necessary for installation
20. Details of vibration isolation system

GS – 03, SCREENS:
03.00 SCOPE OF WORK
fabrication, assembly, testing and inspection, packing, dispatch, transportation, delivery
FOR Purchaser’s site, unloading, handling and storage at site, erection, testing, inspection,
commissioning, guarantee testing and handing over to the client including all electrics and
standard accessories of screens
The scope of the Tenderer shall be deemed to include all such items which although are
not specifically mentioned in the specification, but are needed to make the equipment
complete in all respect for its safe, reliable, efficient and trouble free operation.
a) Mechanical
− Design capacity shall be considered as 120% of rated capacity

safety switches, hoods, sealing materials, structural, mechanical and other
standard accessories including feed and discharge chutes with specified liners,
dust hood etc..
− Provision of necessary fixtures, supporting angles and brackets required for

mounting and supporting the equipment & drive with floor / bins.
b) All Electricals and controls
3. All fixing bolts and nuts including foundation bolts shall be included in the scope of
supply of Tenderer.
4. Statutory approval wherever required shall be taken by the Tenderer for the equipment
5. Tenderer shall furnish necessary technical supervisory personnel to supervise the erection;
testing, commissioning & PG test. The assembly of the equipment shall be made in such a
way that while handling/erection of the equipment at site no problem is encountered.
Erection mark of such assembly shall clearly be marked to facilitate the erection of the
equipment
6. The Tenderer shall submit detailed proposals setting forth his terms, conditions and fees
for rendering the following services.
7. Training of Purchaser’s personnel in all branches connected with the operation and
maintenance of the equipment.
specification, tender drawing, and instruction to the Tenderer, General Conditions of
Contract (GCC), or any other part of the document.

03.01 TECHNICAL SPECIFICATION (Vibrating Screens)
1. General

where applicable in addition to the requirement mentioned herein.
The Supplier shall make his own calculation in respect of motor kilowatt to ensure
satisfactory performance of the equipment.
Adequate no. of locating pins and match marking shall be provided for easy assembly and
dismantling of the equipment.

possible extent to ensure interchange-ability.
2. Equipment Specification (Mechanical)
a) The screen shall be of continuous duty type, robust construction and shall be fabricated
from steel plates and structural of adequate strength and of balanced design. All welded
parts will be stress relieved and all holes will be drilled and not punched. Welding shall be
avoided as far as practicable to avoid stress concentration. All bolting shall be huckbolts
and nyloc nuts. Sharp edge on screen body will be avoided. The screen body will be
adequately reinforced at supporting points where vibrating mechanism is connected to the
screen body. It will be provided with suitable back plate at feed end to prevent spillage of
material. The screen body will be supported on adequate number of springs to give
adequate rigidity to the equipment as well as transmission of dynamic force to the
supporting structure will be minimum, to the extent possible. The springs will have fixed
spring-constant throughout its operating range. It shall be floor mounted inclined at 8
degree (max.) with horizontal and installed as per design requirement.
b) Screening surfaces shall be adequate to render 90% (min) efficiency of screening
c) The tenderer shall offer the linear motion screen with the direct force exciter (DFE) until
and unless the requirement changes due to specific technical reasons. The motion to DFE
shall be imparted through cardon-shaft. Other type of screens shall be specifically
mentioned in the data sheet. The tenderer may also offer unbalanced motor type screen
where the unbalance motors are directly mounted on the screen frame.
d) The screen shall have in-built design feature to overcome the additional load likely to
occur when the screen passes through the resonance zone. Such momentary additional
loads shall not be transferred to the supporting building structures.
e) The screen deck shall be provided with side liners upto a height 50mm more than material
depth.
f) Wherever applicable the screen shall be provided with heavy duty, self-aligning, vibration
duty spherical double row roller bearings in such a manner as would reduce maintenance

and refitting time. The load distribution due to eccentricity shall be such so as to minimise
shaft deflection and prevent misalignment of bearing races. The bearings shall be
protected from dust effectively by dust tight seals and provided with pressure type
lubrication.
g) The screen deck shall be totally covered.
h) The screen shall be provided with non-clogging screen cloths/ plates. Screen cloth/ plates
support will be suitably planned / devised so that the distance between the supports is
uniform and proper chamber is obtained. The clamping arrangement shall be suitable to
hold the cloth/ plate at proper tension and also allow easy changing.
Wherever impact load due to material fall may encounter, feeding area shall be provided
with blind plate.
Screen will be having secondary induced vibration of screen cloth/ plate to minimise the
choking. The selection of bed area will be done in such a way that the bed depth is limited
to reduce the choking.
i) The vibrating springs of the screen shall be high quality chrome vanadium steel.
j) In order to prevent deterioration of the materials being screened, relatively high speed,
low amplitude vibration of the screen shall be preferred.
k) The drive shall be such that no unwanted vibration forces are transmitted to the stationary
structure. The screen shall be designed for smooth starting and stopping without excessive
bouncing.
03.02 TECHNICAL SPECIFICATION (Flip Flow Screens)
The design, manufacture and performance of the flip flow screen shall comply with all
currently applicable statutes, regulations and safety codes and shall also conform to the latest
applicable Indian or International standards

03.03 Design Criteria-General

FLIP FLOW SCREENS
03.03.01 These shall be double amplitude screens of which 1st system shall make nearly
circular movements.
03.03.02 The 2nd vibrating system shall be connected to the screen box by means of rubber
blocks which shall be arranged parallel with the screening surface.
03.03.03 The cross members for fixing of the screen elements shall be connected alternately to
both of the vibrating systems.
03.03.04 The unbalance exciter consisting of a drive shaft with two outer unbalance masses
shall produce the centrifugal forces, necessary for the screen trough to be brought
into nearly circular vibrations. The diameter of the circle of vibration can be
changed by the adjustable unbalance masses. In the 2nd vibrating system, the circular
vibration shall be superimposed by one reciprocating movement in conveying
direction at each revolution. This shall result in a relative movement of both systems
which tensions and releases the screen elements alternately. The screen deck shall be
of high wear resistant polyurethane material.
03.03.05 During the standstill the screen mats shall be sagging. The vibrating system shall
operate in the overcritical range of the suspension springs with speeds from 750 to
850 rpm.
03.03.06 Normally the amplitudes for circular vibrations shall be 5 – 10 mm and for linear
vibrations 12 – 20 mm.
03.03.07 Drive
The exciter shaft with the unbalance masses shall be by means of a
a) V-belt drive for smaller screens or by
b) V-belt and cardan shaft drive for larger types with Electric motor
c) SQUIRREL CAGE MOTOR, 50 Hz, 4-poles, type of protection IP-54,

structural shape B3, DOL starter.
03.03.08 Screen box
Generally the design of the screen box shall be structure connected with high tensile
huck bolts. The installation of the screen box shall be accomplished with slope in
conveying direction. The angle of slope – between 15o and 25o shall depend on the
operation requirements.
03.03.09 Support:
Rubber hollow springs/ damper shall support the vibrating system of the screen
support structure.
03.03.10 Covering
The screen shall be covered with fast fixing rubber cloth / polymer hood.
Screens shall be complete with receiving /discharge/undersize chute and hood cover.
Inclined access platforms for attending to each point on the screen shall be envisaged.
Provision for fitment of dust suppression / extraction at feed and discharge area shall be
kept.

03.04 DOCUMENTATION
The Tenderer shall submit adequate sets of following technical drawings & technical data/
information with tender for vibrating screens without which the tender shall be considered
as incomplete & may not be considered for acceptance.
a) General description of design consideration and all the assumption made by the
supplier.
b) Specification of individual equipment indicating capacity (rated and designed),

separation size/s, dimension of screen and opening size, drive detail & ratings, safety
factors, duty rating, weight of individual equipment, weight of heaviest part, etc.
c) Make and model of equipment/parts/components.
d) Specification of materials of construction of major parts/ components along with

standards and chemical composition.
e) Catalogues/leaflets for all equipment including bought-out items. Details of bought-

out items with makes shall be given separately.
f) G.A. drgs for the equipment/ system including sections and details giving relevant
information, binding dimension, loads for designing civil/structural works etc.
g) Standard/ special accessories being considered for supply along with the equipment.
h) Requirement of tools and tackles for erection and maintenance.
i) Requirement of utilities and services.
j) Deviation from tender document.
k) Duly filled in questionnaire
2 List of drawing/documents to be furnished by the Successful Tenderer
The following drawing/document shall be submitted by the Successful Tenderer within

one month of placement of order:
a. General arrangement drawing of equipment showing full details of screens, feeders,

chutes, hoods etc in plan and section along with design calculations.
b. Calculation sustaining the screen / feeder size selection and motor power calculation
c. Foundation outline drawing with load data, pocket sizes and location, foundation
bolts and inserts details as required.
d. Fixture details, load data and special erection instruction with allowable tolerances as
required.

e. Specification of oils and lubricants and other consumables and their quantity and
frequency of change.
f. Motor list including kW rating
g. Technical data sheet
3 List of drawings/ documents to be furnished along with equipment by the Successful

Tenderer.
a. Sets of all Approved GA drawings and motor data sheets, complete assembly and
sub assembly drawings of the equipment together with one copy of good quality
polyester reproducible.
b. Drawing of all equipment/ component received from sub supplier together with
one copy of reproducible.
c. Engineering and design calculations
d. Test and warranty certificate for each item of equipment
e. Detailed erection schedule and manuals, assembly/ erection drawings, erection

sequence, special precautions to be followed during assembly/ erection.
f. Test reports and inspection reports
g. Instruction manuals for testing and commissioning
h. Operation, maintenance and safety manuals
i. Requirement of special tools and tackles, if any, for subsequent maintenance
3. Detail drawing and specifications of all wearing out parts and parts subject to
breakage during normal operating conditions.
4. List of spare parts with drawings, sketches, specifications and manufacturer’s

catalogue (two sets and one reproducible and/or two sets of catalogues)
03.05 QUESTIONNAIRE

4. Type of screen :
5. Location / Nos. off :

6. Capacity through :
7. Separation size :
9. Deck size( mm x mm), Panel size & inclination
10. Material of construction of deck plate & other parts
12. Screen cloth/ plate specification and type of perforation
13. Control details
16. Foundation load data for screens & feeders for design of building
17. Duty
20. Guarantee efficiency of the screen
21. Details of spring, i.e. material composition, wire dia , free length etc.
22. Whether anti- vibration pads have been provided below spring base plate
23. a) Stroke and amplitude of vibration

b) Limits of adjustment of amplitude & stroke
24. Gear Boxes (If applicable)

a) Make :
b) Type :
d) Torque rating (kg-m) :
25. Couplings (If applicable)
a) Make and type of high :
speed couplings
b) Make and type of low :
speed couplings
c) Weight (kg) :
26. Bearing
Make :
Expected life (hrs) :

GS – 04, VIBRO - FEEDERS:
04.00 SCOPE OF WORK
FOR Purchaser’s site, unloading, handling and storage at site, erection supervision, testing,
electrics and standard accessories of Vibratory feeders as covered under this specification.
a) Mechanical
− Design capacity to be considered as 120% of rated capacity.

safety switches, structural, mechanical and other standard accessories including feed
and discharge chutes with dust hood, feed control gate etc.
and supporting the equipment and feed chute.
b) Electricals and controls
3. All fixing bolts and nuts including foundation bolts shall be included in the scope of supply
of Tenderer.
4. Two years maintenance spares.
5. Commissioning spares as required during testing and commissioning of the equipment.
6. Insurance spares.
consumables which are necessary for cleaning/ flushing including erection, testing and
commissioning the equipment shall be in the scope of supply of the Tenderer.
8. Necessary tools and tackles for each equipment required for maintenance, testing or
inspection of the equipment.

1. General

The Supplier shall make his own calculation in respect of motor kilowatt to ensure

possible extent to ensure interchange-ability.
2. Equipment Specification (Mechanical)
a. Vibratory feeders shall be of generally electro-mechanical type (any other type shall be
indicated in data sheet for respective equipment). The vibrating units of the feeders shall be
of unbalanced motor type. The vibrating feeders and their mounting arrangement shall be
properly designed to suit the scheme shown in the TS drawing. It shall be ensured that no
vibration is transmitted to the supporting/ surrounding structures. The troughs of the feeders
shall be of tray type construction and shall be made out of minimum 6 mm thick MS plate
(IS: 2062-1992). 10 mm thick liner (SAIL Hard) shall be provided inside the trough along
its length and cross section. The trough liner shall be provided with adequate side guard to
avoid spillage. The trough shall be covered with dust tight hoods with provision of cut out
and flange for dust extraction. The equipment will be provided with enclosed dust proof
vibrators (un-balanced masses).
b. All the feeders shall be of suspended type unless otherwise mentioned in data sheets. Each
vibrating feeder shall be supplied complete with supporting structures, feed chutes,
manually operated feed control gates, hood cover, electrics, plates and fixing nuts and bolts,
suspension rods, ropes, turn buckets etc. All the four suspension ropes shall be provided
with turn-buckle arrangement for adjustment of feeder height and inclination.
c. The successful Tenderer shall ensure that minimum amount of assembly will be required
for erection and commissioning of equipment at site. Site welding etc. shall be avoided as
far as possible
d. The feeders shall be of robust construction and of balanced design.
e. SAIL hard liner of 10 mm thick shall be provided in feed chute
f. All bolts except those with nyloc nuts shall be provided with lock nuts and spring washers.
g. No cast iron parts shall be used (except for pillow block with FG - 260)
h. Equipment shall be designed such that all components are easily accessible for inspection,
repair and maintenance

04.02 DOCUMENTATION
a. General arrangement drawing with bill of material of equipment showing overall

dimension, motor kW, drive arrangement etc. along with load data, weight etc.
b. Supplier's name for components (like motors, coupling, gearbox etc.) catalogues for these
items shall be furnished.
d. List of recommended spares for two years maintenance of plant and equipment along with
itemised price.
e. List of tools and tackles to be supplied with the plant and equipment.
f. Duly filled up questionnaire.
g. The Tenderer has to furnish one copy of the specification drawing duly signed by him as a
token of acceptance along with the list of deviation from tender documents.
04.03 QUESTIONNAIRE
The Tenderer shall furnish the following questionnaire and submit with his offer. This

4 Is it the Tenderer'
s intention, if awarded :
The contract, to comply fully in all respects
5 Location / Nos. off :

6 Type of feeder & Designation :
7 Capacity through :
8 Material of construction of different parts :
9 Total weight and weight of individuals parts :
10 Type of liner and thickness :
11 Motors
a) KW rating :
b) RPM :
c) Type :

GS – 05, VIBRATORY GRIZZLY FEEDERS:
05.00 Scope
FOR Purchaser’s site, unloading, handling and storage at site, insurance during storage,
erection, testing, inspection, commissioning, guarantee testing and handing over to the
client including all electrics and standard accessories of screens.
a) Mechanical
safety switches, hoods, sealing materials, structural, mechanical and other
standard accessories along with feed chute, discharge chute and manual feed
control gate.

05.01 Technical Specification
1. Code & Standards
The design, manufacture, inspection and testing of Vibrating Grizzly Feeder shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Vibrating Grizzly Feeder shall conform to the
latest edition of standards and codes. Other internationally acceptable standards/codes,
which ensure equal or higher performance than those specified, shall also be accepted.
Nothing in this specification shall be construed to relieve the contractor of the required
statutory responsibility.
2. Technical requirement
a. The vibrating grizzly feeder shall be of mechanical type.
b. The grizzly feeder shall be capable to segregate the desired size of material. The
width of vibrating grizzly feeder shall match to feed the material uniformly over
the entire length of subsequent equipment.
c. The screening area excluding solid deck area shall be minimum 0.75 m2 per 100
tonnes/hr of incoming feed. Inclination of the grizzly pan shall be so selected so
as to ensuing proper flow ability of material on the deck without any hindrance.

d. The equipment shall be designed in such a manner that choking does not occur
during operation, particularly during rainy season when the coal gets sticky.
3. Constructional Features
a. The deck of vibrating grizzly feeder shall have continuous solid deck section in
the impact zone under direct material fall and remaining deck shall be fitted with
perforated deck assembly.
b. The solid deck section shall be provided with replaceable SAIL HARD or
equivalent liner plate of adequate thickness.
c. The perforated deck shall be wear resistant and shall be rigidly fixed with main
frame along the length of grizzly deck.
d. The Vibrating Grizzly feeders shall be mounted on the floor with the help of
helical springs made of alloy steel. No rubber / synthetic material for the support
shall be provided.
e. Suitable sealing arrangement shall be provided between the vibrating structure

and chute work to avoid dust nuisance in the surrounding area. Proper
arrangement to avoid dust ingress into lubricant of eccentric shafts shall be
provided. Necessary arrangements shall be provided for maintaining the
complete vibratory assembly.
f. In case V-belt drive to avoid loosening of sheave mounted on eccentric shaft,

suitable arrangement like taper bush or dobicon coupling shall be provided.
Marker plate to indicate stroke length and stroke angle shall be provided.
05.02 Drawing & documents to be submitted by the successful bidder
The Tenderer shall submit adequate sets of following technical drawings & technical data/
information with tender for vibrating screens without which the tender shall be considered
as incomplete & may not be considered for acceptance.
a) General description of design consideration and all the assumption made by the
supplier.
b) Specification of individual equipment indicating capacity (rated and designed),

dimension, drive ratings, safety factors, drive details, duty rating, weight of individual
equipment, weight of heaviest part, etc.
c) Make and model of equipment/parts/components.
d) Specification of materials of construction of major parts/ components along with

e) Catalogues/leaflets for all equipment including bought-out items. Details of bought-

out items with makes shall be given separately.

f) G.A. drgs for the equipment/ system including sections and details giving relevant
information, binding dimension, loads for designing civil/structural works etc.
g) Standard/ special accessories being considered for supply along with the equipment.
h) Requirement of tools and tackles for erection and maintenance.
i) Requirement of utilities and services.
j) Deviation from tender document.
k) Duly filled in questionnaire
2 List of drawing/documents to be furnished by the Successful Tenderer
The following drawing/document shall be submitted by the Successful Tenderer within one
month of placement of order:
a. General arrangement drawing of equipment showing full details of screens, feeders,

chutes, hoods etc in plan and section along with design calculations.
b. Calculation sustaining the screen / feeder size selection and motor power calculation
c. Foundation outline drawing with load data, pocket sizes and location, foundation bolts
and inserts details as required.
d. Fixture details, load data and special erection instruction with allowable tolerances as
required.
e. Specification of oils and lubricants and other consumables and their quantity and
f. Motor list including kW rating
g. Technical data sheet
3 List of drawings/ documents to be furnished along with equipment by the Successful

Tenderer.
a. Sets of all Approved GA drawings and motor data sheets, complete assembly and
sub assembly drawings of the equipment together with one copy of good quality
polyester reproducible.
b. Drawing of all equipment/ component received from sub supplier together with
one copy of reproducible.
c. Engineering and design calculations
d. Test and warranty certificate for each item of equipment
e. Test reports and inspection reports

f. Instruction manuals for testing and commissioning

g. Operation, maintenance and safety manuals
h. Requirement of special tools and tackles, if any, for subsequent maintenance
i. Detail drawing and specifications of all wearing out parts and parts subject to
j. List of spare parts with drawings, sketches, specifications and manufacturer’s

catalogue (two sets and one reproducible and/or two sets of catalogues)
05.03 QUESTIONNAIRE

04. Is it the Tenderer's intention, if awarded :

the contract, to comply fully in all respects
06. Designation
07. Capacity through
09. Deck size( mm x mm), Panel size & inclination
10. Material of construction of deck plate & other parts
12. Screen cloth/ plate specification and type of perforation
13. Control details
16. Foundation load data for screens & feeders for design of building
17. Duty

20. Guarantee efficiency of the screen
21. Details of spring, i.e. material composition, wire dia , free length etc.
22. Whether anti- vibration pads have been provided below spring base plate
23. a) Stroke and amplitude of vibration

b) Limits of adjustment of amplitude & stroke
24. Gear Boxes

a) Make :
b) Type :
25. Couplings
speed couplings
b) Make and type of low :
speed couplings
c) Weight (kg) :
26. Bearing
Make :

GS – 06, GATES (ALL EXCEPT DIVERTER GATES):
06.00 SCOPE OF WORK
FOR Purchaser’s site, unloading, handling and storage at site of the equipment.
The scope of the Tenderer shall also be deemed to include all such items which although
are not specifically mentioned in the specification, but are needed to make the equipment
All fixing bolts and nuts shall be included in the scope of supply of Tenderer.
Two years spares for each type of gates.
Commissioning spares as required during testing and commissioning of the

conveyor system.
The scope of work shall stand supplemented by such details as are given in this
Contract (GCC) or any other part of the document.
1. Only the broad specifications covering the technical requirements for the equipment to be
supplied are indicated. It is not the intent of this specification to specify complete details of
the equipment including design and manufacture. The Successful Tenderer shall carry out
detailed design, engineering and manufacture in a manner that shall ensure smooth and
trouble free performance of the equipment as a whole.
2. The Tenderer shall ensure that minimum amount of assembly is necessary for erection and
commissioning of equipment at site. Site welding shall be avoided as far as possible.
3. All components shall be designed and tested in accordance with latest Indian Standards
unless stated otherwise & agreed to.
4. All components shall be manufactured with material of approved quality & best of
workmanship. The equipment shall be shop assembled for checking operation and accuracy
of parts
5. All working parts of the equipment shall be suitably located for convenient operation,
inspection, lubrication, repairs & easy replacement
6. Rod gates shall be fitted between the bunker & equipment below like feeder/screens etc. to
control the feed rate and to isolate the equipment from the bunker during maintenance. The
gate shall be normally in partial /full open position and shall be controlled manually. The
gates shall be fabricated from rolled steel of minimum ISMC 200 section. All rods shall be
of minimum 32mm dis diameter that ensures no bending and MOC shall be high carbon
steel. The spacing between rods shall be decided based on size of material stored in hopper/
bin & direct material load. The tapered ends of the rod shall rest on square bars placed
beyond zone of discharge. A tray shall be provided on the hopper for storing the rods.
7. Sector gates shall be biparting clamshell type fitted below bins/ bunkers and shall be
electrically operated to regulate the discharge of material from the bins/ bunkers. Sector
gates shall be constructed out of materials having good resistance against impact and sliding
wear rolled plates (Fe 570) after hardening and tempering to HRC 25-3 with 10 thk.
SAILHARD liner. The material of pin shall be C-40 (IS: 1570 – 1979). The sector gears
used shall be made of cast steel grade 23-24 (IS: 1030 – 1989) or EN-8 or equivalent and
the teeth shall match perfectly to render noiseless and smooth service in operation. Wear
resistant liner plate of suitable material shall be provided. Liner shall be provided on the
gate main body and bottom portion. Antifriction ball and roller bearings shall be used
throughout.
• All bolts except those with nyloc nuts shall be provided with grip lock nuts or washers.
Stud or body bolts shall not be used as fasteners for mechanical items.
• Manual lubrication nipples shall be provided for all the bearings.
8. The motor operated flap gates shall be provided in transfer chutes as specified and shall
be complete with electrically operated actuators. The gates shall be of robust construction
and suitable for trouble free operation.
• The flap gates shall be used to divert the flow of material received from feeding conveyor
to the receiving conveyors. The gates shall be operated by an electromechanical linear
actuator. The actuators will be mounted on the chute body/ or on a working / maintenance
platform. The exact mode of support will be intimated to the successful Tenderer.
• The gate body shall be fabricated out of 10 mm thick MS plates with wear resistant,
replaceable liners. The liners will be bolted by counter sunk bolts. The thickness of the
liners shall be adequate so as to give minimum 3 years operating life. The gate plate shall
be 12 thick MS plate with suitable liner.
• The gate shall be capable of changing the direction of material on remote mode of control
even when the material is being discharged from the feeding conveyor pulley. A hand
wheel arrangement shall be provided at the motor side of the actuator for operating the
gate manually (Max effort 25 kg). The hand wheel shall be interlocked with the motor
shaft to avoid simultaneous operation in dual mode.
• The equipment shall be capable of being operated for at least 15 switchings per hour at
rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at rated load
and thrust. The equipment shall be shop tested to prove the requirement.
• The motor rating for the actuator shall be so selected as to provide sufficient thrust (min.
2500 kg) for operation of the flap gates against the moving weight of material and/or flap
gate.
• The flap gate travel shall be in the range of 60° to 70°. Limit switches shall be provided to
indicate extreme positions. Lever arm shall be provided between actuator and flap gate
shaft for obtaining required thrust. Each gate shall be provided with a shaft, a hand lever
and self aligning type antifriction bearings with adequate sealing for dust proofing.

• The actuators shall be capable of preventing any over travel. Suitable travel dependent
limit switches controlling the travel; of the flap gates on either direction shall provided.
These shall be placed internal to the drive unit and shall be completely dust-proof. The
limit switches shall be capable of adjustments to vary to total length of travel of the gates.
• Suitable thrust dependent limit switches shall be provided. This shall trip off the actuator
motor in case of excessive thrust due to jamming the gates during its travel in either
direction.
• Provision for alternative manual operation shall also be made using declutchable hand
wheel. The diameter of hand wheel shall be selected considering a 25 kg (max.) force to
be applied by a single operator.
• Suitable stiffening arrangement shall be provided between the two faces of the gate plate.
At the end of the travel the total length of edge of flap gate shall rest on a suitable
projected surface from chute to prevent leakage of material through the available
clearance between chute and flap gate.
• Suitable self aligned double row ball bearings of approved make in dust tight housing
shall carry the gate shaft
• For standardisation purposes, only one standard type of actuator (of 2500 kg thrust load)
of flap gates shall be provided. Flap gate actuator as a whole and individual component
wise shall be completely interchangeable for all locations.
• The material of gate and actuator shaft shall be EN-8 or equivalent material. The diameter
of the shaft shall be suitable for motor stalled conditions and associated twisting.
9. Rack & Pinion Gates shall be of two types, i.e. motorised actuator operated or manually
operated. All clauses below under “Motorised Rack & Pinion Gate” shall be applicable for
manually operated Rack & Pinion Gates also, except that the mode of operation shall be
manually and hence actuators, drives etc. are only for the motorised type.
10. Motorised Rack & Pinion Gates
• The gate shall be fitted in the transfer chutes between the bunkers / hoppers and feeders to
control the feed rate to the feeder. During maintenance of equipment lying below the
hopper / bunker, the gate shall be utilised for restraining fall of material from the hopper /
bunker.
• The gate shall be normally in partial / full open position. Actuator shall be provided for
opening & closing of the gate. In case of by-passing the actuator, the gates opening shall
be controlled by the hand chains (manually).
• The actuator operated rack & pinion gates shall be suitable for closing and opening the
gate with hopper / bunker full.
• All components shall be designed and tested in accordance with latest IS Specification
unless stated otherwise and agreed to. In such case where Indian Standards are not
available reputed International standards shall be followed.

• Rack and Pinion Gates shall be fabricated from rolled steel plates and section of minimum
ISMC 200. It shall be complete in all respects including gates plate, frame work, operating
chains, sprockets, gear rack and pinion, rollers etc. The gates plate shall have wear
resistant liners and shall slide over rollers mounted on anti-friction bearings. The nos of
rollers shall be such the gate is supported on minimum 3 nos rollers at any position. The
gate plate shall be properly stiffened to avoid distortion of gate plate. The flap shall be
made of minimum 12 mm thick plates and lined. Material of construction for various
elements shall be:-
Gate plate Gate plates to be made from 20 thk ms plates conforming to IS : 2062
and to be suitably lined with sail hard plates of 16mm thk.
Pin C-45 / EN-8
Liner Material SAIL HARD
16 thk. On Gate plate & 10 thk. On side walls.
Rack EN-8 / C-45
Hardness-225 BHN (min)
Pinion EN-8 / C-45
Hardness-250 BHN (min)
Roller EN-8 on Ball bearing.
• The pull required to operate the gate manually (on actuator bypass) shall not exceed 25 kg
when operating under a loaded bunker / hopper.
• All bolts except those with nyloc nuts shall be provided with grip lock nut or grip
washers. Stud or body bolts shall not be used as fasteners for mechanical items.
• Gear boxes used shall be of approved make.
06.02 DOCUMENTATION
a. General arrangement drawing of each type of gates showing overall dimension, profile,
material of construction, weight etc.
b. List of commissioning spares proposed by the Tenderer.
c. List of spares for two years operation.
d. Duly filled up questionnaire.
2. List of drawings to be submitted for approval by successful tenderer
Drawings listed hereinafter shall be submitted to the Purchaser/ MECON for approval,
starting within one month of issue of letter of intent and prior to the commencement of
fabrication.
a) General arrangement drawing of each type of gates showing overall dimension, profile,
material of construction, weight, bill of materials etc.
b) In addition to the above, the Purchaser/ Consultant reserve the right to insist on
submission of calculations/ for component selection.
3. Drawing/data/calculation for reference to be submitted by successful tenderer
- Procedure for testing and commissioning.

- Instruction for storage /erection, testing & commissioning.

06.03 QUESTIONNAIRE

the offer.
06 List of gates with details :

GS – 07, MOTORIZED DIVERTER GATES:
07.00 Scope
The scope of work of the Tenderer shall include design, engineering, manufacture,
FOR Purchaser’s site, unloading, handling and storage at site, erection supervision,
testing, inspection, commissioning, guarantee testing and handing over to the client
including all electrics and standard accessories of Motorised Diverter Gates as covered
under this specification.
The equipment shall be designed as per design criteria given below:
I. Hierarchy of Specifications
a) Technical Specification
b) General Technical Specification (GTS)
d) Indian Electricity Rules & statutory requirements of Central Govt. and
State Govt.
Equipment complying with other recognised Standards such as IEC, BS, VDE, and IEEE
will also be considered if it ensures performance equivalent to or superior to Indian
Standards.
The components and materials used and the equipment supplied shall conform to high
standards of design, engineering and workmanship and shall be suitable for efficient
operation and reliable service in steel plant conditions.
II. Design Basis

− Design capacity of equipment - 20% more than designed stream capacity of feed
conveyor to be considered while calculating motor power
− Pillow blocks
a) Material - cast iron (FG – 260) / cast steel
b) Bearing - Self aligning spherical roller bearing
a) Life - 40,000 working hrs (min.)
b) Construction - Horizontal split type (one end fixed
and the other end expansion type)
− Reducer
a) Service rating of 1.5 times the calculated shaft kW and thermal capacity
of gear box shall be better or equal to that of motor
b) Material - fabricated or cast steel
c) KW rating shall be not less than 1.25 times the
motor kW. Higher value of `a’ or `c'will be
considered
d) No worm gear except for traveling gate

• All equipment shall be designed, manufactured, supplied, erected, tested and

• The Supplier shall make his own calculation in respect of motor kilowatt to ensure
possible extent to ensure interchangeability.
• All equipment shall be designed such that all components are easily accessible for
• The gate shall be capable to allow half flow on to each receiving conveyor or full flow on
to one conveyor or to the other conveyor.
• The gate casing shall be fabricated out of 10 mm thick MS plates with liners and conical
portion of the diverter shall be made of 10 mm thick MS with 5 mm thick stainless steel/
10 thk. SAIL HARD liners. The gate shall move inside a totally enclosed steel framework
mounted below the discharge hood of the feeding conveyor. Positive to and fro motion
for the two positions shall be imparted to the gate supporting frame through rack and
pinion arrangement driven by bevel geared drive. Material of construction of the pinion
and rack shall be minimum C45 or EN8. Adequate stiffeners for strengthening the two
sides of diverter to be provided to avoid any distortion due to material impact.
• The conical gate shall be guided on top and shall slide over rollers at bottom. The rollers
shall be provided with anti-friction bearings and the gate shall be supported on minmum 3
nos roller at all poisitions.
• The gate shall be capable of changing the direction of material on remote mode of control
even when the material is being discharged from the conveyor pulley.
• The drive shaft shall be made of C45. Antifriction ball / roller bearings shall be used
throughout.
• Speed of the gate shall be 30 mm / sec.
• Two numbers Limit switches for positioning and position indication shall be provided
such that if one fails the other indicates the position. For mid positions, if required,
additional position indicator shall be provided.
• Provision for manual operation of the gate shall also be provided at the extended motor
shaft. Manual force required shall not exceed 25 kg.
• Rubber buffers on the gate shall be provided at both ends inside the casing.
• The gate shall be supported on the steel floor beams.
• 2 numbers inspection windows (hinged type and dust tight) shall be provided on drive
side of the casing.
• All bolts except those with nyloc nuts shall be provided with lock nuts or spring washers.
• No cast iron parts shall be used (except for pillow blocks).
07.02 DOCUMENTATION

a. General arrangement drawing of gates showing overall dimension, profile, material
of construction, weight etc.
b) List of commissioning spares proposed by the Tenderer.
c) List of spares for two years operation.
d) Duly filled up questionnaire.

fabrication.
a) General arrangement drawing of gates showing overall dimension, profile, material of

construction, weight, bill of materials etc.
b) In addition to the above, the Purchaser/ Consultant reserve the right to insist on

- Procedure for testing and commissioning.
- Instruction for storage /erection, testing & commissioning.
a) For reference & records.
i. Part list, bill of materials and specification.

ii. Major sub-assembly drawings of drive, safety features, lubrication details
etc.
iii. List of spares, consumables, special tools and tackles.
iv. Operation and maintenance manuals.
07.03 Questionnaire


05. Designation
06. Capacity through
07. Material of construction of different parts
08. Total weight and weight of individuals parts
09. Type of liner and thickness
10. Motors
a) KW rating :
b) RPM :
c) Type :
11. Gear Boxes
a) Make :
b) Type :
12. Couplings
a) Make and type of couplings :
13. Type of Limit Switches :

GS – 08, WEIGH HOPPER:
08.00 Scope Of Work
1. The scope of work of the Tenderer shall consist of design, engineering, manufacture,
inspection, assembly, painting, supply and transportation to site, testing and
commissioning of load cell mounted weigh hoppers, complete with rod gates,
hydraulically operated gates, material Present Detector (MPD) and all accessories
required.
a) Mechanical
− Each weigh hopper shall be complete in all respect including, load cells, dummy
blocks, actuator and discharge gate units (if applicable), cables, safety switches,
structural, mechanical and other standard accessories including supporting frames
and structures. Necessary test weights for calibration of weigh hoppers shall be
included in the scope of supply of the Tenderer

1. Each weigh hopper shall be provided with 3 nos. compression type strain gauge/
pressductor load cells and gates/ feeders as required for the application and indicated in
the Technical Specification Data Sheet elsewhere.
2. The weighed material in the hoppers shall be discharged through a vibrofeeders

suspended from the hopper or a gate operated by an electro-mechanical actuator or
hydraulic / pneumatic actuators, as the case may be.
3. The weigh hoppers shall be fabricated out of 10 mm thick (minimum) M.S. Plates
(IS:2062-1992) and shall be of welded construction with one bolted joint for ease of
maintenance/ handling. Inner surface of the hopper shall be provided with liners. Liner
plates shall be bolted to the mother plates. Size and shape be such that handling is
convenient.
4. The weigh hoppers shall be designed to discharge the required materials onto the
conveyors uniformly in the specified discharge time in normal feed as well as choked feed
condition. Feeding to conveyor will be uniform and centrally throughout the discharge
time.
5. The Electro-mechanical actuator (if applicable) shall be with a high torque drive motor
which shall transmit the torque through a gear reducer unit. Limit of travel of drive rod,
shall be adjustable with the help of travel limit switches. In case of any external obstacle
the adjustable thrust limit switches shall interrupt power to the motor, in either direction
of movement, thereby preventing damage to cylinder and equipment. Provision of manual
operation of the actuator by hand wheel in the event of power failure shall also be kept
with suitable limit switch to prevent the electrical operation in the event of manual
operation of the gate. In case of hydraulic / pneumatic cylinder operated gates suitable
hydraulic / pneumatic system including supply, accumulator, valve stand, piping etc. for
smooth functioning of the system shall be in the scope of tenderer.
08.02 DOCUMENTATION
1. Drawings and documents to be submitted by the Tenderer with tender
The Tenderer shall submit the following technical drawings & technical data/ information
along with tender for weigh hopper without which the tender shall be considered as
incomplete & may not be considered for acceptance.
a. Drawing showing general arrangement of the equipment, general description of

design consideration and all the assumption made by the supplier.
b. Detailed specification for the equipment offered & mounting/ accessories etc.,
together with descriptive literature/ catalogues etc.
c. Details of load cell such as type, rating, make and other details
d. Calculation substantiating selection of equipment.
e. Specification of materials of construction of major parts/ components along with

f. Catalogues/leaflets for all equipment including bought-out items. Details of

bought-out items with makes shall be given separately.
g. G.A. drgs for the equipment/ system including sections and details giving relevant
information, binding dimension.
h. Standard/ special accessories being considered for supply along with the
equipment.
i. Requirement of tools and tackles for erection and maintenance.
j. Requirement of utilities and services.
k. The tenderer shall also duly complete the “Questionnaire” & submit along with
the quotation without which the offer may not be considered.
2. List of drawing/documents to be furnished by the Successful Tenderer
The following drawing/ document are to be submitted by the Successful Tenderer within
a. General arrangement drawing of equipment showing full details of weigh hoppers

in plan and section along with design calculations.

b. Quality assurance plan for inspection
c. Requirement of tools and tackles for erection.
d. Part list, bill of materials and material specification.
e. Major sub assembly drgs., details of liner plates, safety features etc.
f. List of spares, special tools and tackles
g. Operating and maintenance manuals.
3. List of drawings/ documents to be furnished alongwith equipment by the Successful

Tenderer
a) All approved GA drawings, complete assembly and sub assembly drawings of the
equipment.
b) Drawing of all equipment/ component received from sub suppliers.
c) Engineering and design calculations.
d) Test reports and inspection reports
e) Instruction manuals for testing and commissioning
f) Operation, maintenance and safety manuals in ten copies
g) Requirement of special tools and tackles, if any, for subsequent maintenance
h) Detail drawing and specifications of all wearing out parts and parts subject to
i) List of spare parts with drawings, sketches, specifications and manufacturer’s

catalogues.
08.03 QUESTIONNAIRE
The Tenderer shall submit the following details along with the quotation of the
equipment.
1. General arrangement drawing showing overall dimensions and mounting details

of the hopper.
2. Capacity of weigh hoppers- effective and geometric
3. Material and liner of weigh hopper and thickness.
4. Details of feeding Chute to weigh hopper
5. Material & liner for Chute and thickness
6. Total weight of the equipment and weight of individual parts.
7. Weighing accuracy.
8. Weighing range.
9. Control circuit diagram.
10. Response time, repeatability

11. Taring time, repeatability.

12. Load cell
i. Make and type
ii. Model No.
iii. Quantity/ hopper
iv. Measuring principle
v. Enclosure class- IP 67
vi. Rated capacity
vii. Details of output signal.
viii. Deflection related to rated cap.
ix. Rated output signal to rated cap.
x. Zero unbalance related to rated cap.
ix. Maximum temperature.
xii. Compensated temp. range.
xiii. Temp. effect on zero unbalance
xiv. Temp. effect on related out put
xv. Over load capacity
- Safe limit
- Ultimate limit
xvi. Accuracy
xvii. Hysteresis
xviii. Linear error
13. Connecting cable

- Type of cable
- size of cable
14. Mode of discharge from hopper

Via gate / vibrofeeder etc.
15. Mechanism of gate opening : Pneumatic / Hydraulic

GS – 09, BELT WEIGH SCALE:
09.00 Scope Of Work
09.01 The scope of work of the Tenderer shall include design, engineering, manufacture,
electrics and standard accessories of electronic micro-processor based Belt Weigh Scales
as covered under this specification.
• Two years maintenance spares.

• Commissioning spares as required during testing and commissioning of the equipment.
• Insurance spares.
• Required quantity of initial fill of oil, grease, lubricants, hydraulic fluid etc. and other
• Necessary tools and tackles for each equipment required for maintenance, testing or
1. General
Belt weigh scale for measurement of flow rate and total-quantity shall be provided at
specified locations as per relevant requirement as indicated in data sheets. System shall be
complete with flow rate indicator, totaliser, control panel etc.
2. Codes & Standards
The design, manufacture, inspection and testing of Belt Scales shall comply with all the
currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The Belt Scales shall conform to the latest edition of the
following standards and codes. Other internationally acceptable standards/codes, which
ensure equal or higher performance than those specified, shall also be accepted.
IS:11547 Electronic weighing in motion system
3. Equipment Specification
The weigh scale shall be automatic and electronic type. It should be designed for
continuous automatic weighing, metering of coal flow.
Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4 nos.
weighing idlers. It shall have unitized construction for ease of installation and shall be
fully floating type (without pivot points). Minimum 3 nos. hermetically sealed load cells
of precision strain gauge type shall be applied in tension to support the weigh bridge. The

load cells shall have 100% overload protection and shall be structurally safe upto to 250%
of rated belt scale capacity.
Belt scale shall be electronic microprocessor based with its program stored in non-volatile
memory.
It shall be provided with self diagnostic features for trouble shooting of the entire belt
scale system. Succeeding & proceeding station including idlers for load cell station shall
be machined with concentricity of ±0.29mm and supply of same shall be by the tenderer.
Fully automatic zero and span calibration facility shall be provided. The electronic
systems offered by the Bidder shall include all signal conditioning, power amplifiers and
printed circuits etc. The printed circuits shall be encapsulated against dust and moisture.
Belt scale shall be provided with flow rate total quantity etc. Remote flow rate indicators
shall also be additionally provided in the Central Control Room, i.e. duplicated. Special
cables, if any, required for transferring data from scale location to control room shall be
within the scope of tenderer.
The flow rate indicator shall have minimum 4 digits. The flow totalizer should have 8
digits display scale with reset facility.
Complete belt scale system shall be suitable for 50°C ambient temperature and 100%
relative humidity. It shall be suitable for out door installation in a dusty area. The
electronic circuit enclosure, sensors housing shall be dust and watertight. The electronic
printed circuits shall be encapsulated with epoxy or other suitable material for
protection against dust and moisture.
Minimum three years battery back up power failure protection shall be provided.
Belt scale shall be designed for a range of 20% to 120% of rated capacity with an
accuracy of at least ±0.5% throughout its range.
Supply of test weights for calibration of belt scales shall be the tenderer’s responsibility.
Local panel for belt belt scale shall be of sheet metal
09.03 DOCUMENTATION

dimensions.
b. Supplier'
s name for components & catalogues for these items shall be furnished.
d. List of recommended spares for two years maintenance of plant and equipment.

f. Duly filled up questionnaire.
The following drawing/ document are to be submitted by the Successful Tenderer within
a. General arrangement drawing of equipment showing full details of BWS.
c. Requirement of tools and tackles for erection.
d. Part list, bill of materials and material specification.
e. Major sub assembly drgs., safety features etc.
f. List of spares, special tools and tackles
g. Operating and maintenance manuals.

Tenderer
a) All approved GA drawings, complete assembly and sub assembly

drawings of the equipment.
b) Drawing of all equipment/ component received from sub suppliers.
c) Engineering and design calculations.
d) Test reports and inspection reports
e) Instruction manuals for testing and commissioning
f) Operation, maintenance and safety manuals in ten copies
g) Requirement of special tools and tackles, if any, for subsequent

maintenance
h) Detail drawing and specifications of all wearing out parts and parts
subject to breakage during normal operating conditions.
i) List of spare parts with drawings, sketches, specifications and

manufacturer’s catalogues.

09.04 Questionnaire
Type :
Operation :
No. of floating idlers :
Load Cells Details :
Overload protection
Capacity :
Flow Rate Indicator Type/Locations :
Flow totalizer Type/ locations :
Accuracy :
Calibration :
Type of speed governors :
No. of machined idlers :
Concentricity of machined idlers :

GS – 10, VIBRATION ISOLATION SYSTEM:
10.01 Scope
• This specification broadly covers design, engineering, supply and erection of

vibration isolation system for crushers and other such equipment.
• Scope shall include all selection & supply of steel helical spring units and viscous
dampers, including associated auxiliaries for installation of the spring unit dampers
like steel shims, adhesive pads etc.
• All frame (s) pre-stressing of spring elements.
• Static and dynamic analysis of the vibration isolation system with the RCC top deck
and the crusher shall also be included.
• Vibration monitoring & control system wherever specified shall also be included
10.02 Codes and Standards
For the design of crusher foundations, the latest revisions of following codes shall also be
referred:
(i) IS: 456-1978 code of practice for plain and reinforced concrete.
(ii) IS: 2974 (Part-IV) -1979 code of practice for design and construction of machine
foundations - Foundation for rotary type machines of low frequency.
(iii) IS: 1893-1991 (Criteria for earthquake resistant design of structures).
(iv) DIN 4024-1991 Machine foundations: Flexible supporting structures for machines
with rotating masses.
• Detailed dynamic analysis shall be done for the top deck together with springs and
dampers and natural frequencies & amplitudes of vibration shall be determined. A
mathematical model of top deck shall be formulated with three-dimensional beam /
plate finite elements for the purpose of analysis with the springs idealized with
vertical and horizontal stiffness. The mass of the machine together with the top deck
shall be considered for analysis.
• Natural frequency upto at least 10% above the operating frequency shall be
determined and these frequencies shall be checked against the design criteria. Forced
response dynamic analysis shall be carried out for the operating condition, unbalance
forces using a sinusoidal forcing function. Unbalance forces as applicable for the
crusher, shall be used for the purpose. The dynamic forces from the analysis shall be
used for structural design with suitable fatigue factor.
• The vibration isolation system shall be designed for at least 95% isolation efficiency.
• Spring system being supplied shall be of such stiffness that a ratio of at least 10 (ten)
should be possible to be adopted for the stiffness of supporting structure with respect
to the stiffness of the spring system in each direction to achieve decoupling between
the two (The stiffness of spring system being lower).

• The foundation system shall be designed such that a frequency ratio (ratio of
operating frequency to the fundamental natural frequency) of at least 3.5 is achieved.
In addition, the first bending frequency of the RCC deck shall be 20% above the
operating frequency.
• The calculated amplitudes shall not exceed following limits under the specified
conditions.
a) 150 microns for an unbalance force arising out of balance quality grade
G-40 as per ISO: 1940 -1986.
b) 250 microns in case of one millimetre eccentricity in the rotor.
c) 250 micron mean-to-peak for unbalance in case of one hammer broken
condition.
d) Amplitudes need not be checked for three hammers broken condition. It is
sufficient to check static strength under this condition.
The amplitude limits mentioned above are in both vertical and horizontal directions.
The amplitudes shall be calculated at critical points on the top surface of the RCC
deck. The amplitudes shall be checked for the most unfavourable superposition of
modes in any direction. However, phase difference between the maximum amplitudes
occurring in different directions due to the rotating vector may be considered while
superimposing the modes.
• Transient resonance, which may occur during the start-up or coasting down condition
of the crusher, shall be checked and the amplitudes in such a condition should not
exceed one-and- half times those at operating speed for each design condition.
• The following criteria shall apply for the design of the top deck:
a) Dead loads, live loads, seismic loads and dynamic loads shall be
considered for the design. The most unfavourable combination shall be
considered for design.
b) Seismic loads shall be assumed to act together with dynamic loads for a
one-millimetre eccentricity in the rotor. However, seismic loads and
dynamic loads arising out of hammer breakage need not be considered
together.
c) Fatigue shall be considered while designing for dynamic forces. A fatigue
factor of 2.0 shall be used on all dynamic forces to arrive at the equivalent
static force for the purpose of design.
d) Working stress method shall be used for the design of RCC deck. In
survival condition, 10% overstressing may be permitted.
e) The RCC top deck shall be of M-25 grade of concrete as per IS:
456:1978.
f) Fatigue need not be considered for the three hammers broken condition.
g) For calculating unbalance forces, the heaviest hammer (plain or toothed)
shall be considered.
The vibration isolation system, all accessories and the supporting structure shall be
designed to withstand seismic loading in addition to dead loads, live loads and dynamic
loads. The seismic co-efficient shall be taken as per the zone defined by IS: 1893-1991
criteria for earthquake resistant design.

10.04 DOCUMENTATION
a) General arrangement & Sections drawing of vibration isolation system showing overall
dimension and details.
b) Name of supplier.
c) Duly filled up questionnaire.
fabrication.
a) General arrangement drawing of the vibration isolation system showing overall dimension
and details including bill of material etc.
b) Static and dynamic analysis of the vibration isolation system with the RCC top deck and
the crusher shall also be included.
c) All calculations.
d) In addition to the above, the Purchaser/ Consultant reserve the right to insist on
a) General arrangement drawing of the vibration isolation system showing overall dimension
and details including bill of material etc.
b) Static and dynamic analysis of the vibration isolation system with the RCC top deck and
the crusher shall also be included.
c) All calculations.
d) Procedure for testing and commissioning.
e) Catalogues/literatures
f) Operation and maintenance manual.

10.05 Questionnaire

04. Location / Nos. off :
05. Equipment for which intended :
06. Material of construction of different parts :
07. Building in which the VIS is located :
08. Total weight and weight of individuals parts :
09. No. of dampers & load data :
10. No. of springs and capacity of each set :
11. Vibration control & monitoring system : YES / NO

included
12. Detailed features of monitoring system :

GS – 11, TRAVELLING TRIPPERS AND BUNKER SEALING ARRANGEMENT:
11.00 Scope
erection supervision, testing, inspection, commissioning, guarantee testing and handing
over to the client including all electrics and standard accessories of Travelling /Trippers &
Bunker Sealing Arrangement, as covered under this specification.
a) Mechanical
and supporting the equipment and feed chute.
b) Electricals and controls including current collecting angles e.g. CRD or festoon
trolley as per specification’s requirement
3. Two years maintenance spares.
4. Commissioning spares as required during testing and commissioning.
5. Insurance spares.
7. Necessary tools and tackles for each equipment required for maintenance, testing or

1. The tripper shall be designed as per IS: 14386-1996.
2. Travel drive of trippers shall be individual wheel drive, independent of the main
conveyor drive and shall be through electric motor, helical gear box etc. Chain
drive/ open gearing shall not be used. Tripper shall be provided with A.C
Hydraulic thruster brakes for stopping the same at desired location. Travel speed
of trippers shall not exceed 0.5 m/sec.
3. The traveling tripper shall consist of belt scrapper with adjustable rubber strip,
rubber lagged head and bend pulleys complete with shaft bearings, chutes, stops
and limit switches, brakes etc. The tripper shall have two-way discharge chute or
three way chute with flap gate as per application which shall be capable of
discharging material into the bunker openings.
4. Traveling trippers shall be of adequate length with proper slope of conveyor idlers
to match with the flow properties of material being handled. The maximum
inclination of the conveyor belt on the tripper shall not be more than 140
5. Vertical and horizontal guide rollers shall be provided to control sway and uplift
of the belt in unloaded condition. The tripper shall run on standard flat bottom
Indian Rails at least of CR 60. Wheels shall be double flanged with parallel tread
running on anti-friction bearings and shall have min hardness of 350 BHN.
Material of wheel shall be forged steel / cast steel.
6. Traveling trippers shall be equipped with manually operated rail clamps and rail
cleaners and jacking pads.
7. Diverter gates on two way or three way chutes shall be electrically operated.
8. Power supply to the tripper shall be given through motorized cable reeling drum
with trailing cables, cable trays for resting the trailing cables and end limit
switches for protection against over travel of the tripper. The cable reeling drum
and trailing cable of each tripper shall be suitable for the entire length of the
bunker bay. The cables shall have copper conductors, proper insulating material
and braided armoring in accordance with IS: 691.
9. Position indicators shall be provided as per requirement of control logic.

Operating push buttons for local control and emergency stop shall be within easy
reach of the operator on the main conveyor walk way.
10. All stipulation regarding belt pulley, belt scraper, idlers, safety guards, wind
guard, access for maintenance etc. specified for belt conveyors, diverter gates and
discharge chutes shall be applicable for the traveling tripper.
11. The rating of tripper travel motor shall be adequate to move the tripper smoothly
either in forward or opposite direction to belt direction under fully loaded
conditions. Coefficient of friction shall be taken as maximum 0.15.

12. Minimum two drive axles shall be provided for tripper travel. Arrangement shall
be provided at the starting point of the tripper to avoid folding of belt.
13. Provision shall be kept for automatic tripping of bunker bay conveyor in event of
travelling tripper getting dragged (.i.e. travel speed in excess of rated speed).
14. The supporting structures for the rails with necessary end stops shall also be
supplied under this specification. Suitable belt hold down guide pulley shall be
provided over the concave curve of belt over tripper.
15. Suitable bunker sealing arrangement with conveyor belting shall keep the bunkers
sealed and prevent dust emission.
16. Separate openings shall be provided on the bunker floor of each bunker to
measure level of material in the bunker. Hinged door/ flaps shall be provided on
these openings.
17. Suitable gratings are to be provided in between bunkers in the tripper travel zone.
Opening size shall be decided during the detail engineering stage.
18. Suitable dust cover shall be provided over tripper head pulley. Serrated rubber
seal shall be provided at open side to prevent dust nuisance. Suitable dust tight
access doors shall be provided. Counter weighted type belt cleaner shall be
provided below the tripper head pulley to cleaning the carrying side of the belt.
19. Suitable access platform of Chequered plate with ladders, hand railings and
walkways on both sides shall be provided for access / maintenance of equipment
on tripper. Also crossover platform shall be provided with tripper so that operator
can cross the belt through the same.
20. Continuous deck plates shall be provided below carrying idlers on the trippers.

11.02 DOCUMENTATION
1. Drawings / document to be supplied by the Tenderer
a) General arrangement drawing of Mobile Tripper showing overall dimension, profile, idler
spacing, LT drive arrangement, motor kW etc. along with chutes, scrapper, skirt boards,
switches, wheel load, wheel spacing, wheel diameters, power supply arrangement for
travel drive etc.
b) Details of bought-out items & component list.
c) List of commissioning spares proposed by the Tenderer.
d) List of recommended spares for two years maintenance of the equipment.
e) Duly filled up questionnaire given below.
2. Drawings / documents to be supplied by the successful bidder for approval.
a) For approval:
General arrangement drawing showing the following:
i. Constructional feature.
ii. All dimensions and technical parameters as per technical specification.
iii. LT drive & their arrangement
iv. Motor ratings.
v. Speeds.
vi. Maintenance and repair provision.
vii. Operating weight.
viii. Any other information for making the GA drawing complete.
b) For reference / records:
i. Major sub-assembly drawings of drives, safety features, lubrication

arrangement etc.
ii. List of spares, consumables, special tools & tackles.
iii. Operation & maintenance manuals.

01.08 Questionnaire (To be filled by by Tenderer)
1. The Tenderer shall also furnish the following questionnaire and submit with his offer.
General
04 Tripper Details
05 Sealing details :

the offer.
07 Drive details
ix) Motors
a) KW rating :
b) RPM :
c) Type :
c) Bearing
Make :
x) Gear Box
a) Make :
b) Type :
xi) Couplings
speed couplings
b) Make and type of low speed :
couplings
c) Weight (kg) :
xiii) Belt cleaners – type :

− Weight (kg) :

GS – 12, IN LINE MAGNETIC SEPARATOR (ILMS)/ SUSPENDED ELECTRO MAGNET & METAL
DETECTOR :
IN LINE MAGNETIC SEPARATOR (ILMS)/ SUSPENDED ELECTRO MAGNET:
12A.00 Scope Of Work
• The scope of work of the Tenderer shall include design, engineering, manufacture,
over to the client including all electrics and standard accessories of In Line Magnetic
Separator (ILMS)/ Suspended Electro Magnet along with standard electrics, metal down
comer chute as covered under this part of the specification and to make the system
complete.
• The scope of supply and services of the Tenderer for In Line Magnetic Separators/
Suspended Electro Magnets shall include the following:
a) Mechanical
− Provision of necessary fixtures, supporting angles, ropes, turnbuckles and brackets

required for mounting and supporting the equipment.
b) Electricals
• The control panel for all functions & controls for ILMS shall be supplied with adequate no.
of I/Os for integrating with system PLC & sufficient length of cables for monitoring the
panel at suitable place on the wall / floor of building.
• All fixing bolts and nuts including foundation bolts shall be included in the scope of supply
of Tenderer.
• Required quantity of initial fill of oil, grease, lubricants, hydraulic fluid, transformer oil etc.
and other consumables which are necessary for cleaning/ flushing including erection,
testing and commissioning the equipment shall be in the scope of supply of the Tenderer.
• The scope of work shall stand supplemented by such details as are given in this
12A.01 TECHNICAL SPECIFICATION
• General
Inline Magnetic Separators shall be provided for continuous and automatic extraction
and discharge of tramp magnetic pieces from ore, coal and other material being
discharged from conveyors as specified. The sets shall be complete in all respects with
motor, drives, magnets, cleated belts with back – up non magnetic S.S. support plate,
belts, hoppers, chutes, tramp-iron boxes and all electrical ancillaries like control panels
etc. Inline Suspended Magnetic Separator (ILMS) shall be provided for picking up tramp
magnetic pieces buried under material burden from moving Conveyor as specified.
For Suspended Electro Magnets, suspension of magnet shall be done from a monorail
with the help of a Manual Hoist of suitable capacity. The monorail of the hoist shall be
planned such that occasional discharge of tramp iron can be at a safe place outside the
conveyor at a convenient location. The main suspension arrangement shall be provided
with turn buckles for adjustment of operating height. Lifting eyes shall be provided on
magnet for required suspension system.
In addition to suspension arrangement, additional safety wire ropes shall be provided for
supporting the magnet in case of main suspension system failure. Suspended Magnet shall
be complete with magnet with a suitable non-magnetic face plate, electrics (electrical
panel, cables etc.) and any other item to make the system complete.
After all suspended magnets, a metal detector shall be installed over the conveyor which
shall detect any metallic pieces which could not be picked up by the magnet. In case of
detection, the conveyor shall be tripped with suitable audio-visual warning at the central
control room/ desptacher.
All the suspended magnets shall be suspended over the conveyor by electric hoist of
suitable capacity. A 500mm dia pipe chute shall be provided in the building for disposal
of metal pieces picked up by the magnet.
• Codes & Standards
The design, manufacture, inspection and testing of In line Magnetic Separators /

Suspended Electro Magnets shall comply with all the currently applicable statutes,
regulations and safety codes in The Magnetic Separators shall conform to the latest
edition of standards and codes. Other internationally acceptable standards/codes, which
ensure equal or higher performance than those specified, shall also be accepted. Nothing
in this specification shall be construed to relieve the contractor of the required statutory
responsibility.
• Equipment Specification
Magnet core material shall be pure annealed iron or equivalent high permeability
magnetic material. The coil shall be of anodised aluminium foil / strip with class ' H'
insulation, to limit the absolute temperature of the winding to 140 deg. centigrade. The In
line Magnetic Separators / Suspended Electro Magnets shall be air cooled and if
required separate cooler fan has to be provided. The rectifier shall be of silicon bridge
rectifier type only.
The ' Force Index'i.e. the product of flux density in gauss and rate of change of flux
density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000 (gauss
x gauss/inch) minimum in hot condition for mounting height of 400 mm. However, the
strength of the magnet shall not be less than 1000 gauss in hot running condition at 400
mm distance. The minimum strength of the magnet shall be 1000 gauss at the specified
mounting height at the centre of Belt width. Bidder shall to select magnet width to suit
above. The width of the magnet shall be minimum 200mm wider than the width of the
belt.
Mounting height of 400 mm shall be taken between top of conveyor belt or bottom of
falling material trajectory and the surface of magnetic separator belt. Characteristic curve
of magnet with the value of flux density varying between 50 mm to face of conveyor belt
shall be provided. The cross section of magnet shall be suitably designed to provide
sufficient area for magnetising the coil effectively covering full cross section of the
discharge material. The In line Magnetic Separators shall be located such that it picks-
up tramp iron from coal trajectory after it has been discharged from head pulley.
The tramp magnetic pieces buried under coal picked up by the magnetic separator shall be
discharged suitably to ensure that it falls into the tramp iron chute, which shall be
provided upto ground level. The tramp iron chute shall be of minm. 6thk MS plates. All
conveyors with magnetic separator at head end shall have non-magnetic Stainless
pulleys (shell & diaphragm), however, for magnetic separators located other than the
discharge end, the idlers likely to be in zone of magnetic field shall be made of stainless
steel. The liners on discharge chute of ILMS shall be of non – magnetic stainless steel
material only.
For ILMS, the motor and the gear reduction unit for driving the in-line belt shall be
adequate sized with minimum 20% margin to avoid any over loading during operation.
Suitable zero speed switch shall be provided. No Chain/belt drives shall be accepted.
The belt shall be designed to withstand high temperature at the bottom of the magnet and
any serious damage due to the impact of the sharp edges of the tramp iron. The belt shall
be provided with rubber cleats spaced suitably. The belt shall be of fire resistant grade.
Side rollers shall be provided to keep the belt aligned.
The idlers and the pulleys supporting the belt shall be manufactured to the best
engineering practices and shall conform to relevant Indian Standards
Material to be separated as tramp iron by ILMS:
- The maximum weight of 50 Kg having ‘L/D’ > 5 of iron or steel piece

of any shape (except sphere) below the material heap of 250 mm.
- MS round bar with ‘L/D’ > 5
- MS Bolt ‘L’ = 5 X Diameter.
- MS Nuts with Diameter ‘L/D’ > 10 mm

• Construction Requirement
The ILMS units shall be supported by suitable structural member from the top by taking
support from the operating floor beams with turn buckle arrangement to facilitate the
necessary adjustments during operation.
ON/OFF control push buttons with indicating lamps shall be provided at the local station.
Suitable arrangements shall be provided in the magnet for keeping the coil of the magnet
dry from atmospheric condensation when the magnetic separator is not in use.
12A.02 Documentation
a) General arrangement drawing with bill of material of equipment showing overall

dimension, motor kW (if any), drive & suspension arrangement etc. alongwith details of
limit switches, load data, weight etc.
b) Supplier'
s name for components catalogues for these items shall be furnished.
d) List of recommended spares for two years maintenance of plant and equipment along with
itemised price.
e) List of tools and tackles to be supplied with the plant and equipment.
f) Duly filled up questionnaire given
2. List of drawings /data to be submitted by successful tenderer

dimension, motor kW (if any), drive & suspension arrangement etc. alongwith details of
limit switches, load data, weight etc.
b) Supplier'
s name for components catalogues for these items shall be furnished.
d) List of recommended spares for two years maintenance of plant and equipment along
with itemised price.

12A.03 QUESTIONNAIRE
Type & Quantity : ILMS / Suspended Magnet
Suspension device :
Location of ILMS / Suspended Magnet:
Force index (As defined earlier)
Gauss strength of magnet at the specified mounting height
Mounting height :
Weight of total assembly :
Magnetic Separator belt (for ILMS)
(i) Drive Unit

(ii) Belting
(iii) Discharge
.
Tramp Iron Items
(i) MS cube of 20 mm size

(ii) Brake shoe of Railway Wagon (Cast Iron15 Kg.)
(iii) MS plate of 250 x 250 x 100 mm size.
(iv) Shovel Teeth and spikes.
(v) MS round bar of 50 kg with L/D ratio not exceeding 5
Control
Magnetic Cooling system
Location of silicon rectifier unit
MOC of magnet core
MOC of coil
MOC of insulating medium
MOC of pulley shell
MOC of diaphragm
MOC of idler

METAL DETECTOR :
12B.00 Scope Of Work
12B.01 The scope of work of the Tenderer shall include design, engineering, manufacture,
electrics / electronics / microprocessors and standard accessories of Metal Detector as
covered under this specification.
• The scope of supply and services of the Tenderer shall include the following:
a) Mechanical
safety switches, structural, mechanical and other standard accessories, sand hoppers,
markers etc.
and supporting the equipment.
- The Tenderer shall also include supervision services at site during erection, testing and
commissioning of the equipment supplied by them.
b) Electricals
• Necessary hooter / light indicators / alarms and panel with sufficient I/Os for
interconnection with PLC
• All fixing bolts and nuts including foundation bolts shall be included in the scope of
supply of Tenderer.
• Required quantity of initial fill of oil, grease, lubricants, hydraulic fluid etc. and other
inspection of the equipment. The list of such tools and tackles shall be furnished and
included in offer.
• Statutory approval wherever required shall be taken by the Tenderer for the equipment
Contract (GCC), General Technical Specification (GTS) or any other part of the
document.
12B.02 TECHNICAL SPECIFICATION
• Codes & Standards
The design, manufacture, inspection and testing of Metal Detectors shall comply with all
the currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The Metal Detectors shall conform to the latest edition of
standards/codes, which ensure equal or higher performance than those specified, shall also
be accepted. Nothing in this specification shall be construed to relieve the contractor of
the required statutory responsibility.
• Equipment Specification
Metal detectors shall have high reliability with enough sensitivity to detect 25 mm
aluminium sphere below the burden of material. It shall also detect other metals like brass,
copper, stainless steel, manganese steel, bars, scraps etc.
The equipment shall have provision for automatic static calibration with adjustable
sensitivity.
Metal detectors shall be completely solid state using latest state of art technology. It shall
be suitable for 50oC ambient and RH of 100%. The search sensor shall be protected from
rain and direct sunlight by means of a non metallic covering other than wood. Control unit
shall have adjustable controls for sensitivity, ON/OFF push buttons, reset table operation
counter, audio-visual alarms local remote selector switch and all other necessary controls
for trouble free operation of metal detector. It shall be suitable for mounting on wall,
column, structure, etc. with IP-65 degree of protection. It shall be constructed from FRP
of thickness not less than 2 mm.
The metal detectors shall also have the following features:
The coils shall be protected against being struck by an oversized material/ coal.
In order to counteract interference from external sources such as motors, lighting

and radio-transmitters, and to nullify the effect of climate changes/ aging, dual
receiver coils are to be used.
In order to allow passing of metal belt fasteners without giving alarm and at the
same time detection tramps, suitable arrangements shall be provided.
In case a few non-magnetic idlers or non magnetic deck plates are required, the
bidder shall provide these. However, these shall be metallic. Wood shall not be
used.

LED display of COAST COUNT to indicate the number of pieces of tramp iron
detected since last reset shall be provided so that the operator is alerted for the
pieces of tramps, if any, between tramp marker and coil before restoring conveyor.
TOTAL COUNT, which is not resettable, shall also be provided on the same LED
display on demand.
The location of tramp metal pieces shall be indicated by liquid colour spray / sand
bag marker / as agreed by purchaser.
Construction Requirement
Fiber glass enclsosure (with IP-65 degree of protection) shall be provided for
all type of coils.
Suitable tramp metal markers shall be provided.
Local control panel shall be provided with IP-65 degree of protection.
12B.03 Documentation

dimension and details.
b) Supplier'
s name for components & catalogues for these items.
d) List of recommended spares for two years maintenance of plant and equipment.
f) Duly filled up questionnaire.
g) The Tenderer has to furnish one copy of the specification drawing duly signed by him as a
token of acceptance along with the list of deviation from tender documents.
2. List of drawings /data to be submitted by the successful tender

dimension & details.
b. Supplier'
d. List of recommended spares for two years maintenance of plant and equipment
along with itemised price.

12B.04 Questionnaire
Type & Name of Supplier :
Sensitivity :
Enclosure :
Control :
Calibration :
Tramp metal markers (type) :

GS – 13, CHARGING HATCH:
13.00 SCOPE OF WORK
13.01 The scope of work of the Tenderer shall include design, engineering, manufacture,
over to the client including all standard accessories of Charging Hatches.
• The scope of the Tenderer shall also cover inclusion of necessary fixtures, supporting
angles and brackets required for mounting the charging hatches.
• Necessary sealing work required for arresting the dust shall also be under the scope of the
Tenderer.
specification and instruction to the Tenderer, General Conditions of Contract (GCC), or
any other part of the document.
Charging hatches are meant for hermetically dust sealing of bunkers during feeding of
materials by feeding conveyors.
• The working principle of charging hatches shall be as follows:
Raw materials after being discharged from conveyor shall fall into the respective bunkers
through charging hatches. When material is discharged at any section of the inclined
removable slide plate by a shuttle belt conveyor, the pressure generated by the falling
material shall be able to push the respective curtain plates to make the required opening
for being fed to bunker.
The flaps of charging hatch, normally closed, shall open under dead weight of material
and close of its own under gravity after the materials falls into bunker. Thus the dust
emitted by falling material is hermetically sealed.
The charging hatch assembly shall rest on the Insert Plates provided in the respective
bunkers.
The plate used shall be of Mild Steel construction and minimum 10 mm thick. Diameter
of the cross rods shall be minimum 32 mm.
There shall be only one uniform size of charging hatches for all the bunkers.

13.03 DOCUMENTATION
1. Drawing and documents to be submitted with tender
The Tenderer shall submit following technical drawings & technical data/ information
with tender for charging hatches without which the tender shall be considered as
a) General description of design consideration and all the assumption made by the supplier.
b) Typical GA drgs for the equipment/ system including sections and details giving relevant
information, binding dimension etc.
c) Standard/ special accessories being considered for supply along with the equipment
d) The questionnaire filled in
a. General arrangement drawing of equipment showing full details of charging hatches in

plan and section along with design calculations.

Tenderer
1. All approved GA drawings, complete assembly and sub assembly drawings of the
equipment.
2. Drawing of all equipment/ component received from sub supplier.
3. Engineering and design calculations.
4. Test and warranty certificate for each item of equipment.
5. Test reports and inspection reports.
7. Instruction manuals for testing and commissioning.
8. Operation, maintenance and safety manuals.

13.04 QUESTIONNAIRE
1. Make
2. Nos of charging hatches offered / length of each hatch :
3. Gross weight of each charging hatch :
4. Material of construction of charging hatch plate
5. Liner materials used, type, thickness, fixing arrangement
6. Any other information as the Tenderer thinks necessary for installation, operation and
maintenance of equipment

GS – 14, CRANES, HOISTS ETC.:
DOUBLE GIRDER EOT CRANE
14-A.00 DOUBLE GIRDER EOT CRANE
14-A.01 The scope of work covers design, manufacture, fabrication/assembly, shop testing,
painting, supply, storage, erection, testing & commissioning of cranes complete with
electricals and standard accessories with attachments to be installed as covered in data
sheets in Technical Specifications. Relevant codes and practices for the cranes shall be
used.
• All the equipment shall be of reputed make and proven quality with regard to their
performance. The make shall be as per approved list of Purchaser/Consultant.
• The crane shall be inspected and tested during different stages of its manufacture (starting
from raw materials till the completion of the crane) by the Purchaser/ his authorized
representative at the Supplier'
s or his sub-supplier'
s works as per the inspection procedure
mutually agreed between the Purchaser or his authorized representative and the Supplier.
Inspection shall be regarded as a check up and shall be in no way binding on the
Purchaser.
14-A.02 TECHNICAL SPECIFICATION
a. General
i) EOT cranes shall be designed, manufactured and tested in accordance with the latest
revision of IS: 807-1976, 3177-1999 and 4137.
ii) The no of poles for the motors shall be as given below:-
Hoist motion Ct motion LT motion

No of poles for motor for DG
8 6 6
EOT Cranes
No of poles for motor for SG-
6 4 4
EOT / US EOT Cranes
iii) The crane components shall be standardized to keep the number of spares to the
minimum.
iv) All parts requiring replacement or inspection or lubrication shall be easily accessible
without the need for dismantling of other equipment or structures. All electrical cables
shall be so laid that they are not liable to be damaged and can be easily inspected and
maintained and when necessary any damaged cable can be accessed and replaced
individually.
v) All components for cranes of identical capacity and duty shall be interchangeable. Cranes
of the same capacity and duty shall be identical in all respect unless otherwise required.
vi) No cast iron parts shall be used except for electrical equipment and no wood or other
combustible material shall be used unless specifically mentioned otherwise. Deviations, if
any, to this clause shall be permitted only with the specific approval of the Purchaser.
vii) All machinery or equipment included under this specification must be equipped with
safety devices and clearances to comply with recognized standards and Purchaser' s
requirements along with safety codes and statutes prevalent at the place of installation of
the equipment.
viii) For welded construction such as that of bridge girders, end-carriages, rope drums,
gear-boxes etc. steel shall be as per IS: 2062-1992 quality. For welding these members
low hydrogen electrodes shall be used.
ix) All wheels, couplings, open gears etc. shall be provided with covers, opening on strong
hinges. All heavy covers shall be provided with inspection windows.
x) Where down shop leads are located below runway rails, guards shall be provided on the
crane to prevent the hoist ropes from coming in contact with down shop leads.
xi) All bolts except those with nyloc nuts shall be provided with grip lock nuts or spring
washers.
xii) For outdoor cranes all electrical and mechanical equipment which are exposed to weather
shall be completely covered or made weather proof. The covers shall be segmental to
facilitate easy dismantling and assembly.
xiii) The end-carriages shall be fitted with substantial safety stops to prevent the crane from
falling more than 25 mm in the event of breakage of a track wheel, bogie or axle. These
stops shall not interfere with the removal of wheels.
xiv) Fasteners for pedestal blocks, motors, gear-boxes etc. shall be easily removable from the
top. Studs or body bound bolts shall not be used as fasteners for mechanical items except
for fixing cover.
xv) Power & control cables shall be clamped in-groups separately. All trailing cables shall be
clamped with PVC or non-metallic clamps. Group de-rating factor shall be appropriately
taken according to the recommendations of the cable manufacturers based on the method
of laying and number of cables being laid together.
xvi) Guards of approved design, which will push forward off the track, any object placed
across it, shall be attached to each end of the end carriages.
xvii) Parts of steel frames carrying machinery shall be provided with doubling plates of
adequate thickness, riveted or welded and machined to true surface.
xviii) Defects in the material like fractures, cracks, blow holes, lamination, pitting etc. are not
allowed. Rectification of any such flaw is permissible only with the approval of the
Purchaser.
b. Tolerances: The Tenderer / Supplier shall ensure that the crane shall be manufactured as
per the tolerances specified below :
(i) Span over LT wheels : + 6 mm upto 40 metres

(ii) Wheel base
• LT : + 5 mm
• CT : + 3 mm

(iii) Difference in diagonal

• LT : + 5 mm
• CT : + 3 mm
(iv) Long travel wheel alignment : + 1 mm
(v) Tilt of wheels or balancer axle : + 1 mm/1000 mm
(Horizontal & Vertical)
(vi) Trolley wheel gauge : • + 3 mm upto 7500 mm
: span
• + 5 mm above 7500
mm span
(vii) Trolley track gauge : • + 3 mm upto 7500 mm
: span
• + 5 mm above 7500
mm span
(viii) Difference in height between trolley rails
(H) in relation to the trolley track gauge (S)
shall be within the following tolerances:
`S'(mm) `H'(mm)
Upto 2500 : 4
Above 2500 and upto 4500 Above 4500 : 6
: 10
(ix) Horizontal bend of girder in plan : Span / 2000
:
(x) Shift of the web plates of main & end girders : H / 200
from vertical over height `H’ measured near :
the mid span & close to the main diaphragm.
(xi) Twist of the main girder : Span / 1500
(xii) Axis of the flange plates from the axis of the : H / 250
beam
(xiii) Tolerances on camber
• Upto 4 mm : (+) 4
(-) 0
:
• Above 4 mm and upto 8 mm. (+) 5
(-) 0
:
• Above 8 mm and upto 16 mm. (+) 6.3
(-) 0
:
• Above 16 mm and upto 31.5 mm (+) 8
(-) 0
:
• Above 31.5 mm and upto 63 mm (+) 10
(-) 0
(xiii) Over buffer length : + 5 mm
(Over buffer dimension on two sides shall be :
same)
(xiv) Height of center of buffer : + 5 mm
(from top of track rail)

c. The crane after erection shall be tested as follows :
i) Insulation tests mentioned in IS: 3177-1999.
ii) Deflection Test: The deflection test of the bridge girders shall be carried out as
per IS: 3177-1999. After the deflection test with safe working load, the crane
shall be tested for deflection with 25% overload and there shall not be any
permanent set after the removal of the load. The deflection of the bridge girder
shall not exceed 1/900 of span with the fully loaded trolley at the middle of the
span.
iii) Speed Tests :
a) All motion of the crane shall be tested with rated load and speed (together) and
the speeds shall be attained within the tolerance limit.
b) All motions of the crane shall be tested with 25% over load in which case the
specified speeds need not be attained but the crane shall show itself capable of
dealing with the overload without difficulty.
iv) Brake Tests :
a) The hoist brakes shall be capable of braking the movement with rated as well as
overload. However, the braking path with rated load shall not exceed hoisting
speed/120.
b) The long travel and cross travel brakes shall be capable of arresting the motion
within a distance in meters equal to 10% of the speed in meters/min. and the
retardation due to braking shall not exceed the values as given in the table below:
Working condition Retardation, according to percentage number of

driving wheels, (in m/sec2)
100 50 25
Outdoor 0.9 0.45 0.25
(When u = 0.12)
Indoor 1.5 0.75 0.40
(When u = 0.2)
Legend u= Friction Factor
At the manufacturers’ works, dimensional tests, load test, deflection test and permanent
set tests shall be carried out. At the purchaser’s premises, all functional tests including
height of lifts, hook approach, speed tests (with and without load), brake tests, limit
switch operations, safety / emergency switch operation and other tests as per IS 3177 shall
be carried out. Load test, deflection test and permanent set tests shall also be carried out
once again at purchaser’s premises until and unless the same is waved off in writing for a
specific reason.

d. STRUCTURAL DETAILS :
i) The crane bridges shall be of welded double/single web box construction and shall
be designed as per IS: 807-1976 and/or AISE NO. 6. The materials of construction
shall be weldable mild steel in compliance with the relevant standard. However,
high strength weldable structural steel also may be used wherever required in
compliance with the relevant standards.
ii) The crane bridge girder upto 12-m span shall be in one piece. Girders above 12 m
span may be spliced. The number of such splices shall not exceed 2 upto 36 m
span. Beyond 36 m span, the number of splices may be 3. Splices shall be designed
to resist all the forces and moments to which it is subjected to, plus 50% thereof.
However, in no case the strength developed by the splice shall be less than 50% of
the effective strength of the material.
Splices shall be proportioned and arranged so that the gravity axis of the splice is
in line with the gravity axis of the members joined so as to avoid eccentricity of the
loading.
iii) Black bolts shall not be used in the main structure of the cranes.
iv) Cross travel rail shall be fixed to the bridge girders by clamping only and not by
welding.
v) Transverse fillet welding on load carrying members shall be avoided. All butt
welds on tensile zone shall be X-rayed.
vi) Plates, bars, angles and where practicable other rolled sections used in the load
bearing members of structures shall not be less than 6 mm in thickness.
vii) The end-carriages shall be of double web plate box construction and shall be
connected to the girders by welding at shop or by large gusset plates and fitted
bolts to ensure maximum rigidity. Drop stops and jacking pads shall be built-in
features of the cranes. Full length checkered plate platforms shall be provided
along both sides of the cranes in order to ensure easy access to crane crab, long
travel gears and other parts. Safety railings shall be provided on crane bridges and
crab frame. Access to the operator' s cabin shall be via staircases only and not
through ladders. Platforms to facilitate inspection and dismantling of long travel
wheels and main current collectors shall be provided.
viii) Operator's cabin shall be of welded construction and located below bridge girders.
Closed operator' s cabin shall be provided with adequate glazing to ensure good
vision in all directions and glazing shall be accessible for cleaning from cabin
itself.
ix) The closed cabins shall be equipped with circulating and exhaust fans whereas
open cabins shall have only circulating fans.
x) Air-conditioned cabins, if provided, shall be with double glazing & heat insulation.
The temperature inside the cabin shall be maintained at 25+20 C.

xi) All the cabin floors shall be covered with heat and electrically insulated material.
The cabin shall also be equipped with adjustable swiveling type upholstered chair.
xii) The crab frame shall be made of steel plates and rolled sections in welded
construction. Crab frame shall be fabricated in one piece if there are no transport
limitations. If the trolley is fabricated in more than one piece due to transport
limitation, the design of the splice shall be such that one unit of mechanism
mounted on one part of the trolley, does not come over the other part.
xiii) Foot-walks shall be of sufficient width to give at least 500 mm clear passage at all
points except between railing and bridge girder where this clearance may be
reduced to not less than 440 mm.
xiv) The platforms along the bridge girders and over the crab shall allow convenient
access for replacement, inspection, lubrication etc. for different mechanical and
electrical components.
xv) The minimum thickness of checkered plates shall be 6 mm O/P for indoor cranes &
8 mm O/P for outdoor cranes.
e. MECHANICAL DETAILS :
i) Rope drums
Rope drums shall be of cast steel or fabricated out of rolled steel plates. Fabricated
drums shall be stress relieved before machining. The grooves of the drum shall be
smooth finished. Rope drum shall be flanged at both ends.
ii) Rope sheaves
Rope sheaves shall be of cast steel or fabricated out of rolled steel plates.
iii) Wire ropes
The wire rope shall be hemp cored for all cranes. Ropes shall be regular right hand
lay as per IS : 2266-1989. The construction of the ropes shall be 6 x 37 upto 16 mm
diameter and 6 x 36 above 16 mm diameter.
iv) Hook block
The sheaves shall be fully encased in closed fitting guards fabricated out of steel
plates. Smooth opening shall be provided in the guards to allow the free movement
of rope, and holes shall be provided for drainage of the oil.
v) Gears & gear-boxes
Straight and helical spur gearing shall be used for all motions. Worm & bevel
gearing shall not be used. All first reduction gears shall have helical teeth. All
pinions shall be integral with the shaft. All gears shall be hardened and tempered
alloy steel having metric module. Overhung gears shall not be used.

Surface hardness for pinion shall be 255 to 300 BHN and for gears it shall be 215
to 260 BHN. Difference in hardness of pinion and gear shall not be less than 20
BHN. All cast steel gear shall be tested by Gamma Ray. All gears shall be enclosed
in oil tight gear-boxes. Gearboxes shall be of high grade cast iron/cast steel or
fabricated and split at each shaft centerlines. Fabricated gearboxes shall be stress
relieved before machining. For Cross-travel and Long-travel motions, horizontal
gear-boxes shall be used unless and until there is specific requirement for hook
approaches in which case CT shall be provided with vertically gear-boxes with `T'
split and dual (one standby) pump for lubrication.
vi) Connection between rope drum & gear-box
Rope drums of diameter 500mm and above shall have drum-couplings and tooth-
bush coupling (spline shaft type) for diameters less than 500mm.
vii) Wheels
Crab/crane wheels shall be double flanged. Wheels shall be mounted in

anti-friction roller bearing housed in `L'shaped bearing brackets for easy removal
during maintenance. Flange-less wheels with guide rollers are also acceptable.
Solid wheels shall be of forged rolled/cast steel. Wheels from 400 mm diameter
and above may consist of hardened, rolled / forged steel tyre of not less than 60
mm thickness, shrunk on to cast iron center. Minimum wheel diameter shall be
500mm for LT and 320mm for CT.
For process cranes of 100T Capacity and above and for Rotating trolley cranes,
wheels shall be of EN28M material. All Rotating trolley cranes shall be on slew
bearings of RotherDe (Germany) make – (Wheel on rail type RT cranes are not
acceptable).
For M7 and M8 duty cranes, automatic, controlled wheel-flange lubrication shall

be provided.
viii) Coupling
Motor shaft shall be connected to the gearbox-input shaft through flexible shock
absorbing coupling. Rotating parts shall be suitably covered by 3.15-mm thick
sheet steel hinged covers for safety. In case of single motor central drive for Long
travel motion, output shaft of the gear-box shall be connected to the line shaft
through half geared couplings. Intermediate lengths of the line shaft may be
connected through solid flange couplings. Half geared couplings with floating shaft
shall be provided between the wheel and the wheel and the line shaft.
ix) Bearings & bearing housings
Anti-friction bearings shall be used throughout except where required otherwise for
technical reasons.
x) Buffers

Spring loaded type buffers shall be provided on all the 4 corners of the bridge
girders and the end carriages for cross and long travel motions respectively. For
process cranes of 100T Capacity and above and for Rotating trolley cranes, LT
buffers shall be hydraulic/ pneumatic type of OLEO make.
xi) Brakes
Brakes shall be provided for all motions on the high-speed pinion shaft of the gear
train. For Hoist motion DCEM brakes shall be provided. For CT and LT motion,
AC hydraulic thruster brakes of make as per GS-13 shall be used.
xii) Lubrication
Grouped grease lubrication system shall be used for the cranes. Lubrication of the
gears and pinions in the gear-boxes shall be splash fed from the sump.
14-A.03 DOCUMENTATION
a. Information to be furnished by the Tenderer along with the tender:
The tenderer shall submit adequate sets of following technical drawings & technical data/
information with tender for cranes without which the tender shall be considered as
a) General arrangement drawings/clearance diagram of the cranes.

b) Filled up questionnaire
c) List of commissioning spares
d) List of spares for two (2) years normal operation and maintenance
e) List of special/ maintenance tools & tackles.
b. List of drawings/ documents to be furnished by the successful Tenderer for

approval
a) General arrangement drawing of crane showing full details in plan and sections.
b) General arrangement drawing of trolley/ hoist blocks.
c) Single Line Diagrams
d) Quality Assurance Plan for inspection.
e) Detail specification of motor indicating type, KW, rpm, starting torque requirement,
class of insulation, type of enclosure, frame size etc.
f) Power requirement and control scheme.
g) Motor selection, brake selection, wire-rope selection calculations.
h) List of spares for 2 years normal maintenance.
c. List of drawings/documents to be submitted along with equipment by the

successful Tenderer
a) GA drawings, complete assembly and sub assembly drawings of the equipment.

b) Drawings of all equipment/component received from sub supplier.
c) Test and warranty certificate for each item of equipment.
d) Test reports and inspection reports.
e) Instruction manuals for testing and commissioning.
f) Operation, maintenance and safety manuals.
g) Requirement of special tools and tackles.

h) Detail drawing list and specifications of all wearing out parts and parts subject to
i) List of spare parts with drawings, sketches, specifications and manufacturer' s
catalogue.
14-A.04 QUESTIONNAIRE (DOUBLE GIRDER CRANE)
1. DPR/TPR/ Crane No.

2. No. Off
3. Type of Crane
4. Supplier/ Make
5. Capacity (t)
6. Span (m)
7. Duty Class
8. Speeds (normal & Creep ) m/ min
a) Main hoist & creep
b) Aux. Hoist & creep
b) Cross travel
c) Long travel
9. Height of lift (m)
a) Main hook
Above floor
Below floor
b) Aux hook
Above floor
Below floor
10. Crane rail height above floor (m)
11. Max wheel load (t) (without impact)
12. Type of cabin
13. Type of hook:
a) Main hook
b) Aux hook
14. Location (Indoor/ Outdoor)
15. Hook approaches (m)
a) Main hook
b) Aux hook
16. No of rope falls, dia, construction,
& breaking strength for
a) Main hoist
b) Aux hoist
17. Gantry rail size
18. Crab rail size
19. Over buffer dimension (m)
20. Wheel base
21. Wheel diameter for
a) LT wheel
b) CT wheel
22. Handling attachments
23. Special features (weighing device etc)
24. Motor:
( Type, kW, rpm starts/ hr enclosure etc)

a) Main hoist
b) Aux hoist
c) Cross travel
d) Long travel
25. Type of control for each motion with corresponding characteristic curve :
26. Method of obtaining creep speed:
27. Power supply
- Power supply S.L.D:
- Electric equipment specification
28. Control voltage
29. Ambient temp/ Environment
30. Total weight of the crane (t)
31. Break up of crane weight (t)
a) Structural
b) Mechanical
c) Electrical
32. Total weight of the crab (t)
33. Code of design
34. General arrangement drawing, incorporating the front and side elevations, plan,
hook approaches, location of cabin/ pendant, down shop lead, clearance
dimension, handling attachments and other relevant characteristics of the crane.
35. Details of swiveling / rotating arrangement, if any, along with scheme.
36. Any other information

SINGLE GIRDER EOT/US CRANE
14-B.00 SINGLE GIRDER EOT/US CRANE
14-B.01 The scope of work of the Tenderer shall consist of design, manufacture, inspection,
assembly, and painting at manufacturer’s shop as well as at site after erection, supply and
transportation to site, unloading and re-conservation at site, erection testing &
commissioning of Single Girder EOT / Under Slung Cranes of various capacity.
14-B.02 Technical Specification
• Single girder cranes shall be designed, manufactured, assembled and tested in accordance
with the latest revision of IS:807, IS:3177, IS:3938 and other relevant codes and practices
for the cranes to be used in steel plants, steel industry (IPSS) unless otherwise stated.
• The components of the hoist shall be designed, manufactured, assembled and tested in
accordance with the latest revision of IS:3938 and shall be of standard make.
• All working parts requiring replacement or inspection or lubrication shall be easily

accessible without the need for dismantling of other equipment or structure.
• All electrical cables shall be so laid that they are not liable to be damaged and can be
easily inspected and tested.
• For out-door cranes all electrical and mechanical components which are exposed to
weather shall be completely covered or made weather proof. The covers shall be in
segments to facilitate easy dismantling and assembly.
• No cast iron parts shall be used except for electrical equipment and no wood or other
combustible material shall be used unless specifically mentioned otherwise.
• Where down shop leads are located below runway rails, guard shall be provided on the
crane to prevent the hoist ropes from coming in contact with down shop leads.
• All bolts except those with nyloc nuts shall be provided with grip lock nuts or spring
washers.
• All trailing cables shall be clamped with PVC or non-metallic clamps.
• Steel frames carrying machinery shall be machined to true surface.
• All gears and bearings shall be lubricated by splash lubrication/ grease as required. All
greasing points shall be easily accessible.

14-B.03 Structural Design
• The crane structure shall be designed in accordance with the latest revision of IS:807.
• The bridge girder shall consist of main and an auxiliary structure where necessary.
• End-carriages shall be fabricated from rolled steel sections or plates, or both, welded
together to form a box.
• End-carriages shall be of ample strength to resist all stresses likely to be imposed on them
under severe conditions, including collision with other cranes or stops. The length of the
end-carriage shall be such that no other part of the crane is damaged in collision.
• The end-carriage shall be fitted with safety stops to prevent the crane from falling more
than 25 mm in the event of breakage of a track wheel or axle. Suitable jacking pads shall
be provided on each end-carriage for jacking up the crane while changing track wheels.
• For single girder EOT cranes with central L.T. drive, full length M.S. chequered plate
platform shall be provided along the bridge girder for mounting and access to long travel
drive, current collection system, control panels, etc. A clear head-room of minimum 2000
mm shall be made available over the top of platform from the bottom cord of the roof
truss.
• Black bolts shall not be used in the load bearing structures of the crane. Also high tensile
friction grip bolts shall not be used unless approved by the Purchaser.
• Bolts used in shear shall be fitted into reamed holes.
• Transverse fillet welding on the load carrying members shall be avoided.
• All butt welds on structural members, subject to tensile stress, shall be x-rayed.
• Plates, bars, angles and where practicable, other rolled sections used in the load bearing
members of the structure shall not be less than 6 mm thick.
• Steel sections and plates, used for construction shall be of the latest revision of IS:2062
quality.
14-B.04 Mechanical Equipment
a. Design of Mechanisms
Each mechanism of the crane shall be modular in construction with built in facilities for
easy dismantling and maintenance of each assembly as an independent unit.
b. Rope Drums
Fabricated rope drum shall be stress relieved before machining. For the cranes used in
steel plants, the material of the rope drum shall be limited to C.S. / M.S.
c. Wire Rope
The wire ropes shall be regular right hand lay hemp cores as per IS: 2266/1989. However,
ropes working under water and in corrosive atmosphere shall be galvanized and shall
have steel core. For rope arrangement with 2 falls, wire rope shall be of non-spinning
type. For the cranes in steel plant, selection of wire rope shall be as per IPSS.
d. Rope Guides
Suitably designed rope guides with pressure ring/ rope tightener shall be provided for each
lead of rope from the rope drum to prevent the rope from overriding, loosening or rope
coming off the groove.

e. Rope sheaves
For cranes in steel plants, material shall be either CS/MS. Bottom block sheaves shall be
provided with suitable guards to retain the rope in the sheave groove. Equalizer sheave/
bar shall be arranged to turn and swivel to maintain rope alignment under all
circumstances.
f. Wheels
For single girder EOT cranes, the wheels for long travel motion shall be double flanged
with straight tread. The width of wheel tread shall be greater than the rail head by 30 mm.
For under slung cranes hoists block, the wheels shall be single flanged with straight/ taper
tread to suit the track beams. Minimum diameter of the LT wheels for S.G. EOT cranes
shall be 320 mm. However, in case of steel plant duty cranes the combination of wheel
diameter and rail size shall be ensured. Wheels shall be of forged/ rolled/ cast steel with
minimum hardness of 200 BHN in case of single girder under slung cranes running on
rolled steel joist and 300 BHN for EOT cranes and for under slung cranes/ hoists running
on wear resistant flats welded to rolled steel joists. Minimum diameter of CT & LT
wheels for under slung cranes shall be 200 mm.
g. Long Travel Drive
a) For Single girder EOT Cranes
Individual wheel drive (one wheel in each end-carriage) shall be provided when the crane
span exceeds 13 meters. All parts of the long travel drive shall be located above the
platform and easily accessible. The gear-box mounted on platform with foot mounted
motor and brake shall be connected with driving wheel by means of locating shaft and
flexible geared coupling. The use of open gearing, chain and sprocket, pulley and belt etc.
is not permitted.
b) For under Slung Cranes
Dual drive arrangement located at either end of each end carriage shall be provided.
Flange mounted geared motors may also be used.
h. Hoist and Cross-Travel Drive
The hoist and cross travel motions shall be combined in one block which shall be
designed as per IS:3938/1983. It shall be ensured that skidding does not occur under any
condition.
The no of poles for the motors shall be as given below:-
Hoist motion Ct motion LT motion

No of poles for motor for DG
8 6 6
EOT Cranes
No of poles for motor for SG-
6 4 4
EOT / US EOT Cranes

i. Gearing and Gear-boxes
Straight and helical spur gearing in metric module shall be used for all motions. Worm
gearing shall not be used. All gears shall be of hardened and tempered alloy steel with
machine cut teeth. Hardness for pinion shall be 220 BHN and for gears it shall be 200
BHN. All gearings shall be enclosed in oil tight gear-boxes. Fabricated gear-boxes shall
be stress relieved before machining.
j. Bearings and Bearing Housing
Ball and roller anti-friction bearings shall be used throughout unless otherwise specified.
Anti-friction spherical roller bearings shall be provided for live axles of travel wheels.
Housings shall be split on shaft centre line to permit removal of the shaft. The underside
of the base of each bearing pedestal shall be machined and shall bear upon a machined
surface.
k. Motors/ Couplings
For Hoists above 5T, the motor (Foot mounted B3 type) shall be connected to its gear
drive by a flexible coupling. Flange mounted motors (B5) may be used for Hoists of
capacity upto 5T and also for all CT/ LT individual drives. In case of single motor central
drive for CT/ LT motion, foot mounted B3 type motors shall be connected to its gear drive
by a flexible coupling. Output shaft of the gear-box shall be connected through solid
flange couplings. Half-geared couplings with floating shaft shall be provided between the
wheel and the line shaft.
l. Hook Blocks
Hook blocks shall be of enclosed type leaving openings for ropes only so that ropes do not
run off the sheaves. Standard swiveling shank hooks, mounted on thrust bearings shall be
used unless otherwise specified.
m. Brakes
DC Electro-magnetic brakes shall be provided for hoist motion of 5T or more Capacity.

For hoist motion of less than 5T Capacity, DC disc brakes shall be used. For LT, CT and
slew motions (in case of Jib cranes), DC disc brakes shall be used.
n. Buffers
The crane shall be provided with rubber buffers on the four corners of the end-carriages
unless otherwise specified. For electrically operated hoists, steel stops at all the four ends
of the track beam shall be provided.
14-B.05 DOCUMENTATION
a. Drawings and documents to be submitted by the Tenderer with Tender

a. General Arrangement drawings of cranes/ hoists / attachments & signed copies of

Clearance diagram.
b. Duly filled in questionnaire.
b. List of Drawing/ Documents to be furnished by the Successful Tenderer for

approval / reference
a. General Arrangement drawings of cranes/ hoists / attachments & signed copies of

Clearance diagram.
b. Electrical Single Line Diagrams
c. Quality assurance plan for inspection.
d. Specification of oils and lubricants and other consumables and their quantity and
e. Detailed layout plan and sections for power supply system. (Angle Bus bar/Shrouded Bus
Bar/ Festoon Cable etc.)
f. DSL / Trolley line arrangement layout.
c. List of Drawings/ Documents to be furnished alongwith equipment by the

Successful Tenderer
a. Requisite no. of sets of all GA drawings, complete assembly and sub assembly drawings
of the equipment.
b. Drawing of all equipment/ component received from sub supplier.
c. Engineering and design calculations.
d. Test and warranty certificate for each item of equipment.
e. Detailed erection schedule and manuals, assembly/ erection drawings, erection sequence,
special precautions to be followed during assembly/ erection (these shall be despatched
three months prior to FOT/FOR delivery).
f. Test reports and inspection reports.
g. Instruction manuals for testing and commissioning.
h. Operation, maintenance and safety manuals.
i. Requirement of special tools and tackles, if any, for subsequent maintenance.
j. Detail drawing and specifications of all wearing out parts and parts subject to breakage
during normal operating conditions (two sets and one reproducible and/or two sets of
catalogues).
k. List of spare parts with drawings, sketches, specifications and manufacturer’s catalogue
(two sets and one reproducible and/ or two sets of catalogues)
l. All other drawings and documents as stipulated in General Conditions of Contract.
14.B.06 QUESTIONNAIRE (SG EOT/US CRANE)
I/ Crane No. :
ii/ Nos. off :
iii/ Type of crane :
iv/ Capacity (t) :
v/ Span (m) :
vi/ Duty class :
vii/ Location :
viii/ Hoists :

a) Speed with safe working load, m/min :

b) No. of rope falls supporting the load
and specification of rope :
c) Lift of hook above floor, m :
d) Drop of hook below floor, m :
e) kW of motor at specified rating :
f) RPM of motor :
g) Make, type and size of brake :
ix/ Cross - travel
a) Speed with working load, m/min :
b) Wheel base, mm :
c) No. of wheels :
d) kW of motor at specified speed :
e) RPM of motor :
f) Make, type and size of brake :
x/ Bridge
a) Speed with safe working load, m/min :
b) Wheel base, mm :
c) No. of wheel on each end-carriage :
d) Diameter of wheel, mm :
e) Maximum wheel load, kg :
f) No. of motors :
g) kW of motor at specified rating :
h) RPM of motor :
i) Make, type and size of brake :
xi/ Power supply :
xii/ Control voltage :
xiii/ Made and type of control :
xiv/ Total weight of crane, t :
xv/ Total weight of hoist, t :
xvi/ Break-up of crane weight, t :
a) Structural :
b) Mechanical :
c) Electrical :
xvii/ General arrangement drawing showing
details as enumerated :
xviii/ List of deviations from the
Purchaser’s Specification. :

ELECTRIC HOIST
14-C.00 ELECTRIC HOIST
14-C.01 The scope of work of the Tenderer shall consist of design, manufacture, inspection,
transportation to site, unloading and re-conservation at site, erection testing & commissioning
of Electric hoist of various capacity.
14-C.02 TECHNICAL SPECIFICATION
a) The hoist shall be designed in accordance with IS:3938-1983.
b) For outdoor hoists, motors, brakes & other equipment shall be covered to suit to outdoor
operations.
c) All trailing cables shall be clamped with PVC or non-metallic clamps.
d) Defects in the materials like fractures, cracks, blowholes, or laminations are not allowed.
e) No cast iron parts shall be used except for electrical equipments and no wood or combustible
material shall be used unless specifically mentioned otherwise.
f) All working parts requiring replacements or inspection or lubrication shall be easily accessible
without the need for dismantling of other equipment or structure.
g) All bolts except those with nyloc nuts shall be provided with grip lock nuts or spring washer.
h) All parts of the hoist shall be thoroughly cleaned of all loose mill scales, rust or foreign matter
& then painted as specified. All parts inaccessible after assembly shall be painted before
assembly & assembled while paint is still wet.
i) All parts except motors, resistors, gears, thrustors, solenoids, etc. shall be de-rusted manually
& painted as follows:
14-C.03 Mechanical details
01. Wheel & drive
The electric hoist shall run on two pairs of wheels, a pair of which shall be driven by
flange mounted motor through reduction gear. The wheels shall be of cast steel/forged
steel, single flanged with taper / parallel treads to suit to monorail. The wheels shall be
mounted on anti-friction bearings & shall be easily removable for repair & replacement.
The wheel diameter shall be selected such that skidding does not take place even under
unloaded condition.
02. Hoist mechanism
The hoist mechanism shall consist of a bottom block fitted with a standard forged swivel
hook of the specified capacity, supported on 2 or 4 falls of wire rope. However, non-
spinning type of wire rope shall be used for 2 falls rope arrangement. The wire rope shall
be wound on a grooved drum which shall be sufficiently long to accommodate in one
layer the length of rope requisite for the specified lift & in addition not fewer than two
turns at each anchored end & one spare groove at the opposite end. The hoist drum shall
be motor driven.
03. Gearing
Straight & helical spur gearing shall be used for all motions. Worm & bevel gears shall
not be used with specific permission from purchaser. Preferably all first reduction gears
shall have single helical teeth. All gears shall be hardened & tempered alloy or carbon
steel with machine out teeth. Surface hardening of teeth is not acceptable. All gears shall
be enclosed in oil filled gear box except when not possible.
04. Motors/ Couplings
For Hoists above 5T, the motor (Foot mounted B3 type) shall be connected to its gear
drive by a flexible coupling. Flange mounted motors (B5) may be used for Hoists of
capacity upto 5T and also for traverse drive of hoists.
05. Lubrication
All gears & bearings shall be lubricated either by splash lubrication or by grease. If
possible, all the lubricating points shall be grouped together in easily accessible positions.
06. Bearings
Ball & roller antifriction bearings of reputed make shall only be used, with minimum
bearing life as per IS: 3938.
07. Brakes
D.C. Electromagnetic brake / DC disc brakes shall be used for Hoist motion. For LT, CT
and slew motions (in case of Jib cranes), DC disc brakes shall be used.
08. The Electric hoists shall be inspected as per IS: 3938 - 1983 and as specified in GCC.
14-C.04 DOCUMENTATION
1. Drawings and documents to be submitted by the Tenderer with Tender
a) General arrangement drawings of the Hoist with all technical parameters & details.
b) Duly filled in questionnaire.
2. List of Drawing/ Documents to be furnished by the Successful Tenderer for approval

/ reference
a) General arrangement drawing of equipment showing full details in plan and sections.
b) Quality assurance plan for inspection.
c) Specification of oils and lubricants and other consumables and their quantity and

frequency of change (reference)

d) Detailed layout plan and sections for power supply system.
3. List of Drawings/ Documents to be furnished along with equipment by the Successful

Tenderer

b) Engineering and design calculations.
g) Requirement of special tools and tackles, if any, for subsequent maintenance.
h) All other drawings and documents as stipulated in General Conditions of Contract.

14-C.05 QUESTIONNAIRE (ELECTRIC HOIST)
01 General
Item number :
Location :
Capacity :
Duty classification :
Total weight of hoist :
Make :
02 Hoist
Speeds with safe working load :
Lifting height :
a) Above floor level :
b) Below floor level :
Wire ropes
a) Type of construction :
b) Size :
c) Number of falls :
d) Factor of safety :
Rope drum :
a) Materials :
b) Diameter :
Drives
a) Type & material of gear box :
b) Gear & pinion :
c) Material & hardness :
Motors
a) Type & number :
b) Kw rating :
c) Synchronous speed :
d) Class of insulation :
e) Pull out torque :
f) Frame size :
Brakes :
a) Type :
b) Size :
c) Torque rating :
Type & details of limit switches :
Type of couplings :
Type of bearings :
Lifting hook
a) Type :
b) Material :
Type & details of control :

03 Trolley
Speed with safe working load :
Wheels
a) Numbers :
b) Diameter :
d) Max. wheel load :
e) Wheel base :
Drive
a) Type & material of gear box :
b) Gears & pinions :
d) Kw rating :
e) Synchronous speed :
f) Class of insulation :
g) Pull out torque :
i) Frame size :
Brakes
a) Type :
b) Size :
c) Torque rating :
Type & details of limit switches :

Type of coupling :
Type of bearings :
Type & details of controls :
04 Clearance diagram indicating the basic :

dimensions
05 Type & lubrication provided :
06 Type & size of cables :
07 Location & control details of hoist :
block power feeding arrangement

JIB CRANE
14-D.00 JIB CRANE
14-D.01 Scope of work
The Jib Crane shall be designed, manufactured, assembled and tested in accordance with
IS: 807-1976, IS: 3177-1999, IS: 3938-1983 and other relevant codes and practices to be
used in steel plants.
The crane shall conform to various safety codes as applicable.
All parts requiring replacement/inspection/lubrication shall be easily accessible.
Inspection & testing of the hoists shall be conducted as per relevant clause of IS: 3938-
1983.
14-D.02 Design standard and General Details
01. The Crane Structure shall be designed in accordance with IS: 807-1976 for the jib column
and jib arm of the crane. The details of the crane structure indicated in the Single Girder
EOT/US Crane part of the TS shall be followed.
02. The components of electric hoist for the jib crane and the slew drive shall be designed,
manufactured, assembled and tested in accordance with IS:3938-1983 and shall be of
standard make. The details of the electric hoist indicated in the electric hoist part of
the TS (Clause 15C.00) shall be followed.
03. Unless stated otherwise, slew drive shall be motorised.
04. The Structural steel work of the jib crane structure shall conform to IS; 2062-1992.
05. The boom of the jib crane shall be from either rolled steel section of fabricated type.
06. The design of the boom shall be such that the vertical deflection caused by the maximum
rated load with the hoist at the maximum jib radius position on the boom, shall not exceed
1/250 of the boom length.
07. The column of the jib crane shall be of heavy duty steel tube or fabricated / lattice
structure. Proper bearing housing block for housing bearing for supporting the boom shall
be provided at the top.
08. The jib arm support bearing shall be of anti friction ball/ roller bearing.
09. Base plate of the column should be provided with drilling holes of appropriate sizes for
fixing the jib crane on the foundation / support.
10. The foundation bolts will be so designed that 50 percent of the bolts provided will be able
to take the full load of the jib crane and the turning moments.
11. The design of the column of the jib crane shall be such that overall deflection of the jib
does not exceed 1/200 of (boom length, column height) when the jib crane is fully loaded.

12. The connection between the boom and the pillar shall be designed suitably to give proper
end fixing to the boom and to ensure that the play between moving members is kept to the
minimum.
13. All electrical cables shall be so laid that they are not liable to be damaged and can be
easily inspected and tested.
14-D.03 Documentation
Refer documentation for SG EOT /US crane mentioned above.
14-D.04 Questionnaire
Refer questionnaire for SG EOT /US crane mentioned above.

HAND OPERATED CRANE
14-E.00 HAND OPERATED CRANE
14-E.01 The scope of work of the Tenderer shall consist of design, manufacture, inspection,
commissioning of Hand Operated Crane of various capacity.
14-E.02 Technical Specification of Manual Hoist with Traveling Trolley
The bridge shall consist of main girder which shall be of steel section and with an
auxiliary structure where necessary. Girder shall be sufficiently strong and rigid to
withstand the most severe combination of loads that may develop under different working
conditions.
The bridge shall not deflect more than 1/900 of span with safe working load on the
trolley, with trolley stationed at mid span and excluding deflection due to dead load.
There shall be no permanent set when the crane is loaded with 1.25 times the safe
working load.
The bridge girder shall be connected to the end carriages by large gusset plates. The
bridge girder shall be attached to the end carriages by turned fitted bolts.
Match marks shall be provided on each girder to facilitate erection and squaring of the
bridge.
End carriages made of twin channels construction shall be amply strong to resist all
stresses likely to be imposed on them under severe condition, including collision with
other cranes or stops. The end carriage shall be of sufficient width and this length shall
be such that no other part of the crane is damaged in collision. The end carriage shall be
provided with substantial safety devices to prevent the crane from falling more than 25
mm in the event of breakage of a track wheel on axle. These safety devices shall not
interfere with the removal of wheels. Jacking pad device shall be provided on end
carriage and this shall not in any case interfere with the replacement of track wheels, but
shall be located as near to the wheels as possible.
The Manual Hoist and the traverse mechanism shall be as per the details indicated below
under clause 15-F.
14-E.03 DOCUMENTATION
1. Drawings/ Documents to be submitted with the tender.
with tender for manual hoist with traveling trolley, without which the tender shall be
considered as incomplete & may not be considered for acceptance.
a) Typical General arrangement drawings & catalogues.
b) The questionnaire filled in.

2. Final drawings/documents to be furnished along with the equipment :
a) General Arrangement drawings and all data /catalogues.
b) Supply of report on shop tests and material test certificate.
c) Supply of all operating manual, maintenance schedule & lubrication chart.
14-E.04 Questionnaire
1. Equipment No. :
2. Capacity :
3. Quantity :
4. Height of Lift :
5. Travel distance
6. Class of Duty :
7. Make :
8. Minm . Radius of Curvature
Of Track beam size: :
9. Max. Trctive effort (Kgs)
• Hoist :
• Cross Travel
• Long Travel :
10. Movement in ‘m’
corresponding to operating
chain movement of 30m.
• Hoist :
• Travel

MANUAL HOIST
14-F.00 MANUAL HOIST
14-F.01 The scope of work of the Tenderer shall consist of design, manufacture, inspection,
commissioning of manual hoist with traveling trolley of various capacity.
14-F.02 Technical Specification of Manual Hoist with Traveling Trolley
• Ball and roller anti frictional bearing only shall be used.
• Swiveling type standard shank hook mounted on grease lubricated anti-friction thrust
bearing shall be used.
• The Chain Pulley Block shall conform to class-I duty as per IS: 3832-1986.
• Load chain & operating chain shall be of calibrated type.
• Pulley used for the operating mechanism shall have suitable guards to prevent the operating
chain from coming out.
• All the open gearing shall have suitable cover.
14-F.03 DOCUMENTATION
1. Drawings/ Documents to be submitted with the tender.
with tender for manual hoist with traveling trolley, without which the tender shall be
considered as incomplete & may not be considered for acceptance.
a) Typical General arrangement drawings & catalogues of the hoist.
b) The questionnaire filled in.
2. Final drawings/documents to be furnished along with the equipment :
a) General Arrangement drawings and all data /catalogues.
b) Supply of report on shop tests and material test certificate.
c) Supply of all operating manual, maintenance schedule & lubrication chart.

14-F.04 Questionnaire
1. Equipment No. :
2. Capacity :
3. Quantity :
4. Height of Lift :
5. Class of Duty :
6. Make :
7. Minm . Radius of Curvature
Of Track beam size: :
8. Max. Trctive effort (Kgs)
• Hoist :
• Travel :
9. Movement in ‘m’
corresponding to operating
chain movement of 30m.
• Hoist :
• Travel

ATTACHMENTS
14-G.00 ATTACHMENTS
14-G.01 The scope of work of the Tenderer shall consist of supply and transportation to site,
unloading and re-conservation at site, erection testing & commissioning of various
attachment as required for various applications.

GS – 15, ELEVATORS.:
15-A.00 RACK & PINION TYPE ELEVATOR
15-A.01 Scope of Work
• The scope of work of the Tenderer shall consist of design, manufacture, inspection,
transportation to site, unloading and re-conservation at site, erection, testing &
commissioning of Rack and Pinion Type Passenger Elevator. The elevator shall be
complete with electrical equipment and attachment as covered under this specification.
• The elevator shall be complete with car cage, masts with their support, drive system and
door opening/ closing system, battery operated emergency light, alarm bell, complete
electric and control system, car and hoist way illumination system, buffers, switches etc.
and other necessary fixtures and accessories whether mentioned in this specification or
not but necessary for successful installation, safety and operation & maintenance of the
elevator.
• The scope of work of the tenderer shall also include the following:
The elevator shall be operating with or without attendant.
Supply of necessary fixtures, if any, required for erecting the Rack & Pinion Elevator in
position shall also be under tenderer'
s scope of work.
The scope of work shall stand supplemented by this specification, general specification on
quality system, inspection and test of plant & equipment at manufacturer’s premises.
Scope of work of the contractor shall also include the maintenance of the elevators by their
own men, machine and materials including spares and consumables for a period of 12 months
after successful commissioning of the elevator.
15-A.02 TECHNICAL SPECIFICATION
1. Mechanical details
General - The elevators shall conform to the following stipulations, in general:
a) The elevator shall be designed in accordance with applicable norms of IS: 14665-2000
(Part 1, 2 & 3) and IS14665-2001 (Part-4) and other relevant IS specifications and subject
to any modifications and requirements specified herein after.
b) The elevator shall be suitable for continuous 24 hours round-the-clock operation.
c) The Rack & Pinion type passenger elevator cage shall be fabricated with steel
construction with floor made of chequered plate and of minimum 6 mm thick over plain
and suitably braced to ensure rigidity.
d) The elevator cage shall be provided with manually operated collapsible, horizontal sliding
opening door. The cage doors shall be provided with glass panels. The elevator shall be

suitable for operation in a dusty atmosphere of power plants. Cage roof shall also be
provided.
e) The cage floor shall be covered with rubber sheet.
f) The elevator shall be of rectangular cross section enclosed on three sides. The drive
machine shall preferably be located on top of elevator cage.
g) Necessary hand railing all around drive machine shall also be provided to a height of 1.2
m. The power supply to the drive machine shall be through fixed and flexible power cable
using cable guiding devices located on the elevator cage and at regular intervals on the
elevator way.
h) Necessary precaution shall be taken in designing the cage to avoid undue vibration or side
movement of cage during operation.
i) Safety hooks shall be provided in cage to prevent the same from detaching from the mast.
j) The mast shall be in sections of rectangular tubular structure of adequate height to

facilitate quick erection at site. The rack shall be bolted to the lattice/ truss type masts.
The rack shall be aligned and fixed to the mass using dowels. The mast shall be firmly
attached to the building/ chimney walls using anchor bolts and adjustable wall ties.
k) The section of the mast shall be inter-linking section for coupling for various mast
sections like square section to rectangular section. These sections shall be complete with
racks. The mast tube shall be of heavy-duty type.
l) Adequate numbers of spring buffers shall be fitted under the elevator cage directly on the
floor/ base frame with suitable concrete or steel foundation. Buffers shall be located
symmetrically with reference to the vertical centre line of the cage frame within a
tolerance of 50 mm. The stroke of the spring buffer for car shall be equal to or greater
than 40 mm.
m) Spring buffer shall be capable of supporting, without being compressed solid, a static load
equivalent of two times the weight of car and its rated load for car buffers.
n) The elevator drive mechanism shall essentially consists of a reversible electric disc brake
motor, over speed governor (centrifugal brake), gear coupling, reduction gear unit, drive
pinion and progressive type positive action safety device etc.
o) The brake mechanism shall be provided with suitable means for adjustment of brake
torque and magnetic air gap. The mechanism shall be of the “spring reset type” and not
“gravity operated counter weight type”.
p) The brake position shall be such that double shaft extension is provided so that the brake
pulley is not the same as the coupling face.
q) The reducer with extended shaft and the drive pinion mounted on it shall be of adequate
ratio and of heavy-duty type. The drive pinion and rack shall be made of forged carbon /
alloy steel with adequate hardness for the service intended.

r) The drive pinions shall be firmly engaged to the rack by means of rollers, mounted on the
antifriction bearings, at the back of the rack. The pressure exerted on the rack shall be
adequate to ensure proper backlash between the rack and pinion.
s) Double locks shall be provided so that the cage door shall not open during movement of
elevator.
t) Cams operated double limit switches shall be provided to ensure cage stops at all landing
positions.
u) The pinion shall be connected with two separate automatic braking systems, which shall
activate when there is power failure or the elevator exceeds its maximum speed.
v) The elevator cage shall be provided with necessary switches including emergency bell
switch and floor indicator. It shall also be provided with overload alarm and protection.
w) All parts requiring replacement or inspections or lubrication shall be easily accessible

without the need for dismantling of other parts / equipment.
x) Provision shall be kept for emergency exit on top of the car in the event of fire or any
other emergency.
y) A selector switch and a set of push buttons shall be provided on the top above the ceiling
of the car to operate the elevator locally for inspection and maintenance. The selector
switch when set to position “Inspection" shall exclude control from other places and
movement of the car in the desired direction shall be effected by the push buttons. For
normal operation of the elevator, the selector switch shall be set to the position working. It
shall be possible to operate the elevator only when the appropriate button is kept in
pressed condition.
z) Provision shall be made to prevent the opening of any landing door when the car is
passing that zone in response to a call from another landing.
15-A.03 Testing & Commissioning
The testing and commissioning of the elevators shall be done in presence of the
representatives of the manufacturer and owner.
The elevator after erection shall be tested as follow:
• Load test with 100% and 110% of rated load as per IS: 14665 - 2000.
• A static load test with 125% of rated load as per IS: 14665 – 2000 to check that the
brake will sustain the car.
• All other tests on electrical system as mentioned in IS: 14665 - 2000.
• Any other test felt necessary by Owner and supplier to ensure proper functioning and
installation of the lift.
• Demonstration of the functioning of all safety provisions made available in the
elevator.

15-A.04 Design construction and performance requirement.
01. Load:
The elevator shall be designed to lift the pay-load in addition to weight of the car itself
and other accessories.
02. Speed
The elevator shall travel at a speed of at least 25m/min.
03. Size
The inside dimensions of the platform of the car (clear inside) shall be at least 1100mm X
1000mm for Lower Capacities and 1500 x 3000mm for higher Capacities. The inside clear
height of elevator shall be 2200mm.
04. Travel and landings
The lift car shall travel from the landing floor from reference elevation to top landing as
specified in the technical parameters/ data sheets. In between these two levels the car shall
stop at every intermediate platform levels as specified.
06. Car
The car shall be enclosed on all sides by means of car body and door. The sides of
the car shall be lined with heavy gauge stainless steel sheet panel properly braced
and reinforced. The enclosure shall be flush on the inside and securely fastened to
the platform.
The car shall be equipped with handrails on three sides, fan with grills and
suitable lighting with fittings. The light shall be left on during the whole time of
use.
Necessary provisions shall be made for adequate ventilation of the car.

Ventilation opening shall be provided in the enclosure roof as per requirement of
IS: 14665-2000 (Part-3). A separate switch shall be provided in the car for the fan.
The enclosure of the lift car shall withstand a thrust of 35 kgs applied normally at
any point, excepting any vision panel, without permanent deformation.

15-A.05 DOCUMENTATION
1. Information to be furnished by the Tenderer along with the tender:
information with tender for elevator without which the tender shall be considered as
a) General Arrangement of the Elevator indicating details.
b) Filled in questionnaire
2. List of drawings/ documents to be furnished by the successful Tenderer for approval
a) General arrangement drawing of elevator showing full details in plan and sections.
b) Single Line Diagrams.
c) Quality Assurance Plan for inspection.
d) Test and inspection certificate.
e) List of spares for 2 years normal maintenance.
3. List of drawings/documents to be submitted along with equipment by the successful

Tenderer
a. GA drawings, complete assembly and sub assembly drawings of the equipment.

b. Single Line Diagrams
c. Drawings of all equipment/component received from sub supplier.
d. Test and warranty certificate for each item of equipment.
e. Test reports and inspection reports.
f. Instruction manuals for testing and commissioning.
g. Operation, maintenance and safety manuals.
h. List of spare parts with drawings, sketches, specifications and manufacturer'
s catalogue.

15-A.06 QUESTIONNAIRE (R&P TYPE PASSENGER ELEVATOR)
1) Name of manufacturer :
2) Nos. Off :
3) Type of elevator :
4) Capacity,
i in Kg :
ii Number of passenger :
5) Rated Speed (m /min) :
6) Total travel (m) :
7) Nos. of floor to be served :
8) Floor levels :
9) Size of elevator well / mast :
10) Internal size of elevator car :
11) Construction, design and finished car body work :
12) Type of car door :
13) Type of landing door :
14) Type of landing & car door operation :
15) Car entrance :
i Number, size and type of doors. :
ii Cars open in front. :
iii Power or manual operation :
16) Total Weight :
a) Mechanical component :
b) Structural item :
c) Others :
17) Headroom required above top landing :
18) Elevator operation :
19) Method of control :
20) Ambient temperature :
21) Quantity of Motor :
22) Power consumption :
23) Leveling accuracy :
24) Emergency power supply provided? :
25) Intercommunication facility provided? :
26) Brief description of control features and safety interlocks provided

15-B.00 FREIGHT CUM PASSENGER ELEVATOR
15-B.01 Scope Of Work
• The scope of work of the Tendererer includes design, engineering, manufacture,

assembly, inspection and testing, painting at manufacturer’s shop as well at site after
erection, supply including dismantling for transportation, packing, forwarding, loading
and transportation to site, receipt, unloading, storage and re-conservation at site, erection,
testing and commissioning of the elevators at site.
• Obtaining statutory clearances from statutory authority.
• Scope of work of the contractor shall also include the maintenance of the elevators by
their own men, machine and materials including spares and consumables for a period of
12 months after successful commissioning of the elevator.
15-B.02 TECHNICAL SPECIFICATION
1. Mechanical Details
The elevators shall conform to the following stipulations, in general:
a) The elevator shall be designed in accordance with IS: 14665 (Part I) Part – 2/Sec – 1, Part
– 3/Sec – 1)2000 and IS : 14665 (Part 4/ Sec 1 to 9) 2001 and other relevant IS
specifications and subject to any modifications and requirements specified herein after.
b) The elevator will be installed inside the building to facilitate movement of man and
material to various floor levels and shall operate from lower most level to top most level
and will be located at identified location.
c) The elevator shall be equipped with all standard safety systems such as Bell and cranking
in case of power failure, emergency rescue battery back-up, hand wheel connected with
motor shaft for manual lowering of elevator to the nearest landing level incase of power
failure, limit switches, indicators, over speed safety governor for car, emergency light
fittings, etc.
d) Lift shaft is to be provided with adequate lighting.
e) The elevator shall be suitable for continuous 24 hours round-the-clock operation.
f) The motor for the elevator shall be squirrel cage induction motor with VVVF control for
controlling the speed during starting and stopping at landings
g) Trouble-free performance of the elevator incorporating the operational, controlling and

safety requirements, as specified, is to be guaranteed.
h) A selector switch and a set of push buttons shall be provided on the top above the ceiling
of the car to operate the elevator locally for inspection and maintenance. The selector
switch when set to position “Inspection" shall exclude control from other places and
movement of the car in the desired direction shall be effected by the push buttons.

For normal operation of the elevator, the selector switch shall be set to the position
working. It shall be possible to operate the elevator only when the appropriate button is
kept in pressed condition.
i) Provision shall be made for a safety gear, which shall operate in case of free fall or over
speeding of elevator car or counter weight in the descending direction. This safety gear,
while freezing the cabin mechanically to the guides, shall also interrupt the control supply
through a limit switch.
j) The particular landing door shall open only after the elevator car has stopped at the
landing. Additional provision shall be made for opening of the landing door in case of
emergency by means of a special key. The landing doors shall be so designed that their
closing and opening is not likely to injure a person.
k) Provision shall be made to prevent the opening of any landing door when the car is passing
that zone in response to a call from another landing.
l) At all the intermediate levels “Up” & “Down” call buttons with indicators shall be
provided. Car position indicator shall also be provided at all levels. At ground level, “Up”
call button with indicator & at top most level “Down” call button with indicator shall be
provided.
m) The circuit which supplies current to the motor shall not be included in any twin or multi-
core trailing cable used in connection with the control safety devices /signaling equipment.
n) Safe access for maintenance and removal of all mechanical and electrical parts shall be
ensured, without additional scaffolding.
o) For other details relevant BS standards shall be followed.
2. Design construction and performance requirement.
01. Wire Rope
The car and counter weight shall be suspended by steel wire ropes. The number of wire
ropes and size of wire rope shall be so chosen that highest factor of safety is achieved as
per standard. Not less than three independent suspension ropes shall be used. The
minimum diameter of rope shall be 12mm and factor of safety 12.
02. Car
Car frame
Every lift car shall be carried in a complete frame of steel which shall be
sufficiently rigid to withstand the operation of the safety gear without permanent
deformation to the car frame. The car structure shall be of steel with special
painting or of stainless steel.
At least four renewable guide shoes with renewable linings or set of roller guides
shall be provided, two at the top and two at the bottom of the car frame.

Car enclosure
The car shall be enclosed on all sides by means of car body and door. The sides of
the car shall be lined with heavy gauge stainless steel sheet plate properly braced
and reinforced.
The enclosure shall be flush on the inside and securely fastened to the platform.
The car body floor shall be of M.S steel construction with chequered plate top.
Side panels shall be of stainless steel grade 304 1.2mm thk and roof of stainless
steel over MS frame.
The car shall be equipped with handrails on three sides, fan with grills and
suitable lighting with fittings. The light shall be left on during the whole time of
use.
Necessary provisions shall be made for adequate ventilation of the car.

Ventilation opening shall be provided in the enclosure roof as per requirement of
IS: 14665 (Part 3/Sec 1 & 2)-2000. A separate switch shall be provided in the car
for the fan.
The enclosure of the lift car shall withstand a thrust of 35 kgs applied normally at
any point, excepting any vision panel, without permanent deformation.
Car platform
Car platform shall be constructed of structural steel shapes or securely fastened

with steel flooring covered with PVC tiles flooring. The platform shall be
designed on the basis of rated loads evenly distributed. The car floor shall
comprise a smooth non-slip surface.
Since the car leveling device will be used, subsequent aprons of sufficient depth
shall be fitted to the car floor to ensure that no space is permitted between the
threshold and the landing while the car is being leveled to a floor.
Car roof
Car roof shall be covered with sheet metal to prevent dripping of lubricants from
ropes-sheave bearings. The top flooring shall be of steel with decorative false
ceiling. A three pin plug socket with a switch for head lamp shall be fitted on the
top of the car for use during maintenance. The roof shall be strong enough to
support at least two persons.
Provision for slow speed (1/2 of rated speed) operation from car top in up and
down directions in independent mode shall be made to facilitate maintenance of
devices in the hoist way. Necessary fittings shall be provided for this purpose.
Difference in levels of the car floor and landing shall not exceed the figures
indicated in IS 14665 (Para 3/Sec 1 & 2)-2000 under heading “Leveling
Accuracy ".
Suitable lubrication system shall be provided for guide rails as well as for other
items.
Car Door
The elevator car shall be provided with Automatic power driven centrally opening
doors, matching with hoist way doors.
The door of elevator shall open at all the platform levels.
Car door shall have a clear opening of 1800 mm wide X 2200 mm high. The door
operation shall be automatic.
(For specific requirement/ application, and on explicitly mentioning the same,

manually operated, corrugated collapsible gates shall be provided.)
Hoist Way Door
Automatic power driven centrally opening doors having a clear opening of 1800
mm wide x 2200 mm high shall be provided at each of the landing for elevator
door.
(For specific requirement/ application, and on explicitly mentioning the same,
manually operated, corrugated collapsible gates shall be provided for Hoist way)
Door Hangers & Tracks
Hangers and tracks for car door and each having a clear hoist way door shall be
provided. Suitable material shall be used to minimize the noise. Ball bearing
rollers or equivalent arrangement shall be provided to take upward thrust of the
doors. Suitable devices shall be provided for transmitting from one door panel to
the other.
All required material for landing entrance e.g. extruded aluminum or equipment
sills, structural angles, headers etc. shall be provided.
Door operation for car door and hoist way doors
The doors operations shall be automatic. The necessary door cushioning device
shall be provided.
Necessary safety devices shall be provided to prevent the movement of the car
until the car door and hoist way doors are closed properly.
03. Car Self-Leveling Device
The elevator shall be equipped with automatic self-leveling devices to bring the car to the
floor landings. These self leveling shall be correct for over travel or under-travel and rope
stretch.
04. Control and operation
The elevator control shall be through digital controls and VVVF drives.

The operation of the elevator i.e. method of actuating the control shall be “Selective
Collective Automatic Operation” as per clause 3.41.3 of IS 14665 (Part2/Sec1): 2000 with
and without attendant. All accessories required for the collective operation as outlined
therein, namely selector and its driving shall be furnished complete.
The controller shall be microprocessor based.
05. Car Position Indicator in Car
A signal indication shall be provided by the appropriate numeral (which shall be floor no./
level of respective floor) being illuminated when the car is passing the corresponding
floor. The indication shall remain illuminated when the car is stopped at a floor. Up &
Down direction jewel lights shall also be provided. The car position indicators are needed
to be provided at all landings.
Provision to indicate lift capacity in Kg as well as in terms of person, shall be made

available in the car. Other signals like “over load” “Lift is under maintenance” etc. shall
also be provided.
06. Push Button Station and Call- Registered Tell-tale Lights at Hoist way
A single ‘Up” and “Down” push button at terminal landings and “Up” “Down” each
push intermediate landing including call register light for each push button shall be
provided. These shall remain illuminated till the call is answered.
07. Emergency Exit
The elevator car shall be provided with an emergency exit of adequate dimension.
08. Terminal Buffers
The terminal buffers shall be provided for stopping the car and the counter weight at the
extreme ends of travel. All structural steel members required to install the buffers shall be
supplied by the lift supplier.
09. Counter-Weight s and Counter-weight Frames
Counter weight sections shall be mounted on structural metal frames so designed to retain
the weights securely in its place.
Counter –weight frame shall be guided on each guide rail by upper and lower guiding
members attached to the frame
A substantial metal counter- guard of required length shall be provided at the bottom of
the hoist way.
A compensating chain of adequate strength connecting car bottom and counter weight
frame shall be provided for balancing the car and counterweight while running with
minimum load condition.
10. Guides for Car and Counter- weight

Car and counterweight guides shall be of rigid steel and shall be continuous throughout
the entire length and shall be provided with adequate steel bracings and stiffeners. Guide
for both car and counter weight shall meet the requirement of IS: 4666-1980. The
necessary lubrication device for guide rail shall be provided.
11. Terminal Limit Switches and Final Limit Switches
Terminal limit switches for normal operation shall be provided to slow -down and stop
the car automatically at terminal landings and final limit switches shall be provided to
automatically cut off the power and apply the brake, when the car travel beyond the
terminal landing.
3. The elevator after erection shall be tested as follow:
a) Load test with 100% and 110% of rated load as per IS: 14665 - 2000.
b) A static load test with 125% of rated load as per IS: 14665 – 2000 to check that the
brake will sustain the car.
c) All other tests on electrical system as mentioned in IS: 14665 - 2000.
d) Any other test felt necessary by Owner and supplier to ensure proper functioning
and installation of the lift.
e) Demonstration of the functioning of all safety provisions made available in the
elevator.
The contractor shall arrange for weights, slings, wire ropes, stop watches and other necessary
equipment/ instrument to carryout the test.

a) General Arrangement of the Elevator indicating load data, details of various openings in
machine room floor as well as lift well shaft, buffers etc.
c) List of commissioning spare,
e) List of insurance spare for each crane
f) List of special/ maintenance tools & tackles.
a) General arrangement drawing of elevator showing full details in plan and sections.
b) Single Line Diagrams / Circuit diagrams
c) Quality Assurance Plan for inspection.
d) Test and inspection certificate.
e) List of spares for 2 years normal maintenance.
f) List of insurance spare for each crane
g) List of special/ maintenance tools & tackles.

Tenderer

b) Single line diagrams / Circuit diagrams.
c) Drawings of all equipment/component received from sub supplier.
d) Test and warranty certificate for each item of equipment.
e) Test reports and inspection reports.
f) Instruction manuals for testing and commissioning.
g) Operation, maintenance and safety manuals.
h) Requirement of special tools and tackles, if any, for subsequent maintenance.
15-B.04 QUESTIONNAIRE
01. Name of manufacturer :

02. Nos. Off :
03. Type of elevator :
04. Capacity,
i. in Kg :
ii. Number of passenger :
05. Rated Speed (m /min) : 0.5 to 1.0m/sec
06. Total travel (m) :
07. Nos. of floor to be served :
08. Floor levels :
09. Size of elevator well / mast :
10. Internal size of elevator car :
11. Type of car / landing doors :

12. Landing/car door operation : Automatic / Manual
13. Car Enclosure :
14. Total Weight :
i. Mechanical component :
ii. Structural item :
iii. Others :
15. Headroom above top landing :
16. Elevator operation :
17. Method of control : Selective collective automatic control
as per clause no. 3.41.3 of IS: 14665
(Part 2/Sec1): 2000 with or without
attendant. The control panel shall be
located in the machine room. (VVVF
control with pulse width modulation)
18. Ambient temperature : 50o C
19. Quantity of Motor :
20. Power consumption :
21. Leveling accuracy :
22. Emergency power supply :
23. Intercommunication :
24. Electric power supply :
i. Power Voltage (AC) :
ii. Phase :
iii. Cycles :
iv. Wire system :
v. Control voltage (DC) : 415 V ±10%, 3 ph 50 Hz ±5% AC.
25. Signals :Call buttons with Tell-Tale lights at all

Floor and car position indicator in car
and at all landings.
26. Motor Details

i. Make :
ii. Kw rating :
iii. Frame size :
iv. Speed :
v. Duty cycle :
vi. FL amperes :
vii. Class of insulation :
viii. No. of permissible starts per hour :
• Special Feature :

GS – 16, TRANSFER CARS:
16.00 SCOPE OF WORK
The scope of work of the Tenderer includes design, engineering, manufacturing,

assembly, shop testing, painting, supply, transportation to site, unloading & storage,
erection, testing and commissioning of Transfer cars complete with mechanical and
electrical components.
01 The supplier shall ensure that the transfer car is manufactured as per the tolerances
specified below:
01 Track gauge + 3 mm
02 Diagonal of wheels + 3 mm
03 Travel wheel alignment + 1 mm
04 Tilt of wheels or balancer axle + 1 mm
1000 mm (horz. & vert.)
05 Wheel base + 3 mm
06. Travel speed at full notch with rated load, voltage and frequency shall be + 10%
and – 5 % of specified speed.
07 All the axles with wheels shall be parallel to each other. Permissible deviation
from parallelism shall not be more than 1 mm for every 1000 mm length.
No load test:
The transfer car shall be run in both the directions at maximum speed with no load.
During this period, the speed and noise shall be checked. The bearing lubrication system
shall also be checked for proper operation. At the end of this test, no part shall be
excessively heated.
Speed test:
a. Travel motion of the transfer car shall be tested in both directions with rated load on all
the notches and the speeds shall be attained at various notches as per approved speed-
torque curve of the transfer car within the tolerance limits indicated under clause
03.10.06. The absorbed power as well as the speed shall be recorded and compared with
guaranteed values. At the end of these tests no parts shall be excessively heated.
b. Travel motion of the car shall be tested with 25% over-load in which case the specified
speeds need not be attained but the car shall show itself capable of dealing with the
overload without difficulty.
Brake Test
The travel brakes shall be capable of arresting the motion within a distance in meters
equal to 10% of speed in metres/minutes when travelling with rated load at rated speed,
provided there is no skidding.
• GENERAL
a) The transfer car shall be designed, manufactured and tested in accordance with the
relevant clauses of IS: 3177·-1999. The standards referred there in and subject to any
modifications and requirements specified in this specification.
b) The transfer car components shall be standardised to keep the number of spares minimum.
c) All parts requiring replacement or inspection or lubrication shall be easily accessible

without the need for dismantling of other equipment or structures. All electrical cables
shall be so laid that they are not liable to be damaged and can be easily inspected and
maintained.
d) For welded construction such as that of main frames, gear boxes and other load bearing
members, steel shall conform to IS: 2062-1992.
For welding these members low hydrogen electrodes shall be used as per IS 81-1991
grade E8 –542 -C-83H.
• STRUCTURAL DETAILS
Transfer car structures shall be designed in accordance with IS: 807-1990 taking the
following additions/deviations into account.
a) Black bolts shall not be used in the main structures of the transfer car.
b) Bolts used in shear shall be fitted into reamed holes.
c) Transverse fillet welding on load carrying members shall be avoided.
d) All butt welds on structural members subject to tensile stress shall be X-rayed.
e) Minimum thickness of chequered plates for platforms shall be 6 mm over plain for indoor
transfer cars and 8 mm over plain for outdoor transfer cars. Chequered plates shall not be
considered for strength calculations of load carrying members. Chequered plates shall be
supported on a frame of beams adequately designed to take the rated load anywhere on the
transfer car platform.
f) The under frame shall be fitted with substantial safety stops to prevent the transfer car
from falling more than 25 mm in the event of breakage of track wheel, bogie or axle.
These safety stops shall not interfere with the removal of the wheels.
g) Suitable jacking pads at a height of 300 mm from rail top shall be provided on under
frames for jacking up the transfer car when changing track wheels. Jacking pads shall not
interfere with the replacement of track wheels.
h) Main frame shall be fabricated in one piece unless there are transport limitations.
Connection between the two parts of the frame shall be done by machined bolts or rivets.
i) All the mechanical and electrical equipment shall be placed below the top plates.
j) The maximum settlement of the platform under rated load shall not exceed 2-3 mm
limited to span/1000.
k) Chequered plate steps suitably welded at convenient location on either side of the transfer
car shall be provided for climbing up on the platform wherever necessary.
Drive Suspension Frame
a) All the driving mechanism such as motor, brake, gear box etc. shall be mounted on a rigid
rolled section steel frame and suspended below the under frame with one end resting on
the drive axle on anti-friction bearing, while the other end shall be elastically fastened to
the under frame through helical compression springs. Drive Mechanism shall be protected
from heat by providing heat shield on heat exposed area.
b) Clearance between ground and bottom most portion of the car shall not be less than 100
mm.
• MECHANICAL DETAILS
a) Wheels
• Solid wheels of forged, rolled or cast steel conforming to 55C8 of IS: 1570 -1961 shall be
used.
• Wheels shall be heat treated to have a hardness of BHN 300 to 350 on the rolling surface
and flanges to a depth of not less than 10 mm with a smooth pass to the non- hardened
zone.
b) Axles
Axle shall be made of class 4 steel to BE: 1875-1992.
c) Axle Box Assembly
The material of axle box casting shall conform to steel as per IS: 1030-1989 grade-1.
Spring seats, wherever required, shall be finished by machining.
d) Springs
All helical compression springs shall be designed in accordance with IS: 7906-1976 Part-
1.
Spring ends shall be finished square with respect to its axis.
The spring shall be designed on the basis of virtually infinite life i.e. to withstand ten
million load cycles or more without failure.
.
e) Axle Box Frame
Axle box frame of cast steel or fabricated steel construction shall be stress relieved and
accurately machined. The parallelism between the faceplate and their perpendicularity
with the top surface shall be closely maintained.
f) Buffers

Spring loaded or other better type buffers shall be fitted on the four corners of the transfer
car for ensuring soft dashing of transfer car against stop.
Buffers shall be rigidly bolted in place, preferably along the centre line of transfer car
track such that the bolts are not in direct shear.
Buffers shall be designed to absorb the kinetic energy released at 50% of the full load
rated travelling speed, the average rate of deceleration not exceeding 4.8m/sec2 at 40% of
the rated travelling speed.
Buffers shall have a contact surface of not less than 125mm in diameter and mounted so
as to provide 100mm clearance between the fixed structures and car outreach when
buffers of transfer cars are fully compressed.
g) Drive mounted on transfer car
For travel motion central drive shall be used. It shall be mounted as close as practicable to
be centre of the car.
Drive shaft coupling shall be as near to the bearings as possible.
All parts of the travel drive shall be easily accessible for inspection, maintenance and
removal from topside of platforms.
h) Gearing
Straight and helical spur gearing shall be used. Worm and bevel gears shall not be used.
Surface hardness for pinion shall be 255 t0 300 BHN and for gear it shall be 217 to 255
BHN. Difference in hardness of pinion and gear shall not be less than 20 BHN.
i) Gear Box
All gear shafts shall be supported in anti-friction bearings.
In gearboxes splash or automatic lubrication systems shall be used.
The gearbox shall be fabricated of cast steel. Fabricated gearbox shall be made of
minimum 8-mm thick steel plate and shall be stress relieved.
Covers shall be split horizontally at each shaft centre line and fastened and arranged so
that the top half can be removed for inspection and repair without disturbing the bottom
half. Vertical gearbox may be provided with T-splits.
Directly above the mesh line of teeth, there shall be hand-hole with oil tight bolted covers.
The gearboxes shall be provided with breather vents, oil level indicator, dipsticks and
easily accessible drain plugs.
Radial clearance between the gear box inner surface and the outside diameter of the gears
shall be at least 1.25 times the depth of the largest gear tooth inside the gear box or 20 mm
whichever is higher. The facial or side clearance between the inner surface of the gearbox
and the face of the gear or pinion shall be at least 20 mm.
Gearbox shall be mounted on machined surfaces and shall have machined feet. Shims
shall not be used.
j) Bearings
Only anti friction bearings shall be used.

Rated life of anti-friction bearings shall not be less than 40,000 hours.
k) Couplings
Motor shaft shall be connected to gear box input extension shaft through flexible gear
couplings with crowned teeth. Gear coupling shall also be provided between gearbox and
axle wheels if required.
All couplings shall be of forged steel and shall be designed to suit the maximum torque
that can be developed.
Hardness of gear coupling casing shall be more than 340 BHN and that of toothed bush
shall be more that 340 BHN. Bolt connection of couplings shall be easily accessible for
inspection and tightening.
l) Brakes
Double shoe brake shall be provided for the drive of the transfer car and shall be mounted
on the input pinion shaft of the gearbox. The brake shoe shall be of hinged type.
Brake drum shall be forged or of cast steel and shall be completely machined and
dynamically balanced. Diameter of the brake drum shall be selected from preferred
number series. Width of the brake drum shall be 10 mm more than the width of the brake
shoes of each size. Hardness of the brake drum shall be 300 to 350 BHN.
Braking against travelling shall be capable of arresting the mote within a distance in
metres equal to 10% of speed in meters /minute when travelling with rated load and speed,
provided there is no skidding.
Adequate means shall be provided on outdoor transfer car for securely anchoring the same
to the rail when not in use. Co-efficient of reserve of the holding force shall not be less
than 2 considering maximum wind pressure.
In case of power failure there shall be automatic braking of the transfer car.
Brake shoes shall be of cast or forged steel.
m). Shafting
Shafts and axles shall also be checked for endurance and strength. In proportioning shafts,
allowance shall be made for keyways and splines.
Changed of section in shafts shall be made with due allowance for stress concentration.
n). Lubrication

Grouped grease lubrication system for bearings shall be provided for transfer cars.
Minimum internal diameter of grease pipe shall be 6mm. The pipe shall be securely fixed
and protected from damage and assessable throughout.
Effective protection shall be provided to prevent ingress of dust on the lubricant and such
protection shall also be weather proof on outdoor transfer car.
16.02 DOCUMENTATION
a) General Arrangement of the Transfer car indicating load data, details of various openings
in machine room floor as well as lift well shaft, buffers etc.
c) List of commissioning spare
e) List of insurance spare for each crane
f) List of special/ maintenance tools & tackles.
g) List of Preferred Makes.
a) General arrangement drawing of Transfer car showing full details in plan and sections.
b) Quality Assurance Plan for inspection.
c) Detail specification of motor indicating type, KW, rpm, starting torque requirement, class
of insulation, type of enclosure, frame size etc.
d) Power requirement, details of motors, control scheme.
e) Test and inspection certificate.
f) List of spares for 2 years normal maintenance.
g) Ordering specification for operating consumables / supplies.

Tenderer

b) Drawings of all equipment/component received from sub supplier.
g) Requirement of special tools and tackles, if any, for subsequent maintenance.

16.03 QUESTIONNAIRE (TRANSFER CAR)
1. Load carrying capacity :

2. Track gauge :
3. Platform size (length X width) :
4. Maximum side over hang :
5.. Top of platform from rail top :
6. Maximum deflection of platform under
Maximum working load :
7. Total length of travel :
01. Weights
1. Total weight of the transfer car (t) :

2. Break up of weight
a) Electrical :
b) Mechanical :
c) Structural :
3. Weight of the heaviest part/ assembly to be :
handled by the maintenance tackle
02. Parameters
1. Travelling speed (m/min)

with maximum working load :
2. No. of travel wheels :
3. Wheel spacing :
4. Wheel base :
5. Diameter of wheel :
6. Maximum & minimum wheel load :
with or without impact
7. Over buffer dimension :
03. Wheels
1. Type of construction :
2. Material of construction :
3. Hardness :
04. Gears and gear Box.
1. Make :
2. Type :
3. Material of construction for gear box :
4. Material of construction for gear and pinion :
5. Hardness of gear and pinion :
6. Total reduction ratio :
7. Total no. of reduction :
06. Track rail size :
07. Couplings
1. Make and type of couplings between
a) Motor and gear box :

b) Gear box and shaft :
c) End shaft and axle :
08. Make and type of limit switches :

09. Make and type of bearings :
10. Motors detail
a) Type, make and frame size :
b) kW rating at 40% & 60% CDF and :
ambient temp.
c) Motor rpm :
d) No. of start/ hr :
e) Class of insulation :
f) Derating factor considering for
ambient temp. :
g) Calculated motor power :
h) Frame size kW at specified duty :
11. Brake
a) Make, type and size :
b) Minimum braking torque as per catalogue
c) Surface hardness & material of brake drum
12. Make and type of other electrical equipment

Such as panels, contactors. etc. :
13. Wiring, trade name and class of insulation :
14. Cable reeling drum
a) Type and make :

b) Diameter :
c) Cable size, type, makes & totals length :
d) System of cable drum actuation :

GS – 17, FORK LIFT TRUCK (BATTERY OPERATED):
17.00 SCOPE OF WORK
The scope of work of the Tenderer shall consist of design, engineering, assembly, shop
testing, painting, supply, testing and commissioning at site of Fork Lift Trucks complete
with accessories and attachments as covered under this specification and attached
equipment data sheet.
1. Design Standards and General Details
a) The fork lift truck to be supplied under this specification shall be complete with all
attachments, auxiliaries and accessories which are not specifically mentioned in the
specification but are required to make equipment complete in all respects to fulfill the
requirements of the prescribed duties, guaranteed performance and safe operation.
b) The unit offered shall be new, unused and best of its kind. The unit shall also conform to
the latest edition of the applicable Indian Standards and Regulation. Wherever the unit
offered is not in accordance with the relevant Indian Standards and Regulations, the
copies of the Standards to which the equipment conforms shall be submitted along with
the proposal. Each unit shall have a printed sketch showing the load capacity at different
load centers for safe operation.
c) In case, due to standardisation of the products by the Manufacturer, the Tenderer is not
able to quote for the exact specified capacity, he may quote for the next higher standard
capacity. The unit offered shall be able to meet all the requirements of its specified duty.
It would be preferred that the Tenderer shall quote for the equipment strictly conforming
to the “Technical Specification and Equipment Details." In case the unit offered has
modifications and deviations, then the details of such modifications and deviations shall
be clearly indicated. The reasons for such deviations shall also be clearly stated.
d) All surfaces and parts except gears, bearings, etc. shall be properly cleaned / sand blasted/
chemically treated to remove all loose mill scale, rust, mud, foreign materials and then
suitable corrosion resistance coating shall be applied to make the equipment fit for indoor
/outdoor services in tropical weather conditions.
e) The equipment shall be applied with two coats of final paint of approved quality and
colour before despatch from the works.
f) The equipment shall have sufficient lubrication arrangement so that bearing and other
parts do not get unusually heated in course of operation. Sufficient lubrication points shall
be provided wherever necessary and all such points shall be easily accessible. The
Tenderer shall specify the lubricants and also the quantity required for six months period
along with tender.

2. Mechanical Details
a) The fork lift truck shall meet the stability requirements as per IS:4357-1957 (Reaffirmed
-1990) for rated load capacities. The values of stability factor shall be as per IS:5040-
b) Brakes shall be hydraulic power assisted.
c) Mechanical hand brake for parking shall be provided.
d) Tilt and lift & auxiliary functions of the fork lift truck shall be hydraulically operated.
e) Operator’s seat shall be of cushioned and adjustable type. Driver'

s overhead guard & load
back rest shall also be provided.
f) A rigid towing attachment complete with pin or hook shall be provided at the rear of the
truck.
g) All hydraulic hose pipes shall be suitably protected from damage during operation.
h) Suitable check valves shall be provided to ensure safety & control the lowering speed in
case of loss of hydraulic pressures.
3. Electrical Details
a) The drive motor shall be designed and installed to meet the service conditions of battery
operated fork lift trucks. It shall be suitable for operation from 48/36 V battery and shall
be supplied completely wired up with the battery, control and protective equipment as
well as indicating instruments mounted on the dash board.
b) The motor shall be series wound traction type. The rating shall be adequate for normal
service condition as well as for driving the truck up a gradient as specified. The motor
shall be minimum of class "F" insulation.
c) Replaceable covers for easy inspection, replacement and adjustment of carbon brushes
shall be furnished.
d) The terminals of the motor shall be mounted on a terminating plate and all leads brought
and terminated thereto. For repair and maintenance, it shall be possible to disconnect the
motor from its terminals and take the motor out without disturbing any other ancillary
equipment.
e) The motor shall be mounted on resilient pads suitable for the service conditions.
f) Dash board shall be equipped with the following:
a) Battery discharge indicator / ammeter.

b) Instrument pannel lights.
c) Switches for lights.
d) Key type starting switch.
e) Any other instruments, switches, as necessary.

g) The drive controller shall be suitable for speed variation in number of steps both in
forward and reverse direction of movements.
h) Head lights and tail lights suitable for night operation shall be provided.
i) Electric or equivalent horn shall be provided. A bulb horn shall also be provided.
j) The fork lift truck shall be powered by a rechargeable electric storage battery of lead acid
type and of reputed make.
k) The battery shall be used to supply power to the electrical drive motor and auxiliaries of
battery operated fork lift truck.
l) The battery shall be installed within a heavy sheet metal enclosure mounted on top of the
fork lift and wired suitably to the drive motor and other auxiliaries.
m) Battery shall be designed to withstand electrical and mechanical shocks.
n) The battery shall have capacity to meet the duty specified.
o) A low voltage protection shall be incorporated in the battery circuit to prevent excessive
discharge of the battery. The sheet steel enclosure shall be provided with adequate
ventilation and a cover for easy replacement. The enclosure shall be painted with acid
resistant coat of paint. The cover shall be provided with lifting handles and arrangement
for locking.
p) The battery shall be supported on porcelain insulators fixed on to the containers. The
battery terminal posts shall be provided with connector bolts and nuts effectively coated
to prevent corrosion. Lead coated copper connectors shall be used to connect up the cells
of the battery set. The electrolyte used shall be of battery grade sulphuric acid conforming
to IS:266.

17.02 Questionnaire
SL
PARTICULARS DETAILS
NO
i) Equipment No
ii) Model
iii) Capacity, kg
iv) Load centre, mm
v) Numbers off
vi) Type of tyre
vii) Location
viii) Purpose
Ix) Gradability
x) Travel speed on level surface
Laden/Unladen,km/hr
xi) Lifting & lowering at rated capacity

laden/unladen, m/s
xii) Lowering speed at rated

capacity laden/unladen, m/s
xiii) Height of lift,mm
xiv) Overall height

mast lowered, mm
mast raised, mm
xv) Free lift, mm
xvi) Fork
Spreading of forks, mm
Overall width x length, mm
xvii) Overall dimensions

length off fork, mm
Width, mm
Height with guard, mm
xviii) Outer turning radius, mm
xix) Aisle width (90 deg turn)

xx) Total weight unladen kg

with battery
xxi) Motor details

Traction motor :KW x Rating
Pump motor :KW x Rating
xxii) Speed control

xxiii) Tilting angle of mast
Forward/ Backward, degree
xxiv) Working hours
xxv) Ambient temp.
xxvi) Working environment
xxvii) Attachment
xxviii Battery charger unit suitable for
) power supply
xxix) Traction Battery
Voltage, V
Capacity x Rating
Weight, Kg
xxx) Axle load Front/Rear,
Kg in laden Condition
xxxi) Any other special feature

GS – 18, FORK LIFT TRUCK (DIESEL OPERATED):
18.00 SCOPE OF WORK
The scope of work of the Tenderer shall consist of design, engineering, assembly; shop
testing, painting, supply, testing and commissioning at site of Diesel operated Fork Lift
Trucks complete with accessories and attachments as covered under this specification and
attached equipment data sheet, including:
Initial requirements of consumables.
Supply of commissioning spares.
Supply of tools and tackles.
Supply of drawing and document.
4. Design Standards and General Details
The fork lift truck to be supplied under this specification shall be complete with all
attachments, auxiliaries and accessories which are not specifically mentioned in the
specification but are required to make equipment complete in all respects to fulfill the
requirements of the prescribed duties, guaranteed performance and safe operation.
a) The unit offered shall be new, unused and best of its kind. The unit shall also conform to
the latest edition of the applicable Indian Standards and Regulation. Wherever the unit
offered is not in accordance with the relevant Indian Standards and Regulations, the
copies of the Standards to which the equipment conforms shall be submitted along with
the proposal. Each unit shall have a printed sketch showing the load capacity at different
load centres for safe operation.
b) In case due to standardization of the products by the Manufacturer, the Tenderer is not
able to quote for the exact specified capacity, he may quote for the next higher standard
capacity. The unit offered shall be able to meet all the requirements of its specified duty.
It would be preferred that the Tenderer shall quote for the equipment strictly conforming
to the “Technical Specification and Equipment Details." In case the unit offered has
modifications and deviations, then the details of such modifications and deviations shall
be clearly indicated. The reasons for such deviations shall also be clearly stated.
c) All surfaces and parts except gears, bearings, etc. shall be properly cleaned /sand
blasted/chemically treated to remove all loose mill scale, rust, mud, foreign materials and
then suitable corrosion resistance coating shall be applied to make the equipment fit for
indoor /outdoor services in tropical weather conditions.
d) The equipment shall be applied with two coats of final paint of approved quality and
colour before despatch from the works.
e) The equipment shall have sufficient lubrication arrangement so that bearing and
other parts do not get unusually heated in course of operation. Sufficient lubrication

points shall be provided wherever necessary and all such points shall be easily accessible.
The Tenderer shall specify the lubricants and also the quantity required for six months
period along with tender.
f) Specific Details
i) The fork lift truck shall confirm to General Requirements as stipulated in IS:5040
and shall be tested for stability as per IS:4357 - 1974 (Reaffirmed 2000)
ii) Brakes shall be hydraulic power assisted.
iii) Mechanical hand brake for parking shall be provided.
iv) Tilt and lift & auxiliary functions of the fork lift truck shall be hydraulically
operated.
v) Operator's seat shall be of cushioned and adjustable type. Driver'

s overhead guard &
load back rest shall also be provided.
vi) A rigid towing attachment complete with pin or hook shall be provided at the rear of
the truck.
vii) The diesel engine shall be of proven design to meet the service conditions of fork lift
trucks. the engine rating shall be adequate for normal service condition as well as for
driving the truck up a gradient as specified. The engine shall have sufficient reserve
to account for deration & other factors.
viii)Engine starting system inclusive of batteries, alternators etc. shall be provided.
ix) All hydraulic hose pipes shall be suitably protected from damage during operation.
x) Suitable check valves shall be provided to ensure safety & control the lowering speed
in case of engine or pump failure.
xi) Hydrostatic power steering control shall be available in case of engine or pump
failure.
xii) Exhaust gas purifier shall be provided to meet with pollution control norms.
xiii)Replaceable covers for easy inspection, replacement & adjustment of engine

components shall be provided.
xiv) The engine shall be mounted on resilient pads suitable for the service conditions to
minimise vibration &noise.

xv) Dash board shall be equipped with the following:
a) Ammeter for battery charging rate (Incase of battery Operated) & warning
light for alternator.
b) Instrument panel lights.
c) Oil pressure gauge with warning light.
d) Switches for lights.
e) Fuel gauge with warning light.
f) Key type starting switch.
g) Temperature gauge for coolant.
h) Any other instruments, switches, as necessary.
i) Engine hour meter.
xvi) Head lights & tail lights suitable for night operation shall be provided.
xvii) Electric or equivalent horn shall be provided. A bulb horn shall also be provided.
xviii) The fork lift truck shall be provided with a rechargeable electric storage battery of
lead acid type of reputed make.
xix) Brief Tech Parameter
1. Capacity : _____ at 500mm load centre.

2. Type : Diesel Operated
3. No. off : ________
4. Tyre type : Solid Rubber( 2 front + 2 rear)
5. Max Fork Height :
6. Fork Length :
7. Fork width :
8. Speed: :
a) Travel : ~ 8.5km/Hr
b) Lift : ~ 0.2m/sec
c) Lower : ~0.45m/se
8. Turning Radius : ~ 1800mm
Only broad technical parameters and general design guide lines are indicated, the missing
parameters shall be included as data sheet for specific TS.
5. Other Instructions to Tenderer:
a. The Manufacturer shall conduct all tests required to ensure that the equipment supplied,
shall conform to the specification requirements and relevant standards and codes.

b. Purchaser reserves the right for inspection at the works of the Contractor & the
Sub-contractor during entire fabrication / manufacturing period. Such inspection shall not
relieve the Supplier of his obligation in respect of correct supply.
c. Inspection, testing and commissioning of the equipment, shall be carried out in

accordance approved QAP. Format for Quality Assurance Plan for Structural &
Mechanical Equipment has been enclosed as Annexure-II of the TS.
d. All materials shall be of tested quality.
e. Notwithstanding anything stated above the following tests shall be performed in presence
of Purchaser'
s representative :
i) Capacity test at specified and rated conditions.

ii) Stability test as per IS : 4357 - 1974 (reaffirmed -2000)
iii) Routine type tests including dimensional check up.
iv) Gradient test
v) Brake test as per IS:6305(Part-II) - 1980
vi) Turning radius test.
vii) Mast performance test.
f. All equipment & components shall be easily accessible for maintenance. If the equipment
requires any special maintenance facility to be provided by the Purchaser (viz.
maintenance pit, hoisting device etc. ) it should be clearly brought out in the offer.
6. GUARANTEE
The Fork Lift Truck shall be guaranteed for a period of 12 Months form date of successful
commissioning.

7. DESIGN DATA / INFORMATIONS TO BE FURNISHED BY TENDER
SL. PARTICULARS PURCHASER'

S AS OFFERED
NO. REQUIREMENTS
i) Equipment No :
ii) Model :
iii) Capacity, kg :
iv) Load centre, mm :
v) Numbers off :
vi) Type of tyre :
vii) Location :
viii) Purpose Handling and stacking.
ix) Gradability 10 % in both laden and unladen condition as well

as in climbing up and down movements
x) Travel speed on level surface :
Laden/Unladen,km/hr
xi) Lifting & lowering at rated capacity :

With load With out load
xii) Height of lift, mm :
xiii) Overall height :

mast lowered, mm
mast raised, mm
xiv) Free lift, mm
xv) Fork
Spreading of forks, mm :
Overall width x length, mm :
xvi) Overall dimensions length off

fork, mm :
Width, mm :
Height with guard, mm :

xvii) Outer turning radius, mm :
xviii) Aisle width (90 deg turn) :

:
xix) Total weight unladen kg :
xx) Engine details :

Make/Model :
Brake H.P :
RPM :
Fuel consumption/bhp/hr :
xxi) Transmission system :

Type :
No. off speeds forward backward :
:
xxii) Speed control :
xxiii) Tilting angle of mast :
Forward/Backward, degree :
xxiv) Working hours :
xxv) Ambient temp. :
xxvi) Working environment :

xxvii) Attachment :
xxviii) Any other special feature :

GS – 19, VULCANIZING MACHINE & MOBILE BELT CHANGING WINCH:
19-A.00 BELT VULCANIZING MACHINE
Belt vulcanizing machines for belt splice of various widths (as indicated in data sheets)
shall be supplied. The machine shall be easy to handle type. Heating element for Hot Belt
Vulcanizing Machines shall be preferably of flexible type. The equipment shall be
suitable for vulcanizing of entire splice width in single setting. It shall be capable of
applying uniform pressure over splice by pneumatic or hydraulic means.
19-B.00 MOBILE BELT CHANGING UNIT
19-B.01 Scope of work
Mobile belt-changing devices for quick replacement of conveyor belts of various widths
shall be provided. The equipment shall safely replace worn out belts by pulling out the
same while the new belting is put in place. The equipment shall be provided with one
number heavy duty, base mounted, rope winch, power driven from the prime-mover
(Truck) directly including all accessories to operate the same at remote locations. The
minimum length of the rope shall be 300m.
19-B.02 Design Data
1. The truck shall be complete with following facilities:
a) Cabin with seating facility for minimum 2 persons and a driver. The cabin
shall have latest driving facility for driver.
b) It shall be of reputed make and model of minimum 12T Capacity,

complete with all the necessary attachment to drive in the night and dust/
hazardous condition without any external support.
c) Tools & tackles for maintenance of truck including hydraulic jack for
lifting the truck for wheel changing.
2. The belt-changing winch mounted on the platform shall have following features:
a) Adequate pulling force as per the requirement or 4t (whichever is more)

shall be considered.
b) The truck shall have min. 4 nos. out-riggers of robust design for
application during belt changing operation.
c) Winch shall be power driven from the Prime mover with provision of
manual operation.
d) Four numbers mandrels (to put inside the wooden belt reels for rotation, 2
numbers working, 2 numbers spare) and 2 Nos. wooden reels (for belts),
along with any other accessories that may be required to for belt
changing operation shall also be supplied.
e) Two Nos. of belt gripping devices (one for old and one for new belt)

including fasteners & necessary rope fixing arrangement shall be

provided. One spare gripping device meant for spare belt shall also be
provided.
f) Adequate space on the truck deck shall to be provided for transporting

vulcanizing unit, took kit box, belt stretching device etc.
g) The truck shall be designed and selected such that it can remain stable
during operation of the winch considering the rope pull from any possible
direction. Out riggers and ballast shall be provided in the trailer.
h) Circumferential speed of the belt at the stabilized condition of changing

shall be minimum 15m /minute.
1. Drawings and document to be submitted by Tenderer
a) Technical Parameters, constructional features and details of Equipment along with

General Arrangement drawings.
b) Operating weight
c) Filled up Questionnaire
2. List of drawings /data to be submitted by the successful tender

dimension & details.
b. Supplier'
d. List of recommended spares for two years maintenance of plant and equipment
along with itemised price.
19-B.04 Questionnaire
Type & Name of Supplier
Technical Parameters:

GS – 20, PADDLE FEEDERS:
20.00 PADDLE FEEDERS
1. TECHNICAL SPECIFICATION OF PADDLE FEEDER
Paddle feeders shall be furnished and erected complete with rails including necessary
supporting structures, approach/ maintenance platforms with hand railings and ladders,
cable reeling drums with trailing cable, all electrical including machine mounted local
control panel, and dust suppression system, with hose reeling drum wherever necessary
for continuous working.
2. CODES & STANDARDS
The design, manufacture, inspection and testing of Paddle Feeders shall comply with all
the currently applicable statues, regulations and safety codes in the locality where the
equipment is to be installed. The Paddle Feeders shall conform to the latest edition of the
Indian standards and codes. Other internationally acceptable standards/codes, which
ensure equal or higher performance than those specified, shall also be accepted. Nothing
in this specification shall be construed to relieve the contractor of the required statutory
responsibility. In case of any conflict in the standard and this specification, the decision of
the Engineer shall be final and binding.
3. DESIGN REQUIREMENT
- The machine shall be rail mounted travelling type and shall be equipped with a rotating
paddle wheel drawing out material from a continuous long slotted bottom open hopper.
The wheel shall be mounted on a carriage travelling on travelling wheels. The carriage
shall be of robust construction and house all assemblies like paddle, hydraulic power
pack, travel mechanism, cable reeling drum etc. Adequate maintenance approach shall be
provided on the platform for all equipment mounted on the platform with safety hand
railings.
- Travelling paddle feeders of self-contained, self-propelled design shall be furnished and

erected to scoop out the raw-material from the hopper and each feeder shall be capable of
traveling back and forth along the entire length of the hopper and transfer the raw-material
from the hopper uniformly onto the conveyors below. Each Paddle Feeder shall have the
capacity to scoop out raw-material at the guaranteed capacity in both forward and reverse
motions with no indication of wheel slipping (water tank empty). Each Paddle Feeder
shall be designed for guaranteed capacity while handling entire range of lump size.
- The paddle feeder shall be of robust construction for continuous arduous duty. Maximum
interchangeability shall be considered for parts of identical capacity and duty. Antifriction
bearings shall be used throughout.
- It shall operate on the principle of positive discharge and shall not depend on friction or
moisture content.
- The paddle wheel shall be driven by a step less hydraulic drive directly mounted on
paddle wheel. Carriage travel shall be driven by dual-speed motor & gear-box The
operating travel speed of the machine shall be sleeplessly variable through hydraulic
motors from 2m/min to 5m/min.
- In case the tenderer offers a machine with electromechanical long travel drive, machine
shall be provided with drives on each side. In the event of failure of any drive motor, the
corresponding motor on the other side shall be automatically disconnected. However, the
machine shall be operable with the remaining drives at a lower speed. The VVVF control
shall be provided as mentioned above.
- The travel speed shall be such as to maintain constant out put during both forward and
reverse travel of the feeder.
- All equipments shall be designed to withstand any rate of acceleration imparted by drives
or any strain resulting from a sudden change in load. Further the design of Paddle Feeder
carriage should be such that it does not run off from its rails due to sudden change in load
or other reasons.
- The scope of supply shall include necessary electrical for Paddle Feeder and carriage such
as motorized cable reeling drum with trailing cables and stall torque motor of “Demag”
make, cable trays for resting of trailing cables, and end limit switches for protection
against over travel of the feeder carriage. The cable reeling drum and trailing cable of
each feeder shall be suitable for the entire length of the hopper. Mechanical track stops
shall also be provided. For specification of dust suppression equipment for Paddle Feeder
refer relevant section of this volume.
- For designing the paddle wheel as well as travel drive, fully loaded hopper with raw-
material on either side of the paddle wheel to the maximum capacity is to be considered.
The hydraulic system normal average working pressure shall be preferably maintained
within 180 bars and the maximum pressure shall be limited to 230 bar. Further hydraulic
system shall be designed to stall / trip beyond a certain pressure and the stall / trip
pressure shall be 150% of rated pressure. All hydraulic components shall be selected
based on this pressure rating. MOC for hydraulic piping / fittings including reservoir shall
be of SS quality only. The tenderer shall demonstrate the same during PG test.
- Feeder carriage drive shall be suitably designed so that the forward & reverse movement
of carriage can be achieved without stopping the scooping operation. Tank filled with
water in DS trolley shall also be considered for travel drive.
- Rail structure shall be designed considering two wheel support and accounting no
frictional force from the other two wheels and considering hydraulic motor stall condition.
- All drive equipment including hydraulic motor, gear box etc. shall be selected based on
120 % of actual power requirement at specified guaranteed capacity.
- For selection and specification of drive motors, gear boxes, all types of couplings
associated with paddle feeder and other equipment, relevant sections of this specification
shall be referred to.
- The design of paddle feeder should not incorporate a separate loading table (impact
cradle) below the paddle feeders. However, the height of fall of raw-material between
paddle wheel and conveyor belt shall be kept minimum. Further, the length of the skirt
board shall adequately extend on both sides of the paddle wheel so that there is no spillage
of raw-material on to the paddle feeders trolley. Minimum 500 mm extension shall be
considered for this purpose. Hydraulic components shall be provided with dust proof
cover for protection against spillage of raw-material/dust. Pressure /Temp. Gauges shall

be located at convenient locations for continuous observation by operator. Dust covers

shall be provided for all motors, gear boxes, drums etc.
- The paddle wheel shall be reversible type to disengage the paddle in case of paddle
getting jammed in material. Short spikes shall be fitted on the blades vertically for cutting
thorough the material that get packed on the surfaces below the paddle.
- The design and construction of hydraulic system shall be suitable to operate in the
atmospheric conditions and dusty operating environment of the plant. The system shall be
complete and consist of hydraulic fluid, various kinds of valves, accumulators, hydraulic
motors/ hydraulic pumps, various accessories such as filters, strainers, magnet and
restructures, hydraulic pipe work, fittings and fluid passages, flexible pipe work,
sealing devices, instruments for indicating various parameters such as pressure,
temperature etc., control devices for local and automatic operation of the system,
safety devices and alarm for abnormal operating conditions, interlocks for sequencing
and safe operations.
- The wheels shall be double flanged with straight tread, and shall be either of forged,
rolled or cast steel. Clearances between rail head and wheel flanges shall be suitable to the
tolerances as given below:
Track center : ± 5 mm
Rail level : ±5 mm
Longitudinal gradient of the rail : ± 0.5%
4. CONSTRUCTION REQUIREMENT
- The paddle feeders shall run on rails mounted on the supporting structures of associated
conveyors. Both paddle feeder and carriage drives shall be mounted on the feeder
carriage.
- The paddle feeder wheel shall comprise of suitable numbers of vanes with cutting edges.
The vanes shall be of high strength steel construction with removable liner plates of
Hardox-500 - 6mm thk. Vanes shall be easily removable individually. Liner plates shall be
provided wherever the vanes are likely to come in contact with material.
- Wheels shall be heat treated to have a hardness of BHN-280 to 300 on the rolling surface
and flanges to a depth of not less than 8 mm with a smooth pass to the non hardness zone.
The trolley shall be provided with lifting pads for jacking up the trolley for removal of
wheels. The height of jacking pads shall be 300 mm from the rail top and shall not cause
interference with the removal of wheels.
- The feeder carriage shall be of steel construction and of robust design. Skirt plates shall
be provided integral with the equipment for collecting the material drawn by the paddle
feeder from the track hopper and discharging on to the conveyor belt. Feeder skirts of
paddle feeders shall be extended at least by 500 mm on either side of the paddle wheel to
avoid spillage of raw-material. Necessary baffle/retainer plates for suitably guiding the
flow of raw-material from track hopper to the reclaim conveyor being fed by paddle
feeders shall be provided. Hand railing shall be provided on the top deck of feeder
carriage together with an access ladder.

- The feeder carriage shall be provided with suitable number of double flange wheels of
steel construction, complete with sealed bearing unit. The drive mechanism shall be
suitable for continuous reversible motion of the carriage. Start/stop switches shall be
provided at the local control panel for the operation of paddle wheel and feeder carriage.
The carriage shall automatically reverse its motion, when two paddle feeders operating on
the same track hit each other or come within a predetermined distance. Suitable anti-
collision device (infra-red and mechanically operated limit switch type both) shall be
provided. Conveyor shall be able to trip from paddle feeder control panel and provision
shall also be made for tripping of paddle feeder from CHP main control room.
- Wheels shall be heat treated to have a hardness of BHN-300 to 350 on the rolling surface
and flanges to a depth of not less than 10 mm with a smooth pass to the non hardness
zone. Wheel diameter shall be minimum 500mm.
- The power pack shall be mounted on easily accessible location in the carriage platform
- Rope actuated stop switches shall be provided for the traveling structure for emergency
use.
- Suitable indication of paddle wheel rpm shall be provided on the local panel and rate flow
indicator of belt weigh scale provided on conv. shall also be duplicated on local panel of
paddle feeder.
- Rubber buffers shall be fitted on the four corners of the equipment.
- Suitable cleaners shall be provided at the leading as well as trailing side of the feeder
carriage for the track.
- Suitable cable trays shall be provided along the travel of paddle feeder for supporting and
guiding the trailing cables.
- Various equipment of paddle feeder assembly shall be easily accessible. The arrangement
shall be subject to approval of Owner during detail engineering stage. It shall be possible
to replace electrical, mechanical and hydraulic components of paddle feeder when in
position.
- Provision shall be kept for emergency tripping of conveyor below Paddle Feeders from
respective paddle feeders. Further, provision shall also be kept in control schematics for
automatic tripping of conveyor below Paddle Feeders in the event of paddle feeder getting
dragged (i.e. travel speed in excess of rated speed).
- Protection against overloads shall be provided through suitable control system. The
control system shall ensure smooth acceleration for all motions and variable speeds.
- The travel speed shall be such as to maintain constant out put during both forward and
reverse travel of the feeder.
- The brakes shall be AC thrustor operated type and shall be mounted on the input shaft of
gear box. The brake shoe shall be hinged type. Hinge pins shall be of hardened alloy steel
and shall be lubricated.

- Gear boxes shall be of fabricated or cast steel construction. Fabricated gear boxes shall be
stress relieved and shall be made of minimum 8mm thick plates. The gear boxes shall be
provided with breather vents, oil level indicator, dip sticks and easily accessible magnetic
drain plugs. Interior of all gear boxes shall be sand blasted and without paint. Totally
enclosed gear boxes splash or automatic lubrication system shall be provided.
- In case it is not possible to provide enclosed oil tight casings for certain gears, these shall
be completely covered.
- All hydraulic pipes / fittings including reservoir shall be made of stainless steel only.
- The feeder shall be provided with a centralized lubrication system through metal grease
pipes. All pipe works shall be rigidly fixed protected from damage and accessible.
- Safe access for maintenance and removal of all mechanical and electrical parts must be
ensured without and additional scaffolding. All parts requiring replacement or inspection
or lubrication shall be easily accessible. All electrical cables shall be so laid that they are
not liable to damage.
- All exposed moving parts like couplings, brakes, drives, wheels etc. shall be provided
with guards or covers.
- All heavy covers shall be provided with hinged inspection windows.
- Safety hand railings of about 1000 mm height shall be provided where persons may have
to work or approach for operation or maintenance. All edges or openings shall be
provided with tee guards.
5. DUST SUPPRESSION SYSTEM
- Captive dual fluid dust suppression (DFDS) system shall be provided for plough
feeder conveyor system. Movable type dust suppression kit shall be installed in
plough feeder car.
- DS system shall comprise of water tank for 2 hours storage capacity, pumps and
compressor. Air atomization of water shall be done for better spray, control of fine
dust and water conservation.
- Power supply to control unit, compressor and pump shall be given from plough feeder
car. .
- A hose of approx. 3.5m length shall attach to the water supply line of water tank for
filling at regular interval.
- Dust level in the basement work zone shall be limited to 5mg/Nm3.
- All control & instruments required for successful operation of DFDS system such as
material flow switch / material flow sensor etc., pressure gauge, level gauge, solenoid
valve, by-pass line from fan pump discharge to tank compressed air receiver, water &
compressed air, piping network with in the car shall be in the scope of the tenderer.
- At compressor inlet air filter to be provided. 1 no. of each pump and compressor of
DFDS system shall be supplied as reserve unit.
6. TESTING & INSPECTION
- Shaft and wheel forgings – Chemical. Mechanical, Hardness and Ultrasonic Test shall be
conducted.
- Shop trail run to be conducted and performance test shall include checks for noise and
vibration level.
7. DATA SHEET
GENERAL
Type of paddle feeder : Mobile, Rotary plough
Nos. required : Specified in TS
Materials Handled : Specified in TS
Guaranteed (rated) capacity : Specified in TS
Capacity adjustment : 20% to 120% of guaranteed capacity.
Location : Underground below track hopper
Total travel by each feeder carriage : Specified in TS
DESIGN & CONSTRUCTION
Paddle Feeders : Specified in TS.
No. of paddle wheel vanes : Suitable
Material for vanes liners : Hardox-500, 6mm thk
Drive Arrangement
Paddle wheel : Hydraulic motor directly mounted
Feeder Carriage : Motor (Two speed) & gear-box
Minimum no. of starts per hour : 15 Starts/min. (with drive

Equipment minimum 10 consecutive
starts)
Paddle Feeder Rails
Size : 60 kg/m

Support Arrangement : To be mounted on supporting structure of

conveyors with continuous support below
rail.
Feeder Carriage Wheels
i) Nos. : Suitable
ii) Type : Double Flange
iii) Bearings : Sealed type
Anti Collision Drive : Required
Cable Tray Height : Min. 300 mm above floor
Control : Mocro-processor based
Location of Control Panel : On the feeder Carriage
Idlers for Conveyor Belt : As per relevant section for Belt Conveyor
system.
Spacing of carrying idlers in the : 400 mm (maximum)

loading zone of paddle feeders
Chute work and hopper : 10 mm thick Hardoxl or equivalent with

60mm thk reinforced steel backed
rubber in impact zone.
Dust Suppression system : Refer Relevant Chapter

NMDC LIMITED

FOR
CIVIL WORKS
(GS – 07)
MECON LIMITED
RANCHI - 834002

INDEX
PAGES
PART - I MATERIALS 2 TO 51
PART - II WORKMANSHIP 52 TO 198
PART - III NORMS OF CEMENT 199 TO 209

CONSUMPTION
PART - IV DIMENSIONAL TOLERANCE 210 TO 216
PART - V METHOD OF MEASUREMENT 217 TO 228
PART - VI SAFETY REQUIREMENTS FOR 229 TO 241

CONSTRUCTION WORK
ANNEXURE-A LIST OF IS & CODES REFERRED 242 TO 249
Chapter 07 Civil Page 1 of 249

PART – I MATERIALS

C O N T E N T S
1.01 GENERAL
1.01 Scope
1.02 Standard
1.03 Approval and Tests
1.04 Codes
1.05 Rejection of Materials
1.06 Materials for Concrete
1.07 Coarse Aggregates
1.08 Fine Aggregates
1.09 Testing of Sample
1.10 Water
1.11 Admixtures for Concrete
1.12 Interval of Routine Test
1.13 Steel
1.14 Asbestos Cement Products
1.15 Brick and Stones
1.16 Stones (Granite, trap, sandstone and quartzite etc.)
1.17 Hollow and Solid Concrete Blocks
1.18 Hollow Blocks(open & closed cavity)
1.19 Cement, Lime and Water
1.20 Sand for Masonry Mortar
1.21 Sand for Plastering
1.22 Materials for Flooring & Paving
1.23 Timber

1.24 Storage & Inspection
1.25 Moisture Content
1.26 Tolerance for Timber
1.27 Flush Door Shutters, Shelves
1.28 Wood Particle Board
1.29 Veneered Particle Board
1.30 Plywood for general purpose
1.31 Veneered decorative plywood
1.32 Fittings for doors, windows etc.
1.33 Metal doors, Windows, Ventilators and Rolling shutters
1.34 Glass
1.35 Paints
1.36 Water Proofing Materials
1.37 Physical Properties
1.38 P.V.C. Membrane/sheet
1.39 Properties
1.40 Water Bar
1.41 Lead
1.42 Building paper
1.43 Filling Material
1.44 Drainage and Sanitation (internal)
1.45 Sanitary appliances (E.W.C. & I.W.C.)
1.46 Wash Hand Basin
1.47 Flat Back Lipped Urinal
1.48 Mirror Frames
1.49 Toilet Shelf

1.50 Towel rail
1.50 Soap Container
1.52 CP Flush Valves for E.W.C.
1.53 CP Flush Valves for urinals
1.54 Gully Trap
1.55 C.I. Manhole Cover and frame
1.56 Flushing cistern
1.57 Plastic seat & cover for water closets
1.58 Water Supply & Plumbing (internal)
1.59 Shower Rose
1.60 Storage Tank
1.61 Misc. items
1.62 External Sewerage & Drainage
1.63 C.I. Pipes
1.64 Washers
1.65 Gaskets
1.66 Caulking Lead
1.67 Salt glazed stoneware Pipes
1.68 Steel pipes
1.69 Cast Iron Manhole Covers and frames
1.70 Road
1.71 List of materials of approved brand and/or manufacture
1.72 Materials not specified

01 CIVIL
01.01 GENERAL
01.01.01 Scope
This part deals with the requirements of materials for use in construction work
with regard to quality, testing, approval and storage, before they are used on work.
This part is supplementary to Part-II: Workmanship and Other requirements of the
Technical Specifications for civil works.
01.02 Standard
A high standard of quality is required for all materials used in construction work.
They shall be the best of the kind obtainable indigenously in each case and shall
be procured from manufacturers of repute in order to ensure uniformity of quality
and assurance of timely supply.
01.03 Approval and Tests
01.03.01 All materials to be used in construction shall be subject to approval of the

Engineer. The Contractor shall apply sufficiently in advance with samples of the
materials including the supporting test results from the approved laboratory and
other documentary evidence from the manufacturer wherever applicable and
indicating the types of materials and their respective sources. The delivery of
materials at site shall commence only after the approval of the quality, grading and
sources of the materials by the Engineer.
01.03.02 The quality of all materials once approved shall be maintained throughout the
period of construction and periodical tests shall be carried out to ensure that it is
maintained. Such routine tests shall be listed under the different materials and/or
as may be ordered by the Engineer from time to time.
01.03.03 Where a particular "Brand" or "Make" of material is specified in the Schedule of

Items or Technical Specifications, such "Brand" or "Make" of material alone shall
be used on the work. Should it become necessary for any reason (such as non-
availability/ceased to be produced), to use any material other than the specified
"Brand" or "Make", the Contractor shall submit sample of the same to the
Engineer for approval together with test certificates and other documents
necessary for examining and giving approval thereof. Should such change or
substitution of materials, subsequently approved, results in use of material of price
lower than that of the material specified in the Schedule of Items or Technical
Specifications, the rates of work affected by the substitution shall be
proportionately reduced. Similarly, in case the substitution results in use of
material of price higher than that specified in the Schedule of Items or Technical
proportionately increased.

01.04 Codes
01.04.01 The years of publication against various standards, referred in this specification,
correspond to the latest standards as on date of preparation of this specification.
During use of this specification in future, the latest publication as on date shall be
referred to. Where standards are not yet published by the BIS or IRC, adoptable
British Standards or other International Standards shall apply.
01.04.02 In case of any conflict in meaning between these specifications and those of BIS
or IRC, or British /International Standard; the provisions of these specifications
shall prevail.
01.05 Rejection of Materials
01.05.01 Any material brought to site which, in the opinion of the Engineer is damaged,
contaminated, deteriorated or does not comply with the requirement of this
specification shall be rejected.
01.05.02 If the routine tests or random site tests show that any of the materials, brought to
site, do not comply in any way with the requirements of this specification or of
I.S. Codes as applicable, then that material shall be rejected.
01.05.03 The Contractor at his own cost shall remove from site any and all such rejected
material within the time specified by the Engineer.
01.06 Materials for concrete
01.06.01 Aggregates
Aggregates shall comply with the requirements of IS: 383-1970 "Coarse and Fine
Aggregates for Concrete". They shall be hard, strong, dense, durable, clean and
free from veins and adherent coating, vegetable matter and other deleterious
substances; and shall be obtained from approved sources. Aggregates shall not
contain any harmful material such as pyrites, coal, lignite, shale or similar
laminated material, clay, alkali, soft fragments, sea shells and organic impurities in
such quantity as to affect the strength or durability of concrete. Aggregates which
are chemically reactive with alkalies of cement shall not be used. Aggregates
which are not sufficiently clean shall be washed in clean fresh water to the
satisfaction of the Engineer.
01.06.02 Testing
All aggregates shall be subject to inspection and testing. The Contractor shall
submit samples for testing as may be required by the Engineer. Sampling and
testing shall be carried out in accordance with IS: 2386-1963 "Methods of Test for
Aggregates for concrete".

01.06.03 Grading
The Contractor shall ensure that the full range of aggregate used for making
concrete is graded in such a way as to ensure a dense workable mix. The delivery
of aggregates will commence only when the Engineer has approved the samples
and the quality and grade shall be maintained consistent and equal to the approved
sample. Before construction commences, the Contractor shall carry out a series of
tests on the aggregates and on the concrete made there from to determine the most
suitable grading of the available aggregates. Once the most suitable grading has
been found, the grading shall be adopted for the construction of the works and
periodic tests shall be carried out to ensure that it is maintained.
Size and grading of fine aggregates
The grading shall conform to IS: 383-1970 and shall be within the limits of
Grading Zone-III. The maximum size of particle shall be 4.75mm and shall be
graded down. Sand containing more than 10% of fine grains passing through 150
micron sieve or having the fineness modulus less than 2 shall not be used for
concrete work.
Size and grading of coarse aggregates
The nominal maximum size of the aggregates for each mark of concrete or for
each type of work shall depend upon the description of the particular item in the
Schedule of Items and/or according to relevant clauses of IS: 456-1978. The
aggregates shall be well graded and the grading shall conform to relevant
requirements of IS: 383-1970 depending upon the maximum nominal size as
specified or as required.
Fine aggregate for mortar and grout
The grading of fine aggregate for mortar and grout shall be within the limits of
grading zone III and IV as defined in IS: 383-1970.
01.06.04 Storage & stacking
Care shall be taken in the storage to avoid intrusion of any foreign materials into
the aggregates and where two types of aggregates are stored close to each other,
they shall be separated by a wall or plate. In case of stockpiling, care shall be
taken to avoid forming pyramids resulting in segregation of different sized
materials. The height of the stacks shall be generally limited to 150 cm.
01.07 Coarse Aggregates
01.07.01 Types
The type of coarse aggregate viz., stone chips, gravel or broken brick shall be as
described in the Schedule of Items. Unless otherwise specified in the Schedule of
Items, stone chips shall be used as coarse aggregate.

01.07.02 Stone chips
It shall be crushed or broken from hard stone obtained from approved quarries of
igneous or metamorphic origin. The stone chips shall be hard, strong, dense,
durable and angular in shape. It shall be free from soft, friable, thin, flat,
elongated or laminated and flaky pieces and free from dirt, clay lumps, and other
deleterious materials like coal, lignites, silt, soft fragments, and other foreign
materials which may affect adversely the strength & durability of concrete. The
total amount of deleterious /foreign materials shall not exceed 5% by weight
according to relevant clause of IS: 383-1970. If found necessary the stone chips
shall be screened and washed before use.
01.07.03 Gravel
It can be either river bed shingle or pit gravel. It shall be sound, hard, clean,
irregular in shape and suitably graded in size with or without some broken
fragments. It shall be free from flat particles, powdered clay, silt, loam and other
impurities. Before using, the gravel shall be screened and washed to the
satisfaction of the Engineer. However, the foreign/deleterious materials shall not
exceed 5% by weight.
01.07.04 Broken bricks / Brick aggregates
These shall be obtained by breaking well burnt or over burnt dense brick bats.
They shall be homogeneous in texture, well graded in size, roughly cubical in
shape, clean and free from dirt, clay, silt or any other deleterious matter. Before
use, these shall be screened.
01.08 Fine Aggregates
01.08.01 Unless specified otherwise it shall either be natural river sand or pit sand.
Sand shall be clean, sharp, strong, angular and composed of hard siliceous
material. It shall not contain harmful organic impurities in such form or quantities
as to affect adversely the strength and durability of concrete. Sand for reinforced
concrete shall not contain any acidic or other impurities which is likely to attack
steel reinforcement. The percentage of all deleterious materials including silt, clay
etc., shall not exceed 5% by weight. If directed, sand shall be screened or washed
before use to the satisfaction of Engineer.
01.08.02 Crusher dust
Crusher stone dust ( that is retained on 300 micron sieve ) may be used as
replacement for certain quantum of sand aiming to improve the fineness modulus
of fine aggregate. The quantum of replacement for sand shall be arrived at by
suitable trial mixes. The Engineer will decide the final usage of crusher dust
depending on the circumstances.

01.08.03 Lime
Lime for mortars and concrete shall conform to IS: 712-1984 The total of CaO and
MgO content in quick lime shall not be less than 85% (MgO shall not exceed 5%).
Quicklime, after slaking, shall leave a residue of not more than 5% by weight on
IS sieve 85.
01.08.04 Surkhi
Surkhi used in lime concrete for flooring, terracing etc., shall conform to IS: 3182-
1986. Surkhi shall be made from well burnt bricks or brickbats. Surkhi shall pass
through I.S. sieve 3.35mm with at least 50 % of it passing through I.S. sieve
1.70mm and be perfectly clean and free from foreign matter. Surkhi shall not be
made from bricks which have come in contact with any mortar.
01.08.05 Cement
Ordinary Portland cement / Portland slag cement complying with the requirements
of IS:269-1989 and I.S. 455-1989 respectively shall be used for making plain and
reinforced concrete, cement grout and mortar.
Other types of cement may be used depending upon the requirements of certain
jobs with the approval of the Engineer. These shall conform to the following
standards :
Portland Pozzolana Cement IS: 1489-1991

Rapid Hardening Portland Cement IS: 8041-1990
43 Grade Ordinary Portland Cement IS: 8112-1989
53 Grade Ordinary Portland Cement IS: 12269-1987
Hydrophobic Portland Cement .. IS: 8043-1991
High alumina cement for structural workIS: 6452-1989
White portland cement IS: 8043-1989
Sulphate Resisting Portland Cement IS: 12330-1988
01.09 Testing of samples
The Contractor shall supply a copy of the manufacturer's test certificate for each
consignment of cement supplied by him and consignments shall be used on work
in the order of delivery. The Contractor shall supply samples of cement to the
Engineer as frequently as he may require for testing. The sampling of cement for
testing shall be according to IS: 3535-1986. All tests shall be in accordance with
the relevant clauses of IS: 4031 (Part-I to Part-15) 1988 to 1991 & IS: 4032-1985.
01.09.01 Contractor's responsibility
From the time a consignment of cement is delivered at site and tested and approved
by the Engineer until such time as the cement is used on the works, the Contractor
shall be responsible for keeping the same in sound and acceptable condition and at
his expense and risk. Any cement which deteriorates while in the Contractor's
charge and is rejected as unsuitable by the Engineer, shall be removed from the

site to outside the limits of work at the cost of contractor within two days of
ordering such removal by the Engineer.
01.09.02 Stock of cement
In order to ensure due progress, the Contractor shall at all times maintain on the
site at least such stock of cement as the Engineer may from time to time consider
necessary. No cement shall be used upon the works until it has been accepted as
satisfactory by the Engineer.
01.09.03 Storage of cement
The cement shall be stored in such manner as to permit easy access for proper
inspection and in a suitable weather-tight, well ventilated building to protect it
from dampness caused by ingress of moisture from any source. Different types of
cement shall be stored separately. Cement bags shall be stacked at least 15 to 20
cm clear of the floor leaving a space of 60 cm around the exterior walls. The
cement shall not be stacked more than 10 bags high. Each consignment of cement
shall be stacked separately to permit easy access for inspection.
01.10 Water
Water used for mixing concrete and mortar and for curing shall be clean and free
from injurious amounts of oil, acid, alkali, salts, sugar, organic materials or other
substances that may be deleterious to concrete or steel. The pH value of water
shall generally be not less than '6'. Water has to meet the requirements mentioned
in clause 4.3 of IS: 456-2000. Water shall be obtained from an approved source.
Where it is obtained from a source other than a supply main, it shall be tested to
establish its suitability. Water for construction purpose shall be stored in proper
storage tanks to prevent any organic impurities getting mixed up with it.
01.11 Admixture for Concrete
01.11.01 Approval
Admixtures to concrete shall not be used without the written consent of the
Engineer. When permitted, the Contractor shall furnish full details from the
manufacturer and shall carry out such test as the Engineer may require before any
admixture is used in the work.
01.11.02 Types
Integral water proofer
Admixtures used as integral water proofer shall be free of chlorides and sulphates
and shall conform to IS: 2645-1975. The application and doses shall be as per
manufacturer's specification.

01.12 Interval of Routine Test
The routine tests of materials, delivered at site, shall be at the following intervals :
Aggregates - Fortnightly or for every 200 m3 for each aggregate

whichever is earlier and in other respects generally as per IS : 2386 (Part 1 to 8)-
1963.
Cement - Fortnightly or for each consignment, within 4 days of

delivery and in other respects generally as per IS : 4031-1988.
Water - Once in two months for each source of supply and in other
respects generally as per IS : 456-1978.
Reinforcement - For each consignment within 4 days of delivery in

accordance with I.S. 1786-1985, I.S. 1599-1985 and I.S. 1608-1972.
01.13 Steel
01.13.1 For Reinforcement
Reinforcing bars for concrete shall be round steel bars of the following types as
may be shown on the drawing :
i) Plain mild steel bars conforming to Grade-I of IS : 432-1982 "Mild Steel &
Medium Tensile Steel for Concrete Reinforcement".
ii) "High strength deformed steel bars conforming to IS : 1786-2008 for

Concrete Reinforcement".
iii) Reinforcement fabrics conforming to IS:1566-1982 "Hard Drawn Steel Wire
Fabric for Concrete Reinforcement"
All reinforcement bars shall be of uniform cross sectional area and be free from
loose mill scales, dust, loose rust, coats of paint, oil or other coatings which may
destroy or reduce bond. Unit weight of reinforcement bars conforming to I.S. 1786
is as given below.
Nominal Size (Dia) Mass Per Metre Run

(mm) (Kg)
6 0.222
8 0.395
10 0.617
12 0.888
16 1.580
18 2.000
20 2.470
22 2.980
25 3.850
28 4.830
32 6.310

01.13.02 Binding wire
Binding wire for reinforcement shall be annealed steel wire 20 BWG conforming
to IS : 280 -1978 "Specification for Mild Steel Wire".
01.13.03 Light structural work and inserts
Steel for light structural work and for preparation of inserts and embedments shall
conform to IS: 2062-1992 "Steel for general structural purposes - Specification."
01.13.04 Steel Tubes
Steel tubes for use in light structural work and inserts shall be of light or medium
class (as may be specified in drawings or the schedule of items) and of grade YST
25 conforming to IS : 1161 - 1979 "Specification for Steel Tubes for Structural
Purposes".
01.13.05 Foundation Bolts
Bolts to be embedded in concrete shall, unless otherwise detailed in drawings,

conform to IS : 5624-1970 "Specification for Foundation Bolts". Material for
bolts, shall, unless otherwise mentioned in drawings or the schedule of items, be
of steel conforming to IS : 2062-1992.
Nuts and locknuts shall conform to IS : 1363 (Part 1 to 3) -1992 "Specification for
Black Hexagon Bolts, Nuts and Lock Nuts (Diameter 6-39 mm) and Black
Hexagon Screws "Specification for Hexagon Bolts and Nuts (M-42 to M-
150)".
Plain washers shall conform to IS : 2016 -1967 "Specification for Plain Washers
and spring washers shall conform to IS : 3063 -1972 "Spring Washers for Bolts,
Nuts & Screws".
01.13.06 Steel Tubes for non-structural use
Steel tubes for non-structural use shall conform to IS : 1239 (Part-I) -1990
"Specification for Mild Steel Tubes, Tubular and Other Wrought Steel fittings, Part-
I : Mild Steel Tubes".
Fittings for steel tubes used for non-structural purposes shall conform to IS : 1239
(Part-II) -1992 "Specification for Mild Steel Tubular and Other Wrought Steel Pipe
Fittings".
01.13.07 Threaded fasteners
Bolts and nuts for fastening shall conform to IS:1367 (Part 1)-1980 "Technical
Supply Conditions for Threaded Fasteners".

01.13.08 Testing
Test certificates from manufacturer shall be submitted for each consignment. Any
additional test which the Engineer may require shall be done according to IS :
1786-1985, 1566-1982, 280-1978, 2062-1992, 1161-1979, 2614-1969, 3063-1972,
1239 (Part 1 and 2)-1990 and 1992 and 1367-1980.
01.13.09 Cast Steel
Quality
Cast steel shall conform to IS : 1030-1989 "Carbon Steel Casting for General
Engineering Purpose". Unless otherwise specified, it shall conform to Grade2.
01.13.10 Conduits
Steel for electrical wiring
Rigid steel conduits for electrical use shall conform to IS : 9537 (Part 2) - 1981 for
rigid pipes and to IS : 3480-1966 for flexible conduits. Fittings for conduits shall
conform to IS : 2667-1988.
All conduit pipes shall be finished with galvanised or stove-enamelled surface. All
accessories shall be of threaded type and pipes shall be jointed by means of screwed
couplers only. Bend in conduits shall be made to the dimension shown in drawing,
but a minimum of 12 times the diameter. Where shown in drawing they shall be
treated with anticorrosive preservative as specified.
Non-metallic conduit for electrical wiring
Non-metallic conduits for electrical use shall conform to IS : 9537 (Part 3) -1983 for
rigid pipes and to IS : 6946 -1973 for flexible pipes. Fittings shall conform to IS :
3419-1989.
Bends shall be achieved by bending the pipes by inserting suitable solid or

inspection type normal bends, elbows or similar fittings.
01.14 Asbestos cement products-Deleted
01.15 Brick and stones
01.15.01 Bricks
Bricks for masonry in foundations, walls and other locations shall be common burnt
clay building bricks having minimum crushing strength of 5 N/sq.mm., or such
other strength as may be described in the Schedule of Items, when tested in
accordance with IS : 1077-1992 "Common Burnt Clay Building Bricks". They shall
be sound, hard and thoroughly well burnt, with uniform size having rectangular
faces with parallel sides and sharp straight right angled edges and be of uniform
colour with fine compact uniform texture. Bricks shall be of uniform deep red
cherry or copper colour. They shall be free from flaws, cracks and nodules of free

lime. Water absorption after 24 hours immersion in cold water shall be not more
than 20% by weight. They shall not absorb more than 10% by weight of water after
immersion for six hours. They shall emit a clear metallic ringing sound when struck
by a mallet and shall not break when dropped on their face, from a height of 60 cm.
Fractured surface shall show homogeneous, fine grained uniform texture, free from
cracks, air holes, laminations, grits, lumps of lime, efflorescence or any other defect
which may impair their strength, durability, appearance and usefulness for the
purpose intended. Underburnt or vitrified bricks shall not be used. Samples of bricks
brought to the site shall be tested periodically for compression and other tests
according to IS : 3495 (Parts-1 to 4) -1992 "Method of Test for Burnt Clay Building
Bricks". Where the size of bricks is not specifically mentioned, it shall be taken to
mean conventional sizes as is commonly available in the area. In case modular
bricks are to be used, it shall be accordingly specified in Schedule of Items. The
bricks shall be classified on the basis of average compressive strength as given in
table 1 of IS : 1077-1992.
01.15.02 Handling
Bricks shall be unloaded by hand and carefully stacked and all broken bricks shall
be removed from the site.
01.15.03 Samples and Inspection
Representative samples shall be submitted by the contractor and approved samples

retained by the Engineer for comparison and future reference. Bricks shall be
obtained from approved manufacturer. All bricks shall be subject to inspection on
the site and shall be to the approval of the Engineer who may reject such
consignment as are considered by him to be inferior to the quality specified. The
Contractor shall provide all labour and plant required for the inspection and conduct
such test as shall be required by the Engineer without additional charges.
01.15.04 Brick Bats
Brick bats shall be obtained from well burnt bricks of approved quality.
01.15.05 Laterite Stone Blocks
These shall conform to IS : 3620 -1979 "Laterite Stone Blocks for Masonry". The
laterite stone blocks shall have a minimum compressive strength of 30 kg/cm2 and
to be tested as per IS : 1121-1974. The blocks shall be minimum 15 cm thick but not
exceeding 30 cm. They shall be dressed to the desired sizes and shapes with an axe.
Laterite stones shall be well seasoned by exposure to air before dressing and using
on work.
01.16 Stone (granite, trap, sandstone, quartzite etc.)
01.16.01 Stone used shall be strong, durable, dense, compact, close grained, homogeneous,
fire resistant and shall be obtained from sources approved by Engineer. Stones shall
additionally be hard, sound, free from cracks, decay and other flaws or weathering
and shall be easily workable. Stones with round surfaces shall not be made use of.

01.16.02 Stones shall have a crushing strength of not less than 200 kg/cm2. Stones with
lesser crushing strength may be used in works with prior approval of the Engineer.
Stones shall be non-porous and when tested in accordance with IS : 1124 -1974
"Method of Test for Determination of Water Absorption Etc.," shall show water
absorption of less than 5% of its dry weight when soaked in water for 24 hours.
Tests for durability and weathering shall be done in accordance with IS : 1126-1974
and IS : 1125-1974 respectively. The working of stones to required sizes and their
dressing shall be as per IS : 1127-1970 "Recommendations for dimensions and
workmanship of natural building stones for masonry work" and IS : 1129 -1972
"Dressing of Natural Building Stones". Stones especially limestone and sand stones
shall be well seasoned by exposure to air before use in construction works.
01.16.03 Size
Normally stones shall be of size that could be lifted and placed by hand, between 20
to 30 kg per piece. The length of stones shall not exceed 3 times the height and the
breadth on base shall not be greater than 3/4 of the thickness of wall or less than
15cm. The height of stone may be up to 30cm.
01.16.04 Dressing
Random rubble
Stones shall be hammer dressed on the face, the sides, and the beds to enable it to
come into close proximity with the neighbouring stone. The bushings in the face
shall not project more than 4cm on all exposed faces and 2cm on a face to be
plastered, nor shall it have depressions more than 1cm from the average wall
surface.
Coursed rubble - first sort
Face stones shall be hammer dressed on all beds, and joints, so as to give them
approximately rectangular block shape. These shall be squared on all joints and
beds. The bed joint shall be rough chisel dressed for at least 5cm back from the face,
and side joints for at least 4cm such that no portion of the dressed surface is more
than 6mm from a straight edge placed on it. The bushing on the face shall not
project more than 4cm as an exposed face and one cm on a face to be plastered. The
hammer dressed stone shall also have a rough tooling for a minimum width of
2.5cm along the four edges of the face of the stone, when stone work is exposed.
Coursed rubble - Second sort
Dressing shall be as specified in 5.6.4.2 except that no portion of dressed surface

shall exceed 10mm from a straight edge placed on it as against 6mm for first sort.
Stone for veneering
Stone lining up to 8cm shall be treated as veneering work. The stone shall be cut
into slabs or required thickness along the planes parallel to the natural bed. Every
stone shall be cut to the required size and shape so as to be free from any waviness
and to give truly vertical and horizontal joints. Adjoining faces shall be fine chisel
dressed to a depth of a 6mm, so that when checked with a 60cm straight edge, no

point varies from it by more than 1mm. All edges shall be chisel dressed to be true,
square and free from chippings. Top and bottom faces shall be dressed to within
3mm tolerance and vertical faces to within 6mm tolerance, when checked with a
60mm straight edge. Dressing at the back shall not be done.
Hollow and solid concrete blocks
01.17.01 Cement concrete blocks used in the construction of concrete masonry load bearing
as well as non-load bearing walls shall conform to the requirements of IS : 2185
(Part 1)-1979. Physical properties such as density, compressive strength, water
absorption etc., shall be determined in accordance with the procedure laid down in
IS : 2185 (Part 1) -1979 and shall conform to the requirement laid therein. When
inspected visually all blocks shall be sound, free from cracks, broken edges,
honeycombing and other defects which would interfere with the proper placing of
blocks or impair strength or permanence of construction.
01.17.02 Dimensions and tolerance
The blocks shall be made in sizes and shapes to suit the particular job and shall
include stretcher, corner, double corner or pier, jamb, header, bullnose and floor
units.
The nominal dimensions of concrete block shall be as follows :
Length : 400, 500 or 600mm

Height : 200 or 100mm
Width : 50, 75,100, 150, 200, 250 or 300mm
In addition, blocks shall be manufactured in half and other suitable lengths and
shapes to suit Architectural requirements.
The maximum dimensional tolerances shall be plus or minus 5mm in length and
plus or minus 3mm in height and width.
01.18 Hollow blocks (open and closed cavity)
The blocks having solid material about 50% to 75% of total volume of the block
calculated from the overall dimensions shall be termed as hollow blocks. Grade-A
blocks used as load bearing units shall have a minimum block density of 1500
kg/m3 and shall have minimum average compressive strength of 3.5, 4.5, 5.5 or 7.0
N/mm2 at 28 days as specified.
Grade-B Blocks used as load bearing units shall have block density less than 1500
kg/m3, but not less than 1000 kg/m3 and shall have compressive strength of 2.0,
3.0, or 5.0 N/ mm2 or as specified.
Grade-C blocks used as non load bearing units shall have block density less than
1500 kg/m3, but not less than 1000 kg/m3 and compressive strength of 1.5 N/mm2
at 28 days.

01.18.01 Solid blocks
The blocks having solid material more than 75% of the total volume of the be block
shall be termed as solid block. Solid blocks (Grade-D) used as load bearing units
shall have a block density of not less than 1800 kg/m3 and compressive strength of
4.0 or 5.0 N/mm2 as specified.
01.18.02 Mix proportion
The concrete mix used for blocks shall not be richer than one part by volume of
cement to six parts by volume of combined aggregates before mixing.
01.18.03 Surface texture and finish
Surface texture, that is, very fine closed texture or coarse open texture and finish,
whether coloured or not shall be according to the drawing, description in the
Schedule of Items or instructions of the Engineer.
01.18.04 Marking and certificate
The blocks shall be marked permanently indicating the Grade of the unit,
identification of the manufacturer and the year of manufacture. Manufacturers test
certificate shall be supplied with the delivery of each lot.
01.19 Cement, lime and water
Cement, lime and water shall conform to the specification under the Section
Concrete of this part.
01.20 Sand for masonry mortar
Sand for masonry mortars shall be natural sand, crushed stone sand or crushed
gravel and shall comply with IS : 2116 - 1980 "Sand for Masonry Mortars". The
sand shall be hard, durable, clean and free from adherent coatings and shall not
contain amount of clay, silt and fine dust more than 5% by wt. Sand shall not
contain any harmful impurities such as iron pyrites, alkalies, salts, coal, mica and
organic matters. The particle size grading of sand for use in mortars shall be
within the limits as specified in Table I of above code.
01.21 Sand for plastering
Sand for use in mortars for internal wall, ceiling and external plastering and
rendering shall conform to IS:1542 -1992. It shall not contain any harmful
impurities such as iron pyrites, alkalis, salts, coal, mica and organic matters.
Percentage of salt and dust shall not be more than 5% by weight. Grading of sand
shall be within the limits specified in clause no. 5.1 of above code. Fineness
modulus of naturally occuring sand shall not be less than 1.5.

01.22 Materials for flooring & paving

01.22.01 Cement and binders
Cement
Cement, fine aggregates, reinforcement and water used shall comply with the
requirements of concrete as per clauses 2.1, 2.3, 2.6 and 2.7 of this part.
01.220.2 Water
Water for construction shall be clean, soft, free from loam, salt and organic
materials. Hard water shall not be used.
01.22.03 Aggregates
Coarse aggregate
Coarse aggregate shall conform to the requirement as per clauses 2.1 and 2.2 of
this part.
For granolithic floor the screeded bed shall comprise of aggregates size 15mm and
down graded and topping shall comprise of clean fine stone chippings, size 4mm
and down. For concrete floor with hardener treatment the topping shall comprise
of stone chippings, size 6mm and down and for in-situ terrazzo flooring,
chippings shall be within sizes 12mm to 6mm graded. The marble chips for
topping of terrazzo floor shall be of 3-6mm size and shall conform to Grade-I of
IS : 2114-1984 "CP for laying in-situ terrazo floor finish".
Common burnt clay bricks
Common burnt clay bricks shall conform to IS : 1077-1992 and comply with
requirements under the section "Brick and Stones" of this part.
Rubble
Rubble of approved quality shall be used and shall be clean and free from dirt. The
loose and weathered sections shall be removed before use. Rubble used as hard
core shall have a least lateral dimension (thickness) between 100mm and 225mm,
depending on the thickness of hardcore.
01.22.04 Tiles
Terrazzo Tiles
Terrazzo tiles shall be machine made under a minimum pressure of 140 kg/cm2. It
shall have a minimum total thickness of 20mm including a minimum of 6mm
thick topping. It shall be of size, texture, colour, shade and pattern as specified in
schedule of item and as approved by the Engineer.
White tile glazed
White glazed tiles shall be of approved manufacture and quality and shall
conform to IS:777 - 1988 "Glazed Earthenware Tiles. They shall be true in shape,
free from hair cracks, crazing spot, chipped edges and corners and surface shall be
perfectly flat without warps and of uniform colour. The top surface shall be glazed
either gloss or matt as specified. The tiles, normally shall be 149mm x 149mm or
99mm x 99mm size and shall not be less than 5mm thick or as specified. The
tolerance on average facial dimension value shall be plus or minus 0.8 and on
thickness plus or minus 0.5mm. The specials such as coves, internal and external

angles, beads, cornices and their corner pieces shall be of specified sizes and of
thickness not less than the thickness of tiles.
Coloured tiles
Only glaze shall be coloured as specified. The size and specification of tiles shall
be same as for the white glazed tiles.
Marble tiles
It shall conform to IS : 1130 -1960 "Marble (Blocks, Slabs and Tiles)". Marble for
paving and facing work shall be of selected quality, hard, sound, dense and
homogeneous in texture (with crystalline texture) and free from cracks, decay,
weathering and flaws and shall be of kind and quality, size and thickness as
specified in schedule of items. The samples of tiles shall be got approved by the
Engineer before use. The tiles shall be cut to the requisite dimensions.
01.22.05 Pigments
Pigments incorporated in mortar or used for grouting shall be subject to approval
of Engineer and as per table I of IS : 2114-1984.
01.22.06 Red Oxide of Iron
Red oxide of iron where used for "Red Artificial Stone Flooring" shall be of
quality approved by the Engineer, and shall be of uniform tint.
01.22.07 Hardening Agents
Hardening agents such as ironite used for "Cement Concrete Flooring with
Hardener Treatment", shall be of quality approved by the Engineer for every work.
01.22.08 Dividing Strips
Dividing strips shall be of aluminium, glass, brass, copper, plastic or similar
materials as specified in the schedule of item and of quality approved by the
Engineer. Strips shall be 1.5 mm thick unless otherwise specified penetrating to
the full depth of the flooring. Aluminium strips when used shall have a protective
coating of bitumen.
01.22.09 Marble chips
It shall be in sizes varying from 1mm to 25mm and in different colours as per
requirement. Marble chips shall be hard, sound, dense and homogeneous in texture
with crystalline and coarse grains. It shall be uniform in colour and free from
cracks, stains, decay and weathering and shall be obtained from approved source.
01.22.10 Marble Powder
It shall be clean, free from dust and other foreign materials and of approved quality,
obtained from approved source. It shall pass through sieve 300 conforming to IS:
460- (Part-1)-1985.
01.23 Timber
01.23.01 General
All timber used for carpentry and joinery works shall be new. It shall be well
seasoned by a suitable process conforming to IS : 1141-1973 before being planed
to the required sizes. It shall be sound, straight, free from sap, radial cracks, decay,
fungal growth, boxed heart, pitch pockets, borer holes, splits, loose knots, flaws or

any other defects and shall show a clean surface when cut. Timber shall conform
to the requirements of IS : 1003 (Part 1&2)-1983 to 1991. The finished
components shall be given suitable preservative treatment wherever necessary.
Teak wood/Sal / Bija Sal / Deodar / Kail and other varieties of timber
01.23.02 Teak wood
The timber shall be of good quality and well seasoned. It shall be of fairly uniform
colour and shall be free from defects such as cracks, dead knots, shakes etc. No
individual hard and sound knot shall be more than 15 sq. cm. in size and aggregate
area of all such knots shall not exceed 2 % of the area of the piece. Wood shall be
generally free from sap wood but traces of the same shall be allowed. The timber
shall be fairly grained having not less than 2 growth per cm width in cross section.
01.23.03 Sal / Bija sal wood
Timber shall be of good quality and well seasoned. It shall have fairly uniform
colour, reasonable straight grains and shall be free from all defects as mentioned
in previous clauses. No individual hard and sound knot shall be more than 6 sq.
cm. in size and aggregate area of all such knots shall not exceed 2 % of the area of
the piece. There shall not be less than 5 growth rings per 2 cm of the width.
01.23.04 Deodar wood
The timber shall be of good quality and well seasoned. It shall have fairly uniform
colour, reasonable straight grains and shall be free from all defects as mentioned
in previous clauses. No individual hard and sound knot shall be more than 15
sq.cm. in size and aggregate area of all such knots shall not exceed 2 % of the area
of the piece. There shall be at least 3 growth rings per cm width in cross section.
01.23.05 Kail wood
The timber shall be generally as specified in clause 8.2.3 for Deodar wood.
However, there shall not be less than 2 growth rings per cm width in cross section.
01.23.06 Other varieties of timber
The timber as named in the item of work shall be used. It shall be well seasoned
and generally free from defects such as dead knots, cracks, shakes, sap wood etc.
However, traces of sap wood shall be allowed and sound and hard knots up to 2 %
of the area of the piece shall be allowed.
01.24 Storage and inspection
Timber shall be carefully stored and subject to inspection on site, piece by piece.
The Engineer may reject such pieces as are considered by him not of the quality or
meeting the requirements specified herein.
01.25 Moisture Content
Timber shall be accepted as well seasoned if its moisture content does not exceed
the permissible limit as per IS : 287-1973.
01.26 Tolerances for Timber

For timber allowance as specified in the IS : 1003 (Part 1&2) 1983 to 1991 shall
be applicable.
01.27 Flush Door Shutters, Shelves
Flush door shutters, shall be wooden, solid core or cellular and hollow core type,
as may be shown in drawing or described in the Schedule of Items or directed by
Engineer. They shall be obtained from an approved source of manufacture,
covered on face with commercial ply, wood veneer or other finish as may be
necessary. Solid core shutters shall conform to IS : 2202 (Part 1&2)-1983 to 1991
and cellular or hollow core shutters to IS : 2191 (Part 1&2)-1983. The resin used
shall be phenol formaldehyde. A full size sample door shall be offered for
inspection and approval.
01.28 Wood Particles Boards
Particle boards for general purposes shall be of medium density conforming to

IS:3087-1985. These are of four types, Flat pressed single layer board (FPSI),Flat
pressed three layer board (FPTH), Extrusion pressed solid board (XPSO) and
Extrusion pressed tubular core (XPTU). Adhesive shall be BWR, WWR or un-
extended CWR type. High density wood particle board shall conform to IS:3478-
1966 and are in flat sheets or moulded forms. These shall be of type 1 (BWR type
of resin) or Type 2 (WWR or CWR type of resin). Both types of boards shall be of
Grade A (resin content 20 to 50 percent) and Grade : (resin content 8-12 percent).
01.29 Veneered particle board
These shall conform to IS : 3097-1980 and shall be of two grades. Exterior (grade-
I with BWP or BWR type adhesive) & interior (grade-II with WWR or CWR type
adhesive). Each grade of boards shall be of 4 types, solid core general purpose,
solid core decorative, Tubular core general purpose and Tubular core decorative
and accordingly designated.
01.30 Plywood for general purpose
Plywood for general purpose shall conform to IS:303-1989. Depending on type of

adhesive used for bonding veneers, it is of 4 grades, BWP (boiling water proof),
B.W.R (boiling water resistant), WWR (warm water resistant) and CWR (Cold
Water resistant). Any species of timber may be used for plywood manufacture.
However list of species, for the manufacture of plywood is given in Annexure 'B'
of the IS : 303-1989 for guidance.
Plywood is classified in 10 different types as per appearance of the surface. These

are type AA,AB,AC,AD,BB, BC,BD,CC,CD and DD as detailed in IS : 303-1984.
It is available from 3 ply to 11 ply with thickness from 3mm to 25mm.
01.31 Veneered decorative plywood
This quality of plywood shall conform to IS : 1328-1982. These plywood shall be

of two types Type 1 and Type 2 as per details given in IS : 1328-1982. Species of

timber for decorative face commonly used are given in Table 1 of IS : 1328-1982
but the purchaser shall specify the particular veener to be used. Timber for cores
and backs shall be either class I or II as specified in IS : 303-1989. Adhesive used
shall be BWR or WWR synthetic resin.
01.32 Fittings for doors, windows, etc.
01.32.01 General
Fittings shall be of iron, brass, aluminium or as specified. These shall be well

made, reasonably smooth and free from sharp edges, corners, flaws and other
defects. Screw holes shall be countersunk to suit the head of specified wood
screws. All hinge pins shall be of steel and their riveted heads shall be well
formed.
Iron fittings shall be finished bright or black enameled or copper oxidised or

painted as specified. Brass fittings shall be finished bright, oxidised or chromium
plated and aluminium fittings shall be finished bright or anodised as specified.
Fittings shall be got approved by the Engineer before fixing. Screws used for
fittings shall be of the same metal and finish as the fittings. However, anodised
cadmium/chromium plated M.S. screws of approved quality shall be used for
fixing aluminium fittings.
01.32.02 Hinges
Butt hinges
These shall be mild steel but hinge (medium), brass butt hinges, extruded
aluminium alloy butt hinges or as specified. Type (light/medium/heavy weight)
and size shall be as specified in the drawing or schedule of items. Brass /
Aluminium and M.S butt hinges shall conform to Indian Standard Specification
for butt hinges IS : 205-1992 and IS : 1341-1992 respectively. Hinges shall be
finished bright or satin polished or anodised.
Sliding Door Bolts
Mild steel sliding door bolts shall conform to IS : 281-1991 and are of 2 types,
plate type and clip or bolt type. Plate type bolts shall have plates and straps stove
enameled black with hasp and bolt finished bright or copper oxidized or nickel /
chromium plated. Clip or bolt type are copper oxidized or plated. All screw holes
in the M.S bolts shall be countersunk. Diameter of bolt for plate type is 12mm and
for clip type is 16mm.
Non ferrous metal sliding doors are of brass or aluminium alloy and shall conform
to IS:2681-1979. Brass sliding bolts are of 150 to 450mm size with bolt dia being
16mm for 150 to 300mm and 18mm for 375 and 450 size. Aluminium alloy
sliding bolts are of size 200 to 450mm with 16mm bolt dia. Brass quality is
finished satin, polished or plated and aluminium alloy bolts are anodised.
For both ferrous and non-ferrous metal bolts the size of the sliding bolt is
determined by the length of the bolt.

Door Rim Latch
This shall be of mild steel, brass, aluminium alloy or as specified and of sizes 75,
100, 125 and 150mm denoted by overall length of the body measured from outside
face of the fore end to the rear end. These are of type 1 and type 2 and shall
Tower Bolts
Tower bolts may be of one of the following types and shall conform to IS : 204
(Part 1 and 2)-1991 and 1992.
i) Barrel tower bolts
These shall be of bright finished/stove enamelled/ black painted mild steel

tower bolts, brass barrel tower bolts with cast brass barrel and rolled or
drawn brass bolt/brass barrel tower bolts with barrel of extruded sections
of brass and rolled or drawn brass bolt/brass barrel tower bolts with brass
sheet barrel and rolled or drawn brass bolt. Aluminium barrel tower bolts
with barrel and bolt of extruded section of aluminium alloy-bolts and
barrel anodised.
ii) Semi-barrel tower bolts
These shall be mild steel semi barrel tower bolts full cover/open type with
mild steel sheet pressed barrel and cast iron/mild steel bolt. Bolt bright
finished other parts stove enameled black.
iii) Rivetted or spot welded tower bolts
These shall be mild steel tower bolts rivetted type with black flat and mild
steel/cast iron bolt and open staple.
iv) Skeleton tower bolts
These shall be of bright finished / stove enameled / black painted mild

steel or brass bright finished skeleton tower bolts with cast brass/extruded
sections plate and staples and rolled or drawn brass bolt or Aluminium
skeleton tower bolts with plates staples and bolt or extruded sections of
Aluminium alloy plate and staple anodised.
01.32.03 Door handles
Door handles shall conform to IS : 208-1987 and shall be of 4 types. Type 1 is cast
Iron / Brass / Aluminium or zinc alloy die casting and available in 75,100,125
150mm sizes. Type 2 is mild steel pressed oval in 75, 100,115 and 135mm sizes.
Type 3 is mild steel present half oval in 75,90 and 100mm sizes. Type 4 is
fabricated (brass / aluminium alloy) in 75,100 and 125mm sizes. The size of the
handle shall be determined by inside (grip) size overall size and internal depth of
the handles shall be as detailed in IS : 208-1987.

Finish for type 1 shall be satin/nickel plating, copper oxidising and bronze finish
for cast-brass and zinc die cast handles and stove enamelled black or copper
oxidized for cast iron handles. Aluminium handles shall be anodized. Type 2 and 3
handles shall be stove enamelled black. For type 4 it shall be satin finish, nickel
plating, copper oxidized and bronze finish for brass handles and anodizing for
aluminium handles.
01.32.04 Mortice lock and rebated mortice lock
Mortice lock with latch and pair of lever handles shall have body of steel,
Aluminium alloy or brass and shall be right or left handed as shown in the
drawing or as directed by the Engineer. It shall be of the best Indian make of
approved quality and shall conform to IS: 2209 / 6607-1976/1972. The shape and
pattern shall be approved by the Engineer. The size of the lock shall be determined
by its length. The lock for single leaf door shall have plain face and that for double
leaf door a rebated face. Lever handles with springs shall be mounted on plates
and shall weigh not less than 0.5 kg per pair. These shall be of brass, finished,
bright chromium plated or oxidised. The locks shall be of 65, 75 and 100 mm
sizes.
01.32.05 Floor door stopper
These are for the use of the door shutters of 30, 35,40 & 45mm thickness. It is
made of aluminium alloy/ brass with springs of phosphor bronze or hard drawn
steel wire and tongue of aluminium/brass/nylon/ plastic. The floor door stoppers
shall conform to IS : 1823-1980 and shall be best Indian make of approved
quality. Width of cover plate is 40mm but its overall length is 140mm for 30 and
35mm thick shutters & 150mm for 40 and 45mm shutters. The body shall be cast
in one piece and fixed to cover plate by brass or M.S screws. On the extreme end
there shall be rubber cushion to absorb shocks. The extension of the door stopper
shall be in flush with floor and be finished bright/satin/chromium plated or
anodised.
01.32.06 Hooks and eyes
These shall be of mild steel or hard drawn brass and shall generally conform to IS
: 207-1964.
01.32.07 Casement window handles
These shall be made of cast brass, steel protected against rusting, aluminium,
pressed brass or as specified. Casement handles for single leaf window shutter
shall be left or right handed and shall weigh as specified.
01.32.08 Casement Peg Stays
These shall be made of cast brass, steel protected against rusting, aluminium, cast
alloy or as specified. The stay shall be made from a channel section and shall be
300mm long with steel peg and locking bracket. The peg stay shall have three
holes to open the window in three different angles. The shape and pattern of stays

shall be approved by the Engineer. The peg stay shall be minimum 2mm thickness
in case of brass and aluminium and 1.25 mm in case of steel.
01.32.09 Quadrant Stays
These shall be made of cast brass, aluminium alloy, CP iron or as specified. The
shape and pattern shall be approved by the Engineer. It shall weigh as specified.
01.32.10 Fan Light Pivots
These shall be made of mild steel, cast brass or aluminium alloy or as specified
and shall generally conform to IS : 1837-1966.
The pattern and the shape of the catch shall be as approved by the Engineer and
size and finish shall be as specified.
01.32.11 Fan light catch
These shall be made of mild steel, cast brass, aluminium alloy or as specified and
shall generally conform to IS : 364-1993. Steel springs of the catch shall be 0.90
mm dia, 6 coils, 12 mm internal diameter and 20 mm long. The pattern and the
shape of the catch shall be as approved by the Engineer.
01.32.12 Steel frames
These shall conform to IS:4351-1976. The frames shall be manufactured from

commercial mild steel sheets of 1.25mm thickness and are suitable for door
shutters 30 to 40mm thick. The door frames are designated as per profile A, B
and C.
Profile A Size 105x60mm : rebated for one set of shutters

Profile B Size 125x60mm : rebated for one set of shutters
Profile C Size 165x60mm : rebated for two sets of shutters.
Miscellaneous Items :
01.32.13 Putty
The material shall be homogeneous paste and shall be free from dust and other
visible impurities. Putty shall conform to IS : 419-1967 for wood work.
01.33 METAL DOORS, WINDOWS, VENTILATORS AND ROLLING

SHUTTERS
01.33.1 General
Materials used in the fabrication of doors, windows, and ventilators shall be the
best procurable and conforming to relevant Indian Standards.
01.33.2 Steel doors, windows and ventilators
Steel sections used for fabrication of doors, windows and ventilators shall be
standard rolled steel sections specified in IS : 1038, IS : 1977, IS : 1361 or IS :

7452 year 1983, 1975, 1978 and 1990 respectively as appropriate or as specified in
drawing and Schedule of Items. Rivets shall conform to IS : 1148-1982.
01.33.03 Aluminium door, windows and ventilators
Aluminium sections for fabricating doors, windows, ventilators, partitions etc.,

shall be extruded sections conforming to IS : 1948-1961 & IS : 1949-1961 or as
manufactured by Indian Aluminium Company Limited or approved equivalent
The alloy used shall conform to Designation HE 9 - WP of IS : 733-1983.
01.33.04 Steel rolling shutters, rolling grills
These shall conform to IS : 6248-1979.
01.33.05 M.S. bolts etc.
M.S. bolts, nuts, screws, washers, peg stays and other mild steel fittings shall be
treated for corrosion. Putty for glazing shall conform to IS : 419-1967. Glass
panes and glazing shall conform to the specification detailed under this series.
01.33.06 Hardware and fixtures shall be as specified in the drawings or Schedule of Items.
All hardware and fixtures shall be able to withstand repeated use. Door closers
shall be suitable for doors weighing 61 80 kg, unless otherwise stated. Each closer
shall be guaranteed against manufacturing defect for one year and any defect
found within this period shall be rectified or the closer replaced free of charge.
Concealed door closers shall be either floor mounted or transom mounted, suitable
for installation with metal doors. It shall conform to the performance requirements
and endurance test stated in IS : 3564 1986 Appendix-A.
01.33.07 The mastic for caulking shall be of best quality from a manufacturer approved by
the Engineer. In general, the mastic for fixing of metal frames shall conform to IS
: 1081-1960 and/or as approved by the Engineer.
01.34 Glass
01.34.01 General
Plain, ground, frosted or rough cast wired glass shall be used as shown on the
drawing or as specified in the Schedule of Items. It shall be procured from a
reputed source of manufacture and be of the best quality. All glass panes shall be
free from flaws, specks, bubbles etc. Glass panes shall be of thickness 3mm or
more as required. Weight of 3mm thick glass pane shall not be less than 7.5
Kg//sqm. The tolerance of glass panes, except wired glasses, in length and width
shall be plus or minus 2 mm for 3 to 6.3 mm glass sheets. Tolerance in thickness
of glass sheets shall be +/- 0.2mm for 3mm and 4mm thick glasses and +/- 0.3mm
for 4.8, 5.5 and 6.3mm thick glasses.
01.34.02 Plain transparent glass
Plain transparent glass for glazing and framing shall conform to IS: 2835-1987. It
shall be free from flaws, specks, bubbles or distortions.

01.34.03 Ground and frosted glass
Glare reducing or heat absorbing glass shall be "Calorex" or approved equivalent

and special care shall be taken to grind smooth and round off the edges before
fixing.
01.34.04 Thickness
Glass shall have the following thickness, unless otherwise stated in the Schedule
of Items or drawings
Upto 60 cms x 60 cms ... 3 mm

do- of larger size ... 4 mm and 4.8mm
Sheet glass for doors ... 5.5 mm
Rough cast wired ... 6.4 +/- 0.4 mm
01.34.05 Inspection
All glasses shall be subject to inspection on the site. Glass found to suffer from
defects shall be rejected. Samples submitted for inspection shall be selected so as
to be representative of the consignment.
01.35 Paints
01.35.01 General
All paints, varnishes, distemper or other surface coating materials shall be of

approved quality conforming to the appropriate Indian Standard, wherever such
standard is available, and be obtained from a manufacturer of repute. If there is
more than one quality for one particular product, only first quality shall be used
unless otherwise stated in the Schedule of Items.
01.35.02 Sampling and testing
The Engineer may, at his discretion, require samples of paint to be tested. In such
cases testing will be according to IS : 101 (Part 1 to 8) -1964 to 1993.
01.35.03 Storage
Paints, primers, distempers and varnishes shall be delivered in sealed containers.

They shall be stored in cool dry condition to the satisfaction of the Engineer.
01.35.04 Paints for priming
Ready mixed paints for priming coats of steel and iron work shall either comply
with IS : 2074-1992 "Ready Mixed Paint", "Red Oxide Zinc Chrome Priming" or
Red Oxide metal primer as specified. For wood work it shall be pink/white wood
primer as specified by the manufacturer of the synthetic enamel paints, conform-
ing to IS : 3536-1966.

01.35.05 Paints for finishing
Ready mixed oil synthetic enamel paint of approved manufacturers like Berger,
Jenson & Nicholson, Shalimar, I.C.I., Asian, Garware and Goodlass Nerolac
paints only shall be used unless otherwise specified. Paint shall be of first grade
quality of the above manufacturers ie., Luxol Brolac, Superlac, Dulox gloss,
Apocolite, Garcoat and Nerolac respectively.
If for any other reason, thinning is necessary, the brand of the thinner
recommended by the manufacturer, shall only be used with the specific permission
of the Engineer.
Aluminium paint for general purpose shall be in Duel Containers. It shall be of

manufacturers as for synthetic enamel paints above.
01.35.06 White wash
White was shall be prepared from freshly burnt fat, white in colour lime slaked on
spot, conforming to IS : 712-1984 mixed and stirred with sufficient water to make
a thin cream. Best and approved quality gum and ultra marine blue only shall be
used in lime wash.
01.35.07 Colour wash
Colour wash shall be prepared by adding mineral colours, not affected by lime, to
white wash.
01.35.08 Water proofing cement paint
Cement paints shall comply with IS: 5410-1992 and shall be of approved brand
and manufacture like Snowcem India Ltd., Berger, Jenson & Nicholson &
Shalimar paints. The shade shall be approved by the Engineer before its
application.
01.35.09 Distemper
Dry/synthetic washable distemper of approved brand and manufacture like Berger,

Jenson & Nicholson, Asian, Shalimar, Garware & Goodlass Nerolac shall be used.
The shade shall be approved by the Engineer before application of the distemper.
and shall comply with IS : 427-1965 and IS : 428-1969.
01.35.10 Varnish
Varnish for the finishing coat shall be copal finish or synthetic class varnish of
approved brand. Varnish for the under coat shall be flatting varnish of the same
make as the top coats and shall be to the satisfaction of the Engineer.
01.35.11 Polish
French spirit polish shall be of an approved make conforming to IS: 348-1968. In

case it is to be prepared on site, the polish shall be made by dissolving 0.7 kg of

best, shellac in 4.5 litres of methylated spirit without heating. To obtain required
shade pigment may be added and mixed. Shallac shall conform to IS : 5467-1986.
Wax polish for wood work
The polish shall consist mainly of waxes and Organic solvents with or without
water and shall be of smooth consistency, homogeneous, Semi-Solid mass and
free from gritty materials. It shall not flow at ordinary temperature. It may be
tinted with an oil soluble colour. The polish shall not crumble or dry too rapidly
and shall produce non-tacky polished surface. The polish shall be amenable to
smooth spreading on the furniture surface and the gloss shall appear on gentle
rubbing with a soft polishing cloth.
The wax polish shall conform to IS : 8542-1977.
Where wax polishing is to be prepared at site, it shall be prepared by heating two

parts of "Bee Wax" two parts of boiled linseed oil over a slow fire. When
dissolved but still warm, one part of turpentine is to be added. The boiled linseed
oil, bees wax and turpentine used shall be of approved quality and complying with
IS : 77-1976, IS : 1504-1974 and IS : 533-1973 respectively.
01.35.12 Plastic (Acrylic) emulsion paint
Plastic emulsion paint of approved manufacturers like Jenson & Nicholson,

Goodlass Nerolac, Shalimar, Berger, Asian and Garware paints only shall be used
unless otherwise specified and shall comply with IS : 5411 (Part 1)-1974 & (Part
2)-1972 as applicable. Cement primer used for priming work both for oil bound
distemper and plastic emulsion paint shall be of the same manufacture as that of
distemper or plastic emulsion paint used. For dry distemper priming, whiting of
approved quality shall be used.
01.35.13 Creosote oil or coaltar creosote
It is primarily used for preservation of wood. It shall be a homogeneous liquid and

shall liquify completely on being warmed to 38 degree C with stirring and shall
remain liquid on cooling down to 32 degree C and on standing at that temperature
for 2 hours.
The material shall conform to IS : 218-1983. All persons handling the creosote oil
should be fully aware of the hazards involved in handling . Skin should be
protected from coming in direct contact and eyes should be protected by using
safety goggles while handling the material.
01.35.14 Coaltar Black Paint
Coaltar paint film protects surfaces by serving as a barrier against the action of
moisture and other corrosive agents. Coaltar black paint is generally used as a
protective and anti corrosive paint of iron and steel as well as protection of other
building surfaces. For this it has to be applied under proper condition and on
suitably prepared surface. Coaltar should be applied by brush only and is not

recommended for locations which are not likely to be well ventilated. Coaltar
paint shall conform to IS : 290 1961.
The material is of two types : Type A Quickly drying and Type B Slow drying. It
shall be a homogenous black solution type paint consisting of a base prepared by
blinding suitable grades of Coltar pitch, washed free from ammoniacal liquor, tar
acid bases etc. Consistency, permeability, thickness and surface preparation etc.
shall be as per para 5 and A-2 of the above code.
01.35.15 Floor Polish - Paste
The polish shall consist mainly of waxes and organic solvents with or without
water.
The paste floor polish shall be of smooth consistency, homogenous, semi-solid-

mass and free from gritty material. It shall not flow at ordinary temperature. It
shall be so constituted and prepared that on application by means of a clean cloth,
it shall spread easily and evenly and shall give with minimum buffing a firm and
glossy surface free from greasiness or tackiness. The polish film after spreadng
with a cloth shall not take more than 10 minutes to dry. The polished floor shall
neither be slippery nor show any resistance to easy walking.
Floor polish paste shall conform to IS : 8591-1977.
01.36 WATER PROOFING MATERIALS
01.36.01 Integral Cement Waterproofing Compounds
Integral cement waterproofing compounds, i.e. admixture for waterproofing

purposes shall fully comply with the requirements of IS : 2645-1975. Properties
like permeability, setting time, compressive strength shall be in accordance with
the requirements of this code when tested as per procedure laid therein. Calcium
chloride content of the product used shall be made known to Engineer before use.
01.36.02 Bitumen
The bitumen bonding material for waterproofing shall conform to the

requirements laid down in IS : 702-1988 or IS : 93-1992 or IS : 217- 1988 or IS :
454-1961 depending upon whether industrial bitumen, paving bitumen or cutback
bitumen is used. For selecting the particular type and grade of bitumen to be used
the relevant item in Schedule of Items shall be referred to.
01.36.03 Bitumen primer
Bitumen primer used for application to concrete and masonry surfaces and
bitumen for the purpose of waterproofing shall conform to requirements given in
IS : 3384-1986 and pass tests in accordance with the procedure laid down in
appropriate IS mentioned in Table-I of IS : 3384-1986. Bitumen primer should be
free from water and shall preferably ;be made from the same grade of bitumen as
used in bonding.
01.36.04 Bitumen Felt

Bitumen felts used for water proofing purposes shall be as specified in IS: 1322-
1982. Physical properties shall conform to the requirements and tests shall be
carried out as per procedure laid down in IS :1322- 1982. Base, (whether fibre or
Hessian), type and grade of felt shall be as mentioned in the relevant items under
Schedule of Items. Unless otherwise stated, hessian base felt Type-3, Grade-2
shall be used.
01.36.05 Bitumen Mastic
Bitumen mastic used for water proofing of roofs shall have the physical properties
as mentioned in IS : 3037-1986 when tested with the procedure laid down in
appropriate IS mentioned in IS : 3037-1986.
01.36.06 Bituminous Compounds
Bituminous compounds when used for waterproofing of porous masonry, concrete

floors, walls and roofs shall conform to the requirements of IS : 1580-1991.
Physical properties shall be governed by the requirements of this code when tested
in accordance with the procedure laid therein.
01.36.07 Surface Application Materials
Waterproofing material for application on mortar or concrete surface shall

conform to IS: 9862 1981. The primer shall be suitable for spray or brush
application. It shall have properties enabling it to penetrate through pores or cracks
and fill them up, making the surface impervious.
01.36.08 Polymer based paints
The materials used shall be high polymer based chloride and sulphide free cement
and waterproofing additions and epoxy based waterproofing paints as per
manufacturer's specification and approved by Engineer.
01.36.09 Fibre glass R. P. tissue
The fibre glass R.P. tissue is a thin flexible uniform mat, composed of glass fibre
in an open porous structure bonded with a suitable inert material compatible with
coal tar, asphaltic enamel and oil plastic based wall paint. The fibrous glass mat is
reinforced with continuous filament glass yard at 3/8" (10mm) pitch in the
longitudinal direction.
01.37 PHYSICAL PROPERTIES
i) Weight The average weight of fibre glass R.P. tissue shall not be less
than 50 gms/sq.sm.
ii) Thickness The fibre glass R.P. tissue shall have a thickness not less than
0.4mm.

iii) Tear Strength The tear strength shall be not less than 900 grams in the
transverse direction.
iv) Breaking This shall have a minimum breaking strength of 13 lb/in

Strength (2.32kg/cm) in the longitudinal direction.
v) Porosity This shall have a porosity when related to pressure difference

across the sample of not less than 0.022" (0.56mm) and not
more than 0.76" (1.92mm) of water guage at an air velocity of
200fpm.(100cm/sec.).
vi) Pliability There shall be no cracking of the tissue mat when bent over a
1/8" (3.2mm) radius after immersing for 10-15min. through a 90
degree arc.
vii) Temperature The fibre glass tissue shall be Resistance under a load of hot
bitumen at 530 degree F (276 degree C) for one minute.
07.37.01 Primer
Primer shall conform to requirements laid down in IS : 3384-1986. It is to be

prepared by blending turpentine and blown grade bitumen in the ratio of 60:40 by
weight.
01.37.02 Blown materials
Blown grade bitumen shall be conforming to IS : 702-1988 and residual grade

bitumen conforming to IS:73 respectively. This shall be prepared by heating to
correct working temperature.
01.37.03 Surface finish
Pea sized gravel/grit 6mm and down.
01.38 P.V.C. Membrane/Sheets
Polyvinyl chloride sheets for the purpose of water proofing and other underground
use are specially developed sheets made from the compounded resin of grade
MP/DP/CR-02 and shall be resistant to the passage of gross water and water
vapour. It shall be corrosion resistant and resistant to a wide range of acidic and
alkali reagents, saltpetre action, salt water and ultra violet rays etc. PVC sheets
manufactured by approved and reputed firms like Maxlok Polymer Ltd. shall only
be used
The sheets shall consist of Knobs or Lugs jutting out of the sheets in a grid fashion
so as to provide a perfect grip in the mortar and concrete. Sheet thickness, spacing
of the knobs and their projection from the sheet shall be as specified in the item.
The sheets shall be of maximum practicable length and width unless otherwise
specified.

The adhesive used for jointing shall be of approved quality and of grade C-02.
The sample of the material shall be got approved before use.
01.39 Properties
i) Chemical Composition : Resin Plasticiser Inhibitor Stabiliser UV Barrier.

ii) Thickness : Not less than 0.25 mm
iii) Rupture/Tensile Strength : Not less than 225Kg/cm2

iv) Adhesive bond Strength : : Not less than 7.1 Kg/cm
[width]
v) Elongation at Break : 130%
01.40 Water bar
01.40.01 General
Water bar for use in construction/expansion joints in concrete and reinforced

concrete structures shall be of copper sheet, galvanised steel sheet, rubber or PVC
as shown in drawing or described in the Schedule of Items. It shall be subject to
approval of Engineer.
01.40.02 Jointing
The water bar shall have dimensions as shown in drawing. Where water bars are
required to be lengthened or otherwise jointed the joining shall be done in such a
way as to achieve a perfectly watertight joint.
01.41 Lead
01.41.01 General
Lead for joints in cast iron spigot and socket pipes shall be melted from pure soft
pig lead conforming to Type-I of IS : 782-1978. "Caulking Lead". Where lead
wool is allowed for caulking, it shall be equal to or better than Type-II of IS : 782-
1978. Lead flashing shall conform to IS : 405 Part I&II-1992.
01.42 Building paper
01.42.01 Building paper shall be bitumen impregnated paper conforming to IS: 5134 1977,
or such other as may be approved by the Engineer.

01.43 Filling material

01.43.01 General
Filling material shall conform to what is shown in drawing, described in the

Schedule of Items or otherwise directed by the Engineer. Earth or sand for filling
under floors shall correspond to those described elsewhere in these specifications.
01.43.02 Mastic Bitumen
Mastic Bitumen shall conform to IS : 3037-1986 or IS : 5871-1987 as appropriate.
01.43.03 Flexible boards
Flexible boards for use in expansion joints shall correspond to the description
given in drawing or the Schedule of Items or the instruction of Engineer.
01.44 Drainage & sanitation (Internal)
01.44.01 General
All materials, pipes, specials, fittings, fixtures etc., to be used in the works shall be
of best quality and class specified in relevant IS Code. Where specified these shall
be of specific manufacture and quality and shall be procured from manufacturer or
their accredited stockists and be marked with manufacturers' names and trade
mark. Contractor shall submit to the Engineer samples of all materials, pipes,
specials, fittings fixtures for approval before use in the works. Such approved
samples shall be retained by the Engineer till completion of works. Pipes and Spe-
cials may be any or combination of following types:-
i) PVC Pipes
ii) Stone Ware Pipes
iii) Sand Cast Iron Pipes for soil waste & Ventilation
iv) CI Pipes for rain water
vi) R.C.C Pipes
01.44.02 High density PVC pipes and fittings
This shall conform to IS : 4984-1987 and IS : 8008 (Part 1 to 7)-1976 unless

otherwise specified.
01.44.03 PVC waste pipe
This shall conform to IS : 4985-1988 unless otherwise specified.
01.44.04 Stoneware pipes & fittings
All stoneware pipes, bends, gully traps and sewer traps shall be of the best salt
glazed variety inside and outside, hard burnt dark grey colour, perfectly sound,
free from fire cracks and imperfection of glaze, truly circular in cross section,
perfectly straight, of standard nominal length and depth of socket and barrel.

These shall be of approved manufacture and shall comply with the requirement of
IS: 651-1992. These pipes shall be of grade AA unless otherwise specified.
01.44.05 Sand cast iron pipes & fittings conforming to IS : 1729-1979
All soil waste and vent pipes and fittings used in the work shall be cast iron and
shall conform to IS: 1729-1979. The pipes shall have spigot and socket ends, with
bead on spigot end and shall be with or without ears. The pipes shall be free from
cracks and other flaws. The interior of the pipe and fittings shall be clean, smooth
painted inside and outside with DR Angas smiths solution or other approved anti-
corrosive paint.
The standard weights and thickness of pipe shall comply with the requirements of
IS: 1729-1979. The tolerance on wall thickness and weight shall be minus 15
percent and minus 10 percent respectively. Pipes weighing more than the nominal
weight given below may be accepted provided they comply in every other respect.
Nominal size Weight per piece in Kg. excluding earsOverall length

1500 mm 1800 mm 2000 mm
50 9.56 11.41 12.65
75 13.83 16.52 18.37
100 18.14 21.67 24.15
150 26.70 31.92 35.66
Specials and Fittings shall include bends, offsets, branches of various types,
junctions etc., as required for the work which shall be provided according to
drawings and directions of the Engineer. B.M. trap shall have water seal as per I.S.
provisions.
The specials and fittings shall be provided with access doors where so specified or
directed by the Engineer. The access door fittings shall be of proper design so as
not to form cavities in which the filth may accumulate. Doors shall be provided
with 3 mm thick rubber insertion packing, and when closed and bolted they shall
be water tight. The access doors shall have MS studs and bolts or screws or bolts
and nuts.
01.44.06 Cast iron pipes: Rainwater pipe
01.44.06.01 Pipes shall be of approved manufacture, true, smooth and cylindrical, their inner
and outer surfaces being as nearly as practicable concentric and shall conform to
IS : 1230-1979. These shall be sound and uniform casting, free from laps, pin
holes or other imperfections and shall be neatly finished inside and outside. The
ends of pipes shall be reasonably square to their axis.
01.44.06.02 Dimensions
CI rain water pipes shall be of the dia specified in the description of the item and
shall be in full lengths of 1.8 metres including socket ends of the pipes, unless
shorter lengths are required at junctions with fittings. The pipe lengths shall in

each case be with sockets. The pipes shall be supplied without ears unless
otherwise specifically mentioned.
The pipes supplied shall be factory painted with a tar based composition both
inside and outside which shall be smooth and tenacious unless specified otherwise.
Every pipe shall ring clearly when struck all over with a light hand hammer. When
shorter pipes are cut from full lengths they shall be cut with a hacksaw.
Where the pipes are to be embedded in masonry they shall be of Class of pipes as
are used for soil and vent pipes. For the weights of different sizes of these pipes,
the specifications under SCI and vent pipes may be referred to.
01.44.06.03 A.C. pipes and fittings the pipes and fittings shall be of approved manufacture and
shall conform to IS:1626. These shall be homogeneous and free from cracks and
other defects. The pipes shall be straight, smooth and regular in thickness.
The diameter of the pipe shall be as specified. The fittings like heads, bends of
different degrees, offsets of different projections, shoes and junctions shall be of
the type, diameter and size as required for the work. The pipes shall be used in full
lengths as far as possible.
01.45 Sanitary appliances
Sanitary appliances like I.W.C/E.W.C pans, wash basin, urinals and sinks etc.
shall be made of vitreous china or fire clay as specified. These shall be of
Hindustan Sanitary ware or Parry ware make unless otherwise specified and to be
approved by the Engineer. These shall conform to A class quality of IS : 2566
(Part 1 to 15)-1972 to 1985 and IS : 771 (Part 1 to 15) –1979 & 1985 respectively.
01.45.01 European Pattern W.C.
Unless otherwise specified, these shall comprise of :
a) White 'glazed earthenware wash down closet set with 'S' or 'P' trap of
standard size.
b) 'Duco' spray painted 12.5 litres mosquito proof low level M.S or C.I
flushing cistern with valveless siphon, 15 mm ball cock, C.P. brass unions
& couplings for the 32 mm dia flush pipe, 20 mm dia overflow PVC pipe
with mosquito proof cover etc.
c) 'Duco' spray painted 1 1/4" (32 mm) dia G.I. telescopic flush pipe with
buffer clamp, holder bat clamp and 38mm dia PVC pipe or 35/40mm O.D.
high density polythene flush pipe with buffer clamp, holder bat clamp.
d) Approved quality solid plastic W.C. seat and cover, bar hinges, screws
bolt, rubber buffers conforming to IS : 2548 (Part 1&2)- 1983.
e) 15 mm PVC connection pipe with brass couplings at both ends and 15 mm

brass CP cock.

f) Hard wood wooden blocks or other suitable fixing arrangement with

screws and detofix for fixing WC in floor and putty joint with flush pipe
and soil pipe.
01.45.02 Indian pattern W.C.
Unless otherwise specified these shall comprise of :-
a) White glazed earthenware WC pan back entry type.
b) White glazed earthenware 'P' or 'S' trap with or without vent.
c) 12.5 litres approved make mosquito proof M.S.high level flushing cistern
with valveless siphon, 15 mm ball cock, galvanised iron chain handle, cast
iron brackets with wall plugs, brass unions and couplings for flush pipe,
20 mm dia overflow PVC pipe with mosquito proof cover etc.,
d) 32 mm dia GI telescopic or 35/40 mm O.D high density PVC flush pipe

with holder bat clamps.
e) One pair of white glazed earthen ware foot rest set in cement mortar 1:3.
f) 15 mm PVC connection pipe with brass couplings at both ends and 15 mm

brass stop cock.
01.46 Wash Hand basin
Unless otherwise specified these shall comprise of :-
a) White glazed earthenware basin with 2 nos. Concealed Cast Iron Brackets
with wall plugs.
b) 1 no. 15 mm C.P. brass pillar tap.
c) 32 mm C.P. brass waste fitting, C.P. brass chain and rubber plug.
d) 32 mm PVC waste pipe with brass couplings/32 mm C.P. bottle trap.
e) 15 mm PVC connection pipe with brass couplings and 15 mm brass stop

cock.
01.47 Flat Back Lipped Urinal
Unless otherwise specified these shall comprise of:-

a) White glazed earthenware urinal basin back type.
b) CI/M.S mosquito proof high level automatic flushing cistern of capacity

as specified in the Schedule of Quantities with all accessories, cast iron
brackets with wall plugs, brass unions and coupling for flush pipe, 20 mm
dia overflow pipe with mosquito proof cover.
c) 25 mm dia CP brass flush pipe and spreaders with wall clips and brackets.

d) 15 mm PVC connection pipe with brass couplings joint at both ends and
15 mm brass stop cock.
e) 32 mm C.P. brass outlets complete with PVC waste.
01.48 Mirror frames
Mirror frame where specified shall be of fibre glass of approved shape, size,
colour and make.
01.48.01 Mirror shall be of superior glass with edges rounded off or leveled as specified. It
shall be free from flaws, specks or bubble and its thickness shall not be less than
5.0 mm. The glass for the mirror shall be uniformly silver plated at the back and
shall be free from silvering defects. Silvering shall have a protective uniform
covering of red lead paint.
01.49 Toilet shelf
01.49.01 Glass shelf unit shall consist of an assembly of glass shelf, anodised aluminium /
CP brass guard rail and supporting brackets. The shelf shall be of glass of best
quality with edges rounded off and shall be free from flaws, specks, bubbles and
of thickness not less than 5.0 mm. The shelf shall have guard rail, resting on
rubber washers on glass plate.
01.49.02 Ceramics shelf shall be of shape, size and design as specified in the Schedule of
Items.
01.50 Towel rail
Towel rail shall be of CP brass / anodised aluminium with two brackets of same
material, diameter and length as specified.
01.51 Soap container
Soap container shall be of C.P brass, PVC with cp brass brackets of approved
make and design.
01.52 CP flush valves for EWC
The CP flush valve for EWC shall be of "Jaquar" brand of Jaquar & Co., 'ACCO'
brand of Asia Continental Metallwaren Fabric or equivalent quality.
01.53 CP flush valve for urinals
CP flush valve for urinal shall be of "Jaquar" brand of Jaquar & Co., 'ACCO'
brand of Asian Continental Metallwaren Fabric or of equivalent quality.
01.54 Gully trap
Each gully trap shall have one C.I. grating 150 mm x 150 mm and one water tight
pre-cast R.C. cover 300 x 300 x 40 mm thick with 1:1 1/2:3 mix concrete (one

cement: one and half sand : 3 stone chips 20 mm down) including neat cement
finish.
01.55 CI manhole covers & frames
These shall be of light or medium duty (LD or MD) as specified in Schedule of

Items and of cast iron with raised chequered design, lifting key and key hole and
shall be coated with black bituminous base material,. Light duty covers and frames
shall be of either rectangular type, single seal, pattern 1 and 2 having minimum
weight of cover and frame 38 Kg and 25 Kg. respectively or with double seal,
minimum weight of cover and frame being 52 Kg. These may be of square type
also. Single seal with clear openings of 455 and 610 mm with minimum weight of
cover and frame being 20 Kg and 38 Kg respectively, double seal of same
openings shall have minimum Wt. of cover and frame 30 Kg and 55 Kg
respectively. Medium duty covers and frames shall be either of circular type with
500 and 560 mm clear openings and minimum Wt. of cover and frame 116 Kg and
128 Kg respectively or of rectangular type with minimum Wt. of cover and frame
144 Kg.
The C.I. manhole covers and frames shall conform to IS : 1726-1991.
01.56 Flushing cisterns
Manually operated high level and low level flushing cisterns are of 5 litre and 10
litre capacities, both single flush and dual flush type. The cisterns shall conform to
IS : 774-1984 and be made of Cast Iron, Vitreous China or enamelled pressed
steel. The cisterns shall be mosquito-proof.
The thickness of the body including cover shall be not less than 5 mm for Cast
Iron and 6 mm for Vitreous China Cisterns. Steel and lead flush pipe shall have
internal diameter of 32 plus or minus 1 mm for high level cisterns and 38 plus or
minus 1mm for low level cisterns. For high density polyethlyne and unplasticised
PVC pipes the outside diameter of the pipe shall be 40 mm. In case of PVC
plumbing pipes the outside diameter of the pipes shall be 40mm for high level and
50mm for low level cisterns. Steel flush pipes shall be hot dip galvanized
electroplated or vitreous enameled.
The flush pipe shall be securely connected to the cistern outlet and made airtight
by means of a coupling net. Float valve shall conform to IS : 1703-1977 or IS :
12234-1988. Polyethylene float valve shall conform to IS : 9762-1981.
Cast Iron Cisterns shall be painted and finished in accordance with

recommendation made in IS : 1477 (Part 1&2)-1971 or shall have a coating of
enamel.
In general, Materials Construction and operational and performance requirements

shall be as specified in para 3, 4 and 6 of IS : 774-1984.

01.57 Plastic seats & covers for water closets
These shall conform to IS : 2548 (Part 1&2)-1983 and shall be either of thermo-set
or of thermo-plastic quality.
Thermo-set Seats and Covers are moulded from phenolic plastics (Type A) or
Urea Formaldehyde (Type B). Thermo-plastic Seats and Covers are also of Type
A, moulded from Polystyrene or Type B, moulded from Polyprophlene.
Underside of the seats may be either flat or recessed and colour shall be as agreed.
Table Dimesions of the seats and covers shall be as per Table-I of the Code (both
Part 1&2). Hinging device may be either of the following materials :
i) Bronze or Brass with Nickel Chromium Plating

ii) Mild Steel with Nickel Chromium Plating
iii) Aluminium alloy with anodic coating
iv) Suitable plastic with reinforcement.
01.58 Water supply & plumbing (Internal)
01.58.01 General
This section deals with the specification of material for pipes, fittings, fixtures
etc., to be used in water supply works.
All materials, pipes, fittings, fixtures to be used in the works shall be of the best
quality and of the class specified in various clauses herein under. Where specified
these shall be of specific manufacture and quality and shall be procured from the
manufacturer or their accredited stockist and be marked with manufacturers name
and trade marks. The Contractor shall submit to the Engineer samples of all pipes,
fittings, fixtures for approval before being used in the works. Such approved
samples shall be retained by the Engineer till completion of works.
Pipes and pipe fittings may be of any or combination of following types:
i) Wrought iron galvanised pipe

ii) PVC pipes
iii) Cast iron pipes
iv) Steel pipes coated with bitumen composition inside and galvanised
outside.
v) Reinforced concrete pipes
vi) Pre-stressed concrete pipes
vii) Lead pipe (not to be used for potable water)
01.58.02 Galvanised iron pipes and fittings
Generally pipes for installations in buildings shall be medium quality malleable

steel galvanised pipe 'B' class for cold water supply and 'C' class for hot water
supply, having threaded ends with socket at one end.

The details of standard medium quality "B" class pipes and sockets regarding
nominal bore thickness and weight in kg/m are given below:-
Pipe Dia Dimension of Pipe Thick- Dimension of ordinary Wt. of Pipe

(Nominal -ness socket plain end
Bore) Max. Min. Outside dia Min. length
(outside (approx.)
dia)
mm mm mm mm mm mm Kg/m
15 21.8 21.0 2.65 26.90 34 1.21
20 27.3 26.5 2.65 33.70 36 1.57
25 34.2 33.5 3.25 42.00 43 2.42
32 42.9 42.0 3.25 51.00 48 3.11
40 48.8 47.9 3.25 57.00 48 3.59
50 60.8 59.7 3.65 70.00 56 5.07
65 76.6 75.3 3.65 88.00 65 6.49
80 89.5 88.0 4.05 101.60 71 8.43
Note :- Manufacturing tolerances shall be permitted on tubes and sockets in addition to

above as per IS : 1239 (Part 1&2) 1990 to 1992.
The galvanised iron pipes shall be of approved make and conform to IS:1239 (Part
1&2) 1990 to 1992 and of tested quality. The GI pipes shall be of threaded ends
with a socket at one end only. The fittings for GI pipes shall be either galvanised
wrought iron or galvanised malleable iron.
01.58.03 R.C.C, prestressed pipes and fittings
These shall be of approved manufacture and quality and shall conform to IS : 458
1988, IS : 1592 1989, IS : 9627 1988 & IS : 784 1978 respectively.
01.58.04 Cast iron pipes and fittings
The cast iron pipes shall be of approved manufacture and quality and shall
conform to IS: 1536 1989 "Centrifugally Cast (Spun) iron pressure pipe and/or IS
: 1537 1976". Vertically Cast Iron pressure pipe for water, gas and sewage. CI
fittings shall conform to IS : 1538 (Part 1 to 23) 1976.
01.58.05 Steel pipes
This shall conform to IS: 1239 (Part 1&2) 1990 to 1992) and IS : 3589- 1991.
Steel pipes shall be coated with bituminous composition inside and galvanised
outside.
01.58.06 Bib tap and stop tap
Bib tap and stop tap for water services shall be of brass screw down type and shall
conform to IS: 781. Minimum finished weight of bib and stop taps shall be as
given below:
No. of size Bib taps Stop tap

(mm) (kg) (kg)
10 0.30 0.35
15 0.40 0.40
20 0.75 0.75
25 1.25 1.30
32 - 1.80
40 - 2.25
50 - 3.85
The taps shall be tested under internal hydraulic pressure of at least 20 kgf/cm2
and maintained at the pressure for a period of at least two minutes during which
period it shall neither leak nor sweat.
01.58.07 Valves
Unless otherwise mentioned in the Schedule of Quantities these shall be copper

alloy gate, globe and check valve of nominal sizes 8 to 100mm and shall conform
to IS : 778 1984. Valves shall be of class 1 and class 2, suitable upto a temp. of 45
degree C and can sustain non shock working pressure upto 1.0 and 1.6 MPA
respectively. They shall have screwed or flanged ends. All the metal parts shall be
of brass/brass alloy except hand wheel of Cast Iron or other approved quality.
01.59 Shower Rose
The shower rose shall be of heavy quality chromium plated brass with flat bottom,
of diameter 100 mm or as specified with uniform perforations.
01.60 Storage Tank
Storage tank shall be either pressed steel, Galvanised iron, R.C.C or PVC of
specified sizes, capacities, make, manufacture as specified in Schedule of Items. It
shall have facilities for connecting inlet, outlet overflow and washout pipes and a
top cover. Where tanks are to be fabricated by the Contractor the
fabrication/R.C.C detailed drawings shall be got approved by Engineer.
01.61 Miscellaneous items
01.61.01 Half round channel
This shall be made of vitreous china channel with or without outlet/stop end as
specified in Schedule of Items and shall be of approved manufacture.
01.61.02 Urinal partition
This shall be made of vitreous china or R.C.C. with mosaic finish or marble as
specified and shall be of approved make and quality.
01.62 External sewerage & drainage

Unless otherwise specified CI pipe and specials, caulking lead, SW pipe, RCC pipe
shall conform to the following.
01.63 C.I. Pipes
C.I. pipe shall conform to IS : 1536 - 1989 or/and IS : 1537 –

1976 of class as specified in Schedule of Items.
C.I. pipe fittings shall conform to IS : 1538 (Part 1 to 23) -1976 as specified in
Schedule of Items.
Bolts and nuts shall be hexagonal bolts and nuts conforming to IS : 1363 (Part 1 to
3) - 1992.
01.64 Washers
Spring washers conforming to IS : 3063 - 1972 shall be used near the pumps to take
care of vibration. In other places plain washers conforming to IS : 2016 - 1967 shall
be used.
01.65 Gaskets
Gaskets shall be reinforced rubber sheet or compressed fibre board conforming to IS

: 638 - 1979 of thickness between 1.5mm to 3mm or as specified.
01.66 Caulking Lead
Lead for the spigot and socket joints shall conform to IS : 782 - 1978.
01.67 Salt Glazed Stone Ware Pipes
Salt glazed stone-ware pipes used shall conform to IS : 651 - 1992 and shall be laid
as per IS : 4127 - 1983. The pipes shall be of grade AA unless otherwise specified.
01.68 Steel Pipes
Steel pipes and fittings used for encasing shall conform to IS : 1239 (Part 1&2) -
1990 to 1992 medium Class upto 150 mm dia and as per IS : 3589 - 1991 for pipes
of dia 200 mm and above. For pies of dia 200 mm and above fittings, if required
shall be fabricated from pipes itself.
01.69 Cast Iron Manhole Covers & Frames
These shall be of medium or heavy duty (M.D. or H.D.) as specified in Schedule of

Item and of Cast Iron with raised chequered design, lifting key and key hole and
shall be coated with black bituminous base material. Medium duty covers and
frames shall be either of circular type with 500 mm clear opening and minimum
weight of cover and frame 116 Kg and 128 Kg respectively or of rectangular type
with minimum weight of cover and frame 144 Kg.

Heavy duty covers and frames shall be either of circular type with clear openings of
500 and 560 mm and 170 and 208 Kg weight respectively or of double triangular
type with clear openings of 500 and 560 mm and 229 and 255 Kg weight
respectively.
The CI manhole cover and frames shall conform to IS : 1726 - 1991.
01.70 Road
01.70.01 General
Roads shall be understood to include road bed, the wearing surface, berms,
foot-paths, kerbs, culverts and bridges.
01.70.02 Soling Stones
Material for soling shall be natural stone boulders or crushed blast furnace slab.
Stones for soling shall be of height equal to thickness of the soling with tolerance of
plus or minus 25mm and shall not have a base area of less than 250 sq.cm. nor more
than 500 sq.cm. and the smallest dimension of any stone shall not be less than half
the largest dimension. Stones shall be tough, angular, durable and generally free
from flat, elongated, soft and disintegrated particles. They shall also be free from
dirt or other objectionable matter and be obtained from quarries approved by the
Engineer.
Crushed slag obtained from air-cooled blast furnaces slag shall be angular, of
reasonably uniform quality and density and generally be free from any thin,
elongated, and soft pieces, dirt or other objection able matter. The density of slag
should not be less than 1.12 gm/cc and glassy material shall not exceed 20%. Water
absorption when determined in accordance with IS:2386 (Part-III) - 1963. "Methods
of Tests for Aggregates for Concrete : Specific Gravity, Density Voids, Absorption
and Bulking", shall not exceed 10%.
01.70.03 Coarse Aggregate for Water Bound Macadam
Coarse aggregate for water bound macadam shall be natural gravel, crushed stone
obtained from approved quarries or crushed blast furnace slag. Crushed stone shall
be hard, durable, tough and of uniform quality, generally free from flat, elongated,
soft and disintegrated particles. It shall have sharp edges and also not have excess of
dirt and other objectionable matter. When tested as per IS: 2386 (Part-IV) - 1963 for
Los Angeles Abrasion Value or Aggregate Impact Value, the limiting values shall
be 50% and 40% respectively for base course and 40% and 30% respectively for
surfacing course. The flakiness index shall not exceed 15% when tested in
accordance with IS: 2386 (Part-I)-1963 "Methods of Test for Aggregates for
Concrete : Particle size and Shape". Crushed slag aggregates shall meet the
requirements given for soling stones from blast furnace slag.
Size and grading requirements of coarse aggregates shall be as specified in Table-2

of IRC : 19 - 1981, "Standard Specification and Code of Practice for Water Bound
Macadam". The grading number of the table shall correspond to the following layer
thicknesses :
Grading Number Size Range Layer Thickness

1 90 mm to 40 mm More than 90 mm
2. 63 mm to 40 mm 90 mm to 75 mm
3. 50 mm to 20 mm 75 mm to 50 mm
01.70.04 Screenings
Screenings used for filling voids in coarse aggregates for water bound macadam
shall generally be of the same material as the coarse aggregate. Non-plastic
materials such as Kankar nodules, moorum or gravel (other than river bore rounded
aggregates) may be used, provided that the liquid limit and plasticity index are
below 20 and 6 respectively. The fraction passing 75 microns sieve shall not exceed
10%. Size and grading of screenings shall be as specified in Table-3 of IRC-19 -
1981. Type-A screening shall be used for grade number 1 coarse aggregate. Type-B
screenings shall be used for grade number 3. Either Type-A or Type-B screenings
may be used for grade number 2.
01.70.05 Stone Chips for Bituminous Surfacing
Coarse aggregate shall consist of crushed stone, crushed slag or crushed gravel
(Shingle) retained on 2.36 mm sieve. The aggregates shall be clean, strong, durable
and fairly cubical, free from disintegrated pieces, organic and other objectionable
matter. The aggregates shall preferably by hydrophobic and of low porosity. The
mechanical properties and grading shall be in accordance with IRC-29 - 1988
"Tentative Specifications for 4 cm Asphaltic Concrete Surface Course", having
aggregate impact value 30%, Flakiness Index 25% and graded between 20mm and
2.36 mm.
01.70.016 Sand
Sand for use as fine aggregate in bituminous surfacing shall consist of crushed
screenings, natural sand or a mixture of both, passing a 2.36mm sieve and retained
on 75 micron sieve. It shall be clean, hard, durable, uncoated and dry, free from
injurious, soft or flaky pieces and organic deleterious substances.
01.70.07 Binder
Binding material for water bound macadam shall consist of fine grained material
such as stone dust, kankar modules or moorum. The plasticity index shall be
between 4 to 9 when water bound macadam is to be used as surface course and upto
6 when used as sub/base or base course.
01.70.08 Paving Bitumen
It shall conform to IS : 73 - 1992 and shall be of the specified type and grade. The
material shall be homogeneous and shall not foam when heated to 175 degree C.
Various properties like specific gravity, flash point, softening point, penetration etc.
shall be as given in the above code.
01.70.08.01 Bitumen Cut Back

Bitumen cut-back shall conform to specification given in IS : 217 - 1988. It shall be

of three types, Rapid Curing (RC), Medium Curing (MC) and Slow Curing (SC).
These shall comply with the requirements specified in Table - 1, 2 and 3
respectively of the above code.
The above three types of cutback bitumens shall be classified into different grades
on the basis of Kinematic viscosity. Rapid curing type shall be used with aggregates
containing practically no fine aggregates passing through 2.36 mm sieve. Medium
curing bitumen shall be used with aggregates containing less than 20 per cent of fine
aggregates passing through 2.36 mm sieve. Slow curing type shall be used with
aggregates containing more than 20 per cent of fine aggregate passing through 2.36
mm sieve.
Medium curing bitumen of 30 grae i.e. MC 30 shall be used as primer. Manufacturer

shall indicate source and type of the bitumen.
01.70.09 Kerbs
Kerbs may be of stone, concrete or brick as may be shown in drawing or otherwise

directed by Engineer.
01.70.09.01 Stone kerbs
Stones shall conform to the dimensions and shapes given in drawing.
Exposed faces shall be dressed to lines.

01.70.09 Concrete kerbs
Shape and dimension shall conform to the drawing. They shall be pre-cast and the
road side top corner shall be given a chamfer.
01.70.10 Galvanized Steel Barbed Wire for Fencing
These shall be of two types A&B. In both types Barbs shall have 4 points formed by
twisting two point wires, each two turns. In type A (Iowa type) twisting is done
around both line wings and in type B (Glidden type) around one line wire, in both
cases making altogether four complete turns. It shall conform to IS : 278 - 1978 and
shall have the diameter of line and point wire as described in schedule of item.
Galvanized mild steel wire shall conform to IS : 280 - 1978.
Line and point wire shall be circular in section, free from scales and shall be
uniformly galvanized. Line wire shall be in continuous length and shall not contain
any welds other than those in rod before it is drawn.
01.70.11 Galvanized Steel Chain Link Fabric
It will conform to IS : 2721 - 1979. It shall be of width, mesh and wire dia as per
description of Item. For chain link fabric having width upto 2.00 M, of all mesh
sizes, two line wires shall be provided. Whereas for width of 2.40 M and mesh size
exceeding 50mm three line wires shall be provided. These shall be provided at top

and bottom of the fabric, but wherever three line wires have been specified, these
shall be provided at top, bottom and middle of fabric.
The mesh wire and line wire of the fabric shall be manufactured from Galvanised
steel conforming to IS : 280 - 1978. It will have zinc coating of type medium as
given in IS : 4826 - 1979. " Specification for Hot dipped galvanized coatings on
round steel wires". Unless otherwise mentioned in the description of item fabric
with both ends twisted shall be used.
The galvanised steel pipe posts shall consists of 80 mm and 50 mm nominal

diameter. The pipe posts shall conform to IS : 1161 and shall be of medium grade
and galvanised.
01.71 List of materials of approved brand and/or manufacture
Unless otherwise specifically mentioned in the Schedule of Items, Contractor has to

use materials as listed below, of only these brand names/Company's names, which
are mentioned in the approved list for civil, water supply and sanitary items thereon.
A. Building materials
1. TILES (Terrazzo Mosaic Plain) Mehtab Tiles, "NITCO"Indore, Shriram

Tiles. Ahmednagar & any other
approved brand conforming to IS : 1237
-1980
2. FLUSH DOORS Vidarbha Veneer Industries, Woodcrafts,

Western India, Plywood, Kit Ply,
Godavari Plywood, Art Plywood,
National Plywood Industries Pvt. Ltd.
3. PLYWOOD PRODUCTS IPM, Novopan

PARTICLE BOARDS
4. STEEL DOORS, WINDOWS San-Harvice Godrej-Boyce, Mann,

AND VENTILATORS Hopes, Multiwyn, Chamundeshwari,
Doorwyn, Agew Steel.
5. ROLLING SHUTTERS AND Standard, Swastik, Diana, Hercules,

ROLLING GRILLS Prabhat, Vinayagar
6. ALUMINIUM DOORS, Godrej, Ajit India Alumilite, Aardee,

WINDOWS, PARTITIONS Indal
7. WATER PROOFING CICO, Impermo, Accoproof

COMPOUNDS
8. HARDENERS Ironite, Ferrok, Hardonate
9. PAINTS AND DISTEMPERS Jenson & Nicholson, Asian Paints,

Shalimar, ICI, Goodlass Nerolac,

Garware, Berger
10. REDOXIDE Shalimar, Blundel, Eomite

(For IPS Flooring)
11. WATER PROOF CEMENT Super Snowcen, Berger, Jenson &

PAINTS Nicholson and Shalimar.
12. PRESSED STEEL DOOR AND Shirke Polynorm, T.I. Frames, Madras;
WINDOW FRAME Mann, Jaipur; Chandan Metal Products,
Baroda; Agew, Ahmedabad; Multiwyn,
Calcutta.
13. DOOR CLOSERS Everite, Gloster Engineering, Amar,

A.K. Industries, Hardiwyn, Vigvijay,
Dewan Industries.
15. CONSTRUCTION Choksey, CICO

CHEMICALS
B. Sanitary and water supply work (Internal)

(First quality to be used)
1. Cast Iron Pipes and Fittings Hindustan Engineering Products Company

Calcutta, E.L.C., Standard approved
manufacturers of any other brand of fittings
having ISI marking.
2. RCC Pipes Indian Hume Pipe Company, Delhi /

Allahabad / Chandigarh / Lucknow;
Hindustan Pressure Pipes, Kolhapur; Dhere
Concrete Products, Pune or any other
approved manufacturer conforming B.I.S.
Standard
3. GI Pipe Indian Tube Company, Calcutta; Kalinga

Tubes Limited, Cuttack; Gujarat Steel Tube;
Zenith Tube Co. Kolaba; Bharat Steel Tube,
New Delhi; Jindal; Shivmoni Steel Tubes
Limited, Bangalore; Sekhar Iron Works,
Calcutta; Jain Tubes, Ghaziabad; Khandelwal
Tubes, Nagpur.
4. G.I. Fittings International Pipe Works, Calcutta; R.M.

Engineering Works, Jalandhar; Bombay
Metal Company, Bombay; Tarapada Das &
Sons, Howrah; Annapurna Metal Works,

Calcutta.
5. Gun Metal Valves and Copper Leader Engineering Works, Jalandhar; Neta
Alloy Valve Engineering Works, Jalandhar; Lakshmi
Metel Works, Jalandhar; Bombay Metal &
Alloys, Bombay; Luster Sanitary Fittings,
Jalandhar; Annapurna Metal Works, Calcutta.
6. Sluice Valves, Check Valves Shiva Durga Iron Works, Howrah; Leader
etc. Engineering Works, Jalandhar; Kirloskar
Bros. Limited, Pune; Indian Valve, Calcutta;
Geeta Iron & Brass Works, Baroada.
7. Brass Fittings Leader Engineering Works, Jalandhar; L & K

Mathura; Luster Sanitary, Jalandhar;
Annapurna Metal Works, Calcutta; Neta
Metal Works, Jalandhar; Honey Industrial
Corporation, Bombay.
8. C.P. Fittings Ego Metal Works, Ballabhgarh; Jaquar

Industries, Delhi; Soma Plumbing Fixtures
Limited, Calcutta; Gem Sanitary Appliances
Pvt. Ltd.,Delhi; Essco Sanitations, Delhi;
Bilmet, Bombay.
9. W.C. Pan Wash Basin, E.I.D. Parrys, Madras, Hindustan

Urinals, Sink Low down Sanitaryware, Calcutta; Neiveli Ceramics,
Flushing Cistern Tamil Nadu; Cera Ceramics.
10. E.W.C. Seats Nuchem Plastics Limited, Faridabad;

Commander, Bombay; Bestolite Jasco Sales,
Bombay; Agarwala Products, Bombay.
11. Flushing Cistern Arail Brothers, Delhi; Allied Industries,

Jaipur; Fordham Pressing (India) Pvt.
Limited, Bombay; Klassik Enamellers,
Bombay; Sushila Industries, Sundergarh;
Small Machine Tools Company, Howrah;
Thakurdass Surekha Engg. Corporation Pvt.
Ltd., Calcutta; E.I.D. Parry (India) Pvt. Ltd.,
Madras; Hindustan Sanitaryware & Industries
Ltd., New Delhi; Neiveli Ceramics and
Refractories Limited, Tamil Nadu.
12. Hydrants Brady's, Bombay; Firex, Bombay; Upadhya

Valves, Calcutta; Eddy Foundry, Calcutta,
Minimax.
13. Mirrors Atul Glass Works, Vallabh Glass Works,

Goldenfish

14. White Glazed Tiles H & R Johnson TilesCompany, Bombay;

Somani Pilkingtons Co., Haryana
15. Stone Ware (Salt-Glazed) Hind Ceramics Limited, Orissa; Ceramic

Pipes Industries Limited, Sambalpur; Shrikamakshi
Agencies, Madras; Binary Udyog Pvt.
Limited, Howrah; Tirumati Moulds Limited,
Nagpur; Kiran Potteries, Hyderabad; Perfect
Sanitary Pipes, Bharatpur.
01.72 Materials not specified
Any materials not fully specified in these specification and which may be offered
for use in the works shall be subject to approval of Engineer, without which it shall
not be used anywhere in the construction works.

SPECIFICATION FOR CIVIL WORKS

PART – II WORKMANSHIP
GENERAL
1.1 Standard
1.2 Supervision
1.3 Temporary Works
1.4 Codes
1.5 Base Lines and Bench Marks
1.6 Setting Out
1.7 Dewatering
1.8 Safety of Existing Work
1.9 Protection of Existing Services
1.10 Handing Over of Work Site
2.0 Earth work
2.1 Scope
2.2 General
2.3 Setting Out
2.4 Site Clearance and demolition
2.5 Classification of Soil
2.6 Method of Excavation
2.7 Excavation of Soils Other than Hard Rock
2.8 Excavation in Hard Rock
2.9 Cutting and Filling for Site Levelling
2.10 Excavation for Trenches
2.11 Excavations for Foundations
2.12 Excess Excavation

2.13 Disposal of Excavated materials
2.14 Backfilling of Trenches
2.15 Backfilling of Foundations
2.16 Filling Under Floors
2.17 Load Bearing Fills
2.18 Turfing
3.0 Anti-termite treatment
3.1 Scope
3.2 Execution
3.3 Acceptance Criteria
4.0 CONCRETE (PLAIN & REINFORCED)
4.1 Scope
4.2 Materials
4.3 Grades of Concrete
4.4 Mix Design
4.5 Water/Cement Ratio
4.6 Workabilitiy
4.7 Durability
4.8 Trial Mixes
4.9 Nominal Mix Concrete
4.10 Volumetric Mix concrete
4.11 Batching of Concrete
4.12 Water
4.13 Mixing and Transportation of Concrete
4.14 Preparatory Works/Surface Preparation
4.15 Placing and Compaction of Concrete

4.16 Construction Joint & Cold Joints
4.24 Grout
4.25 Concreting in Water Retaining Structures
4.26 Application of Live Load
4.27 Foam Concrete
5.0 Masonry
5.1 General
5.2 Materials
4.17 Requirements for Concreting in Special cases

4.18 Finishes to Exposed Surfaces of Concrete
4.19 Curing of Concrete
4.20 Testing of Concrete
4.21 Steel Reinforcement
4.22 Shuttering
4.23 Damp Proof Course Concrete
5.3 Selection of Mortars
5.4 Cement Mortar
5.5 Brick work
5.6 Stone masonry
5.7 Hollow Concrete Block Masonary
6.0 PLASTERING AND POINTING
6.1 Materials
6.2 Plastering
6.3 Cement Pointing
6.4 Rough Cast Concrete Facing
6.5 Punning with Lime or Plaster of Paris

7.0 FLOORING, PAVING & FACING
7.1 Scope
7.2 Materials
7.3 General
7.4 Sub-base
7.5 Subgrade
7.6 Cement Concrete Flooring with Integral Finish
7.7 Concrete Flooring with Granolithic Finish (Artificial Stone Flooring)
7.8 Dado & skirting Work (Grey Cement Skirting / Dado)
7.9 Flooring & Facing with Redoxide of Iron (Red Artificial Stone Flooring)
7.10 Terrazzo Flooring & Facing
7.11 Glazed Tile Finished Flooring & Facing
7.12 Marble Flooring
7.13 Marble in Facia or Dado
7.14 Flooring/Paving with Hardener like Ironite.
7.15 Chemical resistant tile flooring/facing
7.16 Chemical resistant In-Situ Finished Flooring / Facing
8.0 WOOD WORK
8.1 General
8.2 Joinery
8.3 Shrinkage & Tolerance
8.4 Fixing
8.5 Tarring
8.6 Fittings
8.7 Doors

8.8 Panelled Shutters
8.9 Glazed Shutters
8.10 Flush Door Shutters
8.11 Other type of shutters
8.12 Inspection
9.0 METAL DOORS, WINDOWS AND ROLLING SHUTTERS
9.1 General
9.2 Fixing
9.3 Fittings
9.4 Normal Steel Plate Doors
9.5 Pressed Steel Doors
9.6 Steel Windows, Sashes, Ventilators, etc.,
9.7 Collapsible Gate (Steel)
9.8 Steel Rolling Shutters and Grills
9.9 Guarantee
9.10 Aluminium Doors. Windows, Frames
10.0 GLAZING
10.1 General
10.2 Doors, Windows and Ventilators.
10.3 Northlight Glazing
11.0 WHITE WASHING, COLOUR WASHING & PAINTING
11.1 Scope
11.2 Materials
11.3 White Washing, Colour Washing
11.4 Cement Primer Coat
11.5 Water Proof Cement Paint

11.6 Oil Bound distemper
11.7 Dry Distemper
11.8 Plastic Emulsion Paint
11.9 Bitumen Painting
11.10 Tarring
11.11 Painting to Timber & Steel Surface
12.0 INTERNAL WATER SUPPLY, PLUMBING, DRAINAGE AND

SANITATION
12.1 Scope of work
12.2 Water Supply & Plumbing
12.3 Drainage and Sanitation (Internal)
13.0 EXTERNAL SEWERAGE & DRAINAGE
13.1 Scope of work
13.2 Materials
13.3 Excavation of trenches and pits
13.4 Cast Iron pipes
13.5 Stone ware glazed pipelines (S.W.G)
13.6 Man holes
13.7 Marker plates
14.0 ROAD WORK
14.1 General
14.2 Trenching and Preparation of Subgrade
14.3 Ash Carpet
14.4 Boulder Soling
14.5 Kerbs
14.6 Water Bound Macadam Surfacing
14.7 Preparation of Base and Shoulders

14.8 Spreading Coarse Aggregates
14.9 Rolling
14.10 Application of Screenings
14.11 Sprinkling and Grouting
14.12 Application of Binding Material
14.13 Setting and Drying
14.14 Surface Evenness
14.15 Bituminous Pavements
14.16 Berms
14.17 Kerbs
14.18 Bridges and Culverts
14.19 Boulder Pitching
14.20 Scarifying & Dismantling
14.21 Diversions
15.0 WATERPROOFING TO ROOFS & BASEMENTS & WATER PROOFING

PAINTS
15.1 Scope
15.2 Material
15.3 General Workmanship
15.4 Painting with Hot Bitumen
15.5 Painting with Bitumen Emulsion
15.6 Waterproofing of Roof
15.7 Waterproofing for Basement
15.8 Surface Application
15.9 Guarantee
15.10 Waterproofing course with fibre glass R.P. tissue.

15.11 Waterproofing course with PVC sheets/membrane
15.12 Waterproofing with Non-shrink polymeric waterproof grouting compound.
16.0 MISCELLANEOUS
16.1 False Ceiling
16.2 Wall Panelling & Wooden Partition
16.3 Expansion and Isolation Joints
16.4 Barbed Wire Fencing

GENERAL
1.1 Standard
A high standard of workmanship in all trades will be required. The Contractor

shall ensure that only skilled and experienced workmen are employed.
1.2 Supervision
The Contractor's supervising staff shall be fully qualified and experienced in the
types of work being carried out under their supervision and shall be capable of
ensuring that work is executed efficiently and as per specification.
1.3 Temporary works
Where required, the Contractor shall furnish such details of his temporary works
as may be called for by the Engineer and the Contractor shall satisfy the Engineer
as to their safety and efficiency. The Engineer may direct that temporary works,
which he considers unsafe or insufficient, shall be removed and replaced in a
satisfactory manner.
1.4.0 Codes
referred to. Where standards are not yet published by the BIS or IRC, adoptable
British Standards or other International Standards shall apply.
In case of any conflict in meaning between these specifications and those of BIS
or IRC, or British/International Standards, the provisions of these specifications
shall prevail.
1.5 Base lines and bench marks
The Contractor shall establish and maintain, to the satisfaction of Engineer, the
base lines and bench marks, based on which the works are set out. Where such
base lines and bench marks are provided by the Engineer, the Contractor shall
maintain these throughout the period of construction without causing any
disturbance to them.
1.6 Setting out
The Contractor shall set out all the works to be executed by him, in line with the
standard base lines, levels, position and bench marks and truly as per drawings
within the accepted tolerance limits at no extra cost to Owner. The Contractor
shall be solely responsible for the setting out of all the works, to be executed by
him and the approval of such setting out by the Engineer shall in no way absolve
the Contractor his responsibility for carrying the work to the true lines, levels and
positions as per drawings.

1.7 Dewatering
The Contractor shall carry out all the works, in dry and workable condition and
maintain the same in dry condition till the final handing over of works at no extra
cost to the Owner. For this the Contractor shall make all the necessary provisions
of dewatering, wherever necessary, to the entire satisfaction of the Engineer.
1.8 Safety of existing work
Before taking up any construction adjoining other property or existing work, the
Contractor shall take all steps necessary for the safety and protection of such
property or work at no extra cost to the owner.
1.9 Protection of existing services
The Contractor shall take all precautions necessary to prevent damage to or

interference with underground or over ground services such as cables, drains,
piping or piles, whether shown on drawings or not. Equipment etc., mounted in
position shall be protected against falling debris etc., by means of tarpaulin or such
other material at no extra cost to the owner.
1.10 Handing over of work site
On completion of work, the Contractor shall remove all rubbish, debris, surplus
materials, temporary work etc., from the site. The site shall be handed over in a
tidy and workmanlike manner at no extra cost to the owner.
2.0 EARTH WORK
2.1 Scope
This chapter deals with earth work and excavation for civil works in site,
formation/oversite leveling, foundations, cutting and grading for roads/pavement
and railways, canals, embankments other than water retaining embankments
trenching for drainage and other burried services and the like.
2.2 General
The Contractor shall carry out the excavation strictly to the lines and levels, in
conformity with the drawings or instructions of the Engineer.
2.3 Setting out
Before commencement of earthwork block levels of existing ground shall be taken

by the Contractor jointly with the Engineer, plotted and signed in token of
acceptance of ground levels. Excavation shall not be commenced until the initial
ground levels have been recorded and accepted. Reference lines, bench marks and
base lines shall be set out by the Contractor for control of earthwork operation.
Setting out shall be done with pegs, blocks, bamboo poles or rails, marking
boundaries or centre lines, as the case may be, and the same maintained for
reference and future checking. Chainaie stones at regular intervals shall be set up

for embankments. All setting out operations shall be got checked and approved by
Engineer. However, such checking and approval by the Engineer shall in no way
absolve the Contractor of his responsibilities for carrying out the work to the true
lines, levels and positions as per drawing, and in case any error is noticed at any
stage in the contractor's work, it shall be corrected/rectified by him without any
cost to the Owner.
2.4 Site clearance and demolition
The site shall be cleared of all trees, stumps, roots, brush wood, bushes and other
objectionable materials. Useful and saleable material, if any, shall be the property
of the owner and shall be stacked properly as directed by the Engineer. The areas
to be covered with embankments shall be stripped of top soil to required depths to
expose acceptable founding strata. Top soil unsuitable for use in embankment
construction and other fills shall be disposed off as directed. All combustible
materials shall be stacked and burnt in locations sufficiently remote to eliminate
all danger of fire hazards. All old concrete, brick works and drains which interfere
with construction works shall be dismantled with the approval of the Engineer
taking all necessary precautions prescribed in safety specification. Top soil which
is suitable for use in construction work shall be stockpiled for later use. Other
objectionable materials such as trash, debris, stones, brick, broken concrete, scrap
metal etc., shall be disposed off as directed by the Engineer. Payment for cutting
and removal of trees, stumps, dismantling existing structures and stripping shall be
regulated by the description in the Schedule of Items or Part V of these
specifications.
2.5 Classification of soil
The Engineer will decide the class of any particular soil. Classification of soil
shall be as under and the decision of the Engineer shall be binding on the
Contractor :
A) Ordinary soil
Soils which yield to ordinary application of pick and shovel, phawra rake or other
ordinary digging implements (including earth moving equipment such as
bulldozer, shovels without resorting to blasting) without offering much resistance,
shall be classified as ordinary soil. This includes organic soil, turf, sand, gravel,
loam clay, mud, peat, black cotton soil, soft shale and loose moorum etc.
B) Hard soil
This comprises of all soils that cannot reasonably be excavated by the above
mentioned digging implements, but can be excavated with close application of
pick axe or scarifiers or jumpers to loosen. This includes compact moorum, stiff
clay, hard shale, cobble stone etc.,
C) Soft /decomposed rock
This comprises of rock or boulders which may be quarried or split with crow bars,
pavement breakers etc., This include lime stone, sand stone, weathered rocks and

hard conglomerates etc .and existing structures embedded in earth and tarred
macadam roads, pavements, met in the excavation. The fact that contractor resorts
to blasting for his own reasons shall not mean that the rock is hard and classified
as hard rock.
D) Hard rock
This comprises of rocks which require blasting for excavation. Where blasting is
prohibited, excavation has to be carried out by chiseling, wedging or any other
agreed methods.
2.6 Method of excavation
The Contractor may carry out excavations, filling and compaction by any method
considered most suitable, and befitting the site conditions subject to any stipula-
tions contained in the contract and the specifications. All excavations shall be
required to be kept completely free from water, from whatever source it may
come, during the construction. No foundation work shall be taken up until the
surfaces are properly drained.
2.7 Excavation of soils other than hard rock
Excavation shall be carried out in the most expeditious and efficient manner to the
lines and levels as indicated in drawings or as directed by Engineer. Prior
approval of the Engineer shall be taken for the method to be adopted for
excavation including dimensions, side slopes, dewatering, shoring etc., Such
approval shall not make the Engineer responsible for any consequent damage or
loss caused. All precautions shall be taken to preserve the material below and
beyond line of excavation in soundest condition. All damages done beyond limits
of excavation shall be made good by the Contractor at his own cost in a manner
approved by the Engineer. All excavated materials shall be removed to spoil
heaps, dumping yards or transported for filling as may be necessary. When soil
heaps are formed for future use, heaps shall be protected from washing away due
to rain or surface run off. The sides of excavation shall be maintained in stable
condition by adequate stepping and batter. To prevent entry of surface water and
accumulation of subsoil water in excavated areas, suitable drainage arrangements
as may be needed and directed by Engineer, shall be provided and maintained.
Pumped out water shall be drained off properly avoiding damage to other existing
works. If any pipelines, cables or service lines are likely to be exposed,
excavation around these services shall be carried out manually and all such
services shall be adequately supported and protected at no extra cost.
Excavation shall be carried out in any material encountered including road

surfaces, pavements, burried parts of old foundations, pits or other structures.
Excavated materials shall be placed beyond 1.5 metres of the edge of the
excavation pit/trench or half the depth of the pit/trench whichever is more or
further away as directed by the Engineer. Sumps made for dewatering must be
kept clear of the foundations.
In firm soil the sides of the trenches shall be kept vertical upto a depth of 2.0m
from the bottom and for a greater depth, trench shall be widened by allowing steps
of 50cm on either side after every 2.0m depth from the bottom, so as to give a
vertical side slope of 1/4 : 1. Where the soil is soft, loose or slushy, the width of

the steps shall be suitably increased or sides suitably sloped or suitable shoring
and strutting provided as directed by the Engineer. For trenches deeper than 2.0m,
the Contractor shall obtain detailed instruction from the Engineer in writing
regarding the stepping, sloping of sides or shoring and strutting to be done. For
these bye-works, no extra cost will be paid to the Contractor.
2.8 Excavation in hard rock
Where hard rock is met and blasting is considered necessary for its excavation, the
Contractor shall intimate the Engineer in writing. Excavation in hard rock shall be
done either by blasting or chiseling or by such other agreed methods as may be
required. Levels of hard rock surface shall be taken and got approved by
Engineer before start of excavation. Blasting shall be permitted only when proper
precautions are taken for protection of persons, works and property. The
Contractor shall obtain the necessary licence for procuring, storing and using
explosives.
Blasting operations shall be carried out by a licensed Blaster. The quality and
quantity of explosives, size and spacing of holes depth of holes etc., shall be such
that they will neither open seams nor damage or shatter the rock beyond the
specified lines of excavation. A tolerance of 150 mm will however be allowed
beyond the excavation lines. As excavation approaches final stages, the depth of
holes and the amount of explosives used shall be reduced progressively to avoid
over breakage or damage to founding strata. Any fissures, cracks and voids below
prescribed depth of excavation shall be corrected by removing loose pieces,
shattered or affected rock and replaced by lean concrete of M-5 grade or (1:5:10)
cement concrete in the case of foundations. Where excavated surface is to receive
structural concrete, the surface shall be cleaned of dust and other objectionable
materials.
In cases where blasting, though otherwise required, is prohibited because of any

reason, the excavation shall be carried out by chiseling, wedging or such other
agreed methods. All materials excavated from blasting, chiseling or any such
methods shall be stacked for measurement as directed by Engineer.
2.9 Cutting and filling for site leveling
Excavation and filling operations for site leveling shall be so planned and
executed, that transportation and re-handling are minimised. The sides of
excavation and fills shall be maintained in stable condition by adequate batters,
stepping and dewatering. Materials not desirable shall be disposed off in area
indicated by Engineer. When it is required to blend the material, it shall be done
by selective excavation and filling operation. Wells, ponds, cesspools and water
logged areas shall be emptied of water and deslushed before filling. Filling shall
be done in horizontal layers not exceeding 300mm in thickness as specified or as
directed by the Engineer. All clods shall be broken before placing the fill. Earth
moving equipment shall be allowed to ply over the fill to permit compaction.
Adequate allowance shall be made for subsidence of fill material. Levels shall be
taken and excess or shortfall shall be made good by appropriate cutting or filling.

2.10 Excavation for trenches
Excavation for trenches shall be carried out in materials encountered to enable

laying of service lines or drainage channels or any other desired purpose. Exca-
vation shall be done to lines and levels shown in drawings and shall be done
providing adequate measures for stability. Vertical wooden sleepers or light rails
shall be erected at uniform levels at places where changes of direction and
gradients occur. Centre lines shall be marked on horizontal sleepers or rails, laid
across the trenches. Depths of excavation and pipe invert levels shall be checked
by means of boning rods of appropriate lengths. Trench beds shall be trimmed
and rammed with sprinkling of sand or moorum to required gradients for
continuously supporting the pipelines. Trenches shall be locally deepened and
widened to receive sockets and permit joints to be inspected.
Timbering
In case of trenches, tunnels, channels, drains, manholes, chambers, basement and

other places where the soil is not capable of being retained without the support,
timbering as directed by the Engineer shall be resorted to. It shall be the
responsibility of the Contractor to take all the necessary steps to prevent the sides
from collapsing.
2.11 Excavations for foundations
Excavation for foundation shall be done to the lines and levels indicated in the
drawings. Excavated material shall be transported and stored at convenient spots
for reuse in back filling of foundations and other fills. Surplus material shall be
transported, spread and levelled at dumping areas. Side slopes of excavation
and/or shoring shall be adequate from consideration of stability and working
space. When so required and authorised by Engineer, the sides of excavation shall
be protected with proper shoring, strutting, sheeting and sand bags etc., These
shall be removed only when work in the pit is completed, with the approval of the
Engineer. When it is felt that removal of supports may result in side collapse or
settlement of adjoining ground or endanger adjoining structures and foundations,
they shall be left permanently in position. The last 150 mm of excavation shall be
done and the bottom trimmed to the required levels only when concreting is
imminent. If at any point the natural ground is disturbed or loosened for any
reason, it shall be consolidated by tamping or rolling or made up with concrete of
M-5 grade, or (1:5:10) cement concrete if so ordered by the Engineer at no extra
cost. Where the soil encountered at depths indicated in drawings is loose or weak,
it shall be further excavated to levels of firm strata as may be directed by the
Engineer and filled with lean concrete of M-5 grade/(1:5:10) cement concrete or
sand as directed. If the bottom of excavation has been left exposed not through
neglect or fault of the Contractor and it has become deleteriously affected by
atmospheric action and water, such portion of deteriorated foundation material
shall be removed and made good by lean concrete of grade M-5/(1:5:10) cement
concrete or sand as directed and such extras will be paid for.
2.11.1 For deep excavation in the proximity of existing buildings, foundations, streets,
railway tracks, underground cabling, gas piping, water and drainage lines, and the
like, adequate appropriate precautions shall be taken to protect such structures or

works from damage, displacement or settlement, either as an immediate result of

the excavation or as after effect, discernible with the passage of time. The method
of protection of existing structures and services may include sheet piling, shoring,
strutting slinging or any other method including dewatering. Payment for such
protective work shall be governed by the description given in the Schedule of
Items for the particular work.
2.11.2 For excavation adjoining existing piles care shall be taken to ensure that no pile
under any circumstances is exposed from the top for a height exceeding 2 metres.
No strutting shall be done against exposed piles, nor exposed piles ever used for
tying guy ropes or supports either temporarily or permanently.
2.12 Excess excavation
All excavation done beyond the specified limits or directions of Engineer shall be
considered as excess excavation. They shall be made good as prescribed below by
the Contractor at his cost:
i) Excess excavation in case of site leveling shall be made good by

filling and compacting with material same as the surrounding
material. Degree of compaction shall be at least the same as the
surrounding material.
ii) Excess excavation in case of trenches shall be made good by

filling and compacting with selected earth to the same compaction
as the surrounding material or as directed by Engineer. This shall
be done in layers not exceeding 150 mm thick, moistened and
thoroughly compacted by tamping.
iii) Excess excavation in case of foundation beyond required depths

shall be made good by filling with lean concrete of M-5
grade/(1:5:10) cement concrete.
2.13 Disposal of excavated materials
Excavated materials that are unsuitable for use in construction works or in excess
of construction requirements shall be disposed off in dumping yards or in
locations indicated by Engineer. Waste piles/heaps shall be located in such places
where they will not interfere with natural flow of rain water access or transport or
with the access to nearby structures. When required, they shall be levelled and
trimmed to such lines and levels as indicated by Engineer.
2.14 Back filling of trenches
Trenches shall be backfilled after pipes or service lines are tested and approved.
Filling shall be done with earth in 150 mm thick layers free from unwanted
material and well rammed. Soft material shall be used in bottom of trenches upto
a level of 150 mm above the top of pipes before backfilling with other fill mate-
rials. All clods and lumps shall be broken before placement. Care shall be taken
not to disturb, break or damage the pipes during backfilling and compaction
process.

2.15 Backfilling of foundations
Backfilling of foundations shall be done using suitable soils from excavations.

Soil shall be free from organic matter and other materials which would affect the
stability of the fill and shall be free from boulders, brick bats wood pieces and
other injurious materials, lumps and clods. Before commencement of backfilling
of foundations. all shoring and formwork, bits of timber, cement bags and all
other rubbish shall be removed. Hydro-insulation, Bitumen painting or
application of anti-corrosive protective and anti-termite treatments shall have been
completed. Backfilling operation shall not commence without approval of
Engineer. Backfilling shall be carried out in well compacted layers of 150 mm
thickness. Each layers shall have near optimum moisture content. Layers will
extend to the entire width of excavation and shall be sprinkled with water during
compaction process. Ramming shall be done to achieve firm compaction.
Backfill shall be trimmed and finished to lines and levels indicated in the drawings
and/or as directed by the Engineer. Mechanical equipment like vibratory roller,
vibro earth rammer or vibratory compactor shall be used for compaction.
2.16 Filling under floors
Material for filling under floors shall be soil free from harmful minerals, vegetable
matter etc., and shall not be expansive soils. Filling shall be done in well
compacted layers not exceeding 150 mm in thickness. Each layer shall be
compacted to 95% Standard Procter Density. Sufficient soaking shall be done
before compaction. The entire area to be covered by flooring shall be finally
dressed and trimmed to required levels. Mechanical equipment like vibratory
roller, vibro earth rammer or vibratory compactor shall be used for compaction.
2.17 Load bearing fills
Load bearing fills include embankments for roads and railways and such other
earth fills above ground levels provided for protection of fuel oil tanks, pads for
storage tanks, drain, bunds and the like. Fill materials shall either be selected
earth obtained from excavations for site leveling, trenches and foundations or from
selected borrow areas as may be required. Soils selected for filling in
embankments shall be of uniform quality and free from boulders, organic
materials and other objectionable matter. Soils having high silt and clay content
and having laboratory maximum dry density less than 1.44 gms per c.c. shall not
be used for load bearing fills. For fills greater than 3 m in height soils shall have
laboratory density not less than 1.52 gms per c.c. Soils for top 500 mm of fills for
roads and railways shall have laboratory density not less than 1.65 gms per c.c.
and shall not have marked swelling and shrinkage properties.
Foundation preparation for embankments shall be done as prescribed under site

clearance. The founding strata shall be compacted as much as possible by rolling
or tamping before placement of fill material. The water content of founding strata
should be same as that specified for embankment fill. Any pockets of loose
material or depressions left in founding strata as a result of clearing operation shall
be filled and compacted with the same material as the surrounding founding strata.
When an embankment is to be placed on steep sloping ground the surface of the

ground shall be trenched in steps or trenched or broken up in such a manner that

the new materials bonds well with the founding strata.
Fill material shall not be placed until foundation has been inspected and approved
by Engineer. Material shall be placed in even, continuous, horizontal layers over
full width of embankment in well compacted layers not exceeding 200 mm
thickness. Each layer shall be compacted by means of smooth rubber tyred rollers,
sheep-foot rollers, tractors, tampers or other mechanical means as may be found
suitable for the location. Before rolling, the water content shall be checked and
corrected by sprinkling with water or adding dry material or aeration as may be
required. This shall be followed by mixing and the layer left for soaking before
compaction. The water content shall be within plus or minus 2% of Standard
Proctor Optimum. Density of compacted layers shall be determined by sand re-
placement method. Average compacted density shall be at least 95% of Standard
Proctor Density. The number of tests to be conducted for determination of
moisture content and density shall be as prescribed by the Engineer. Side slopes of
embankments shall be formed along with the main embankment. No side
dumping shall be done for the formation of slopes. When required the width of
each layer shall be constructed slightly in excess of required width and slopes
trimmed to remove loose edge materials and completed to lines shown in drawings
or as directed by the Engineer. Subgrades for road works shall be thoroughly
wetted sufficiently in advance of placing of any base course and it shall be ensured
that it is firm and moist for at least 50 mm below the surface. Should the subgrade
for any reason be loose or have density less than required, it shall be recompacted
and refinished. Excessive loss of moisture in the subgrade shall be prevented by
sprinkling and/or scaling. No traffic or hauling equipment shall be permitted to
ply on finished subgrade and any damage caused to such portion shall be made
good by the Contractor at his own cost.
2.18 Turfing
The slopes of embankment shall be dressed to line and slightly roughened to bond
and hold a surface dressing consisting of 150 mm humus layer of soil. The entire
surface shall then be covered with turf consisting of blocks or strips of grass of
approved species. The sod shall include a net of roots and earth at least 75 mm
thick. The sod shall be laid on slope in close contact and then tamped in place so
as to close and fill the joints between blocks.
Immediately after placing the turf, slope shall be thoroughly wetted and kept wet
for a sufficient period to assure plant growth. Watering shall be continued until
the grass takes root firmly and the whole area presents a uniform appearance. In
the event that the plant growth has not taken place within the period of
maintenance such areas or patches shall be redone by the Contractor at his own
cost.
3.0 ANTI-TERMITE TREATMENT
3.1 Scope
The scope of work includes setting up a chemical barrier against attack by

subterranean termites while the building is under construction.

3.2 Execution
3.2.1 General
Unless otherwise specified all work shall in general be executed as specified in IS

: 6313 Part-II -1981 and as per approved specification of the agency having
special know-how for the job.
All necessary work to ensure uniform distribution and proper penetration of

treating solution shall be done according to the instruction of the Engineer.
Soil treatment shall not be done when it is raining or when the soil is wet with rain
or subsoil water. Once formed, the treated soil barrier shall not be disturb
3.2.2 Chemicals and rate of application
Chemical like chlorpyriphos 20% EC (Conforming to IS 8963 - 1978) in 1%

emulsion shall be applied by pressure pumps, uniformly over the area treated. (1
part chemicals + 20 parts water = 1% emulsion).
3.2.2.1 Treatment of pits, trenches & basement excavations
Foundations, basements etc. may either be fully enveloped by the chemical barrier
or the treatment may start 500 mm below ground level. The bottom surface and
sides of excavation (upto a height of about 300mm) for column pits, walls,
trenches and basements shall be treated with emulsion @ 5 liters per sq.m. of
surface area. Backfills around columns, walls, etc., shall be treated @ 7.5 liters per
sq.m. of the vertical surface. Treatment shall be done in stages following the
compaction of earth in layers. The treatment shall be carried out after the ramming
operation is done by rodding the earth at 150mm centers closed to the wall surface
and spraying the emulsion in the specified dose.
3.2.2.2 Treatment of top surface of plinth filling
Holes 50 mm to 75 mm deep at 150 mm centres both ways shall be made with

crow-bars on the surface of compacted plinth fill. Emulsion at the rate of 5 litres
per sq.m of surface shall be applied prior to laying soling or subgrade. Special
care shall be taken to maintain continuity of the chemical barrier at the junction of
vertical and horizontal surfaces.
3.2.2.3 Treatment of doors, windows & soil surrounding pipes, Wastes and conduits.
Special care shall be taken at the points where pipes and conduits enter the
building and the soil shall be treated for a distance of 150 mm and a depth of 75
mm at the point where they enter the building. All the wooden door/window
frames on the ground floor of the buildings shall be treated with the insecticidal
solution.
3.2.2.4 Treatment of expansion joints
These shall receive special attention and shall be treated in a manner approved by
the Engineer.

The Contractor shall give a 10 year service guarantee in writing supplemented by

a separate and unilateral guarantee from the specialised agency for the job to keep
the building free of termites for the specified period at no extra cost to the Owner.
4.0 CONCRETE PLAIN & REINFORCED
4.1 Scope
This chapter covers the workmanship, special requirements & regulations with
which the contractor must comply to achieve the following two objectives :
(a) The provision, at all locations on the site, of dense workable concrete,
having the specified characteristic strength.
(b) The placing of concrete at all elevations, well compacted by vibrations, in

well aligned and well fixed formwork ensuring the internal and external
dimensions of structures as per drawings and maintaining the size, shape
number and locations of reinforcements, inserts etc., as specified in the
drawings providing the surface finish after stripping off the formwork to
ensure the structural configurations as per drawings as well within the
specified tolerance limits, curing and guaranteeing the characteristic
strength, all as specified.
4.1.1 The mixing, placing, compacting, curing and finishing of concrete shall be done
according to IS: 456-2000 "Code of Practice for Plain and Reinforced Concrete".
4.2 Materials
For materials, reference to Part - I (Materials) shall be made.
4.3 Grades of Concrete
The grades of concrete unless otherwise specified shall be in accordance with the
following table. The grade of concrete to be used in each section of work will be
shown in the drawings or in the schedule of items :
Characteristic Strength i.e.

Grade off Compressive Strength of 15 cm cubes Nominal Maximum
Concrete at 25 days Aggregate Size (mm)
(N/mm2
M-5A 5 63
M-5B 5 40
M-7.5A 7.5 63

Characteristic Strength i.e.

Grade off Compressive Strength of 15 cm cubes Nominal Maximum
Concrete at 25 days Aggregate Size (mm)
(N/mm2
M-7.5B 7.5 40
M-10A 10 63
M-10B 10 40
M-10C 10 20
M-10D 10 12
M-15A 15 63
M-15B 15 40
M-15C 15 20
M-15D 15 12
M-20A 20 63
M-20B 20 40
M-20C 20 20
M-20D 20 12
M-25C 25 20
M-25D 25 12
M-30C 30 20
M-30D 30 12
M-35C 35 20
M-35D 35 12
M-40C 40 20
M-40D 40 12
Notes : A,B,C,D mentioned along with grade of concrete correspond to the maximum
size of coarse aggregate being 63mm, 40mm, 20mm & 12mm respectively.

Unless otherwise specified in the drawings or schedule of items the maximum

nominal size of coarse aggregates for different grades of concrete shall be as under
:
For concreting in very narrow space or in very small 12 mm

thickness
For all reinforced concrete work except in massive 20 mm
foundations
For all ordinary plain concrete & massive reinforced 40 mm
foundations
4.4 Mix Design
4.4.1 General
At the commencement of the contract the Contractor shall make preliminary tests
to determine the proportions by weight of cement, fine aggregates, coarse
aggregates and water necessary to produce required grades of concrete. The mix
proportions shall be selected to ensure that workability of the fresh concrete is
suitable for the conditions of handling and placing and when concrete hardens, it
shall have the required strength, durability and surface finish. The Contractor
shall get approval of Engineer to such proportions before he starts concreting.
However, such approval shall not relieve the Contractor of his responsibility to
produce concrete having compressive strengths as laid down in the foregoing
Table.
No departure from the approved proportions will be permitted during the works
unless and until the Engineer gives written authorisation for any change in
proportion. The Engineer shall have authority at any time to check whether the
mixing of concrete is being carried out according to the approved proportions.
4.4.2 For the all major and important R.C. works and for all special works, the design of
mixes shall be made by the Contractor at his own cost, for each grade of concrete
as well as for various workability. The design of mixes shall be made according
to I.S. 10262-1982 or any other approved standard methods.
4.4.3 The concrete made by designing the mix is termed hereinafter as "Design Mix
Concrete".
4.4.4 The cement content for various grades of concrete shall be based on design mix.
However, irrespective of requirement of cement found out from design mix,
minimum & maximum cement content of concrete shall be in accordance with
Clause No 8.2.4.1 & Clause No 8.2.4.2 of IS 456-2000 respectively.
4.5 Water/Cement Ratio
4.5.1 Where a particular water/cement ratio is stipulated in the design or drawing along
with the characteristic grade of concrete the design of mix shall be carried out by
adjusting the other variable factors to obtain the characteristic strength of concrete
with stipulated water/cement ratio.

4.5.2 In the structures where the impermeability and shrinkage of concrete have an
important bearing on the durability and serviceability of the structures, such as
water retaining structures, basements, underground premises, tunnels, pump
houses, exposed structures near sea side or deserts, prestressed structure, thin pre-
cast members etc. the water cement ratio shall be kept low and preferably not
exceeding 0.45.
4.5.3 The water cement ratio, as achieved in the Mix Design, or as specified in the
drawings shall be adhered to strictly and shall not be varied without the permis-
sion of the Engineer.
4.6 Workability
4.6.1 The workability of fresh concrete shall be such that the concrete is just suitable for
the conditions of handling & placing so that after compaction if becomes
completely consistent and homogeneously surrounds all the reinforcement and
completely fills the formwork.
4.6.2 The workability of fresh concrete at the place of batching/mixing shall be measured
by compacting factor test and at the place of disposition by means of slump test.
During the finalisation of Trial Mixes, the relationship between compacting factor
and slump test shall be established for each grade of concrete as well as for
various levels of workability. The workability tests shall be carried out in
accordance with IS:1199-1959.
4.6.3 Normally, in the condition of low water cement ratio as well as for medium/high
workability, the workability shall be achieved by increasing the cement content, in
consistent with added water.
4.6.4 In cases where the cement content is to be limited to reduce the heat of hydration,
and the water/cement ratio is also to be kept low to reduce the permeability or due
to other requirements the desired workability may be achieved with use of limited
doses of plasticiser or air entraining agent. In such cases the method of mixing
and dosage of the plasticiser/air entraining agent shall be according to the
manufacturer's specification and with the approval of the Engineer.
4.6.5 The usual limits of consistency for various types of structures are given below :
Limits of consistency
Degree of Slump in mm with standard - Use for which concrete is

workability Cone suitable as per IS:1199
Minimum Maximum
Very low 0.0 25.0 Large mass concrete structure
with heavy compaction
equipment, roads and the like.
Low 25.0 50.0 Un congested wide and
shallow R.C.C structures
Mediumm 25.0 75.0 Deep but wide R.C.C

structures with congestion of

reinforcement and inserts
High 75.0 125.0 Very narrow and deep R.C.C

structures with and inserts
congestion due to
reinforcement
Note : Not withstanding any thing mentioned above, the slump to be obtained for work in
progress shall be as per direction of the Engineer. With the permission of the
Engineer, for any grade of concrete, if the water has to be increased in special
cases, cement shall also be increased proportionately to keep the ratio of water to
cement same as adopted in trial mix design for each grade of concrete. No extra
payment will be made for this additional cement.
4.7 Durability
The durability of concrete, depending on the exposure condition, is to be taken

into account while designing the mix. For given aggregates, the cement content
should be sufficient to make sufficiently low water cement ratio and Appendix A
of IS: 456-2000 shall be taken as guideline for durability considerations.
4.8 Trial mixes
4.8.1 After approval of the Mix Design by the Engineer, the Contractor shall make in
presence of Engineer the Trial Mixes for each grade of concrete as well as for
required workability.
4.8.2 Before starting the trial mixes, necessary preparatory works like sieve analysis of
the aggregates, determination of densities of different ingredients and moisture
contents in the aggregates, shall be completed according to the I.S. Codes 383-
1970 and 2386-1963.
4.8.3 Each trial mix shall be handled and compacted by the method which the
Contractor proposes to use for that mix in the works and the mixes shall not show
tendency of inadequate compaction by the method proposed.
4.8.4 The compacting factor and the slump of each trial mix shall be determined
immediately after mixing and the values shall not exceed the maximum value
obtained in the mix design.
4.8.5 Six numbers of 150 mm test cubes shall be made from each trial mix. These shall
be cured and tested in accordance with relevant I.S. codes. In order to have the
specified characteristic strength in the field, the concrete mix as designed in the
Design Mix shall have higher average compressive strength depending on the
degree of quality control at site. If the size and special requirement of the work so
warrants, the trial may be extended to cover larger ranges of mix proportions as
well as other variables such as alternative source of aggregates, maximum size and
grading of aggregates and different type and brands of cement.

4.8.6 Before commencement of the concreting works of particular grade of concrete, the
Contractor must complete the work of trial mixes and subsequent testing of the
test cubes obtained therefrom the design of the Approved Mix for that particular
grade of concrete.
4.8.7 The entire cost of all the trial mixes including all the preparatory works for trial
mixes, preparation of test cubes and their testing shall be borne by the Contractor.
4.9 Nominal Mix Concrete
4.9.1 Nominal mix concrete may be used for all concrete of Grade M-10 and below. If
design mix concrete cannot be used for any reason for Grade M-15 & M-20,
nominal mix concrete may be used with the permission of Engineer, Nominal mix
concrete shall not be used, in any case for Grade of concrete above M-20.
4.9.2 The proportioning of materials for nominal mix concrete shall be in accordance
with Table-3 of clause 8.3 of I.S. 456-2000. The stipulations of Clauses 8.3.1 &
8.3.2 of IS: 456-2000 shall also be taken into consideration.
4.10 Volumetric mix concrete
Where concrete is specified in volumetric proportions such as 1:4:8, 1:3:6, 1:2:4,

1:1 1/2:3, 1:1:2 etc., in the schedule of items, coarse and fine aggregates shall be
measured by volume and cement by weight. The water cement ratio shall be
within 0.45 to 0.70 depending upon the workability.
4.11 Batching of Concrete
4.11.1 Cement
Cement shall always be batched by weight. A separate weighing device shall be

provided for weighing cement. Where the weight of cement is determined by
accepting the weight per bag, number of bags shall be weighed separately to
determine the average net weight of cement per bag and the same shall be checked
regularly
4.11.2 Aggregates
4.11.3 For both Design Mix concrete and Nominal Mix concrete, the aggregates (coarse
and fine) shall be batched by weight.
4.11.4 In particular cases, or where weigh-batching is not possible proportioning by

volume batching may be allowed by the Engineer, provided the Contractor
guarantees the uniformity of aggregates through out the period of construction.
For this purpose, the Contractor shall submit to the Engineer sufficient data
indicating the weight/volume relationship of aggregates for different types of
concrete and after such approval, periodic checks on the weight/volume
relationship of the aggregates shall be made by the Contractor to the satisfaction of
the Engineer. Where aggregates are moist and volume batching is adopted,
allowance shall be made for bulking in accordance with I.S. 2386 (Part-III)-1963.

4.11.5 Suitable adjustments shall be made for the variation in the weight of aggregates
due to variation in their moisture contents.
4.12 Water
4.12.1 Water may be measured either by weight or by volume. When measured by

volume, it shall be by well calibrated conical shaped jar or vessel or from a
calibrated tank fitted to the mixer.
4.12.2 Adjustment of water due to moisture contents in coarse and fine aggregates
It is very important to maintain the water cement ratio constant at its correct value.
For the correct determination of amount of water to be added in the concrete mix,
to maintain the water cement ratio constant, the amount of moisture content in
both coarse and fine aggregates shall be taken into consideration, be as frequently
as possible, the frequency for a given job being determined by the Engineer
according to weather conditions.
4.12.3 Determination of moisture content in the aggregates
Determination of moisture content in the aggregates shall be according to I.S.

2386 (Part-III)-1963. Where tests are not conducted, the amount of surface water
may be estimated from the following table :
Aggregates Surface water carried by Aggregates

% by weight Lit / m3
Very wet sand 7.5 120
Moderately wet sand 5.0 80
Moist sand 2.5 40
Moist gravel & stone 1.25 - 2.5 20-40
chips**
** - Coarser the aggregate, less the water it will carry.
4.12.4 Admixtures
Any solid admixture, to be added, shall be measured by weight, but liquid or semi-
liquid admixture may be measured by weight or volume.
4.12.5 Accuracy of batching
The accuracy of batching shall be within the following tolerance:
Cement within plus or minus 2% by weight.

Aggregate within plus or minus 5% by weight.
Water within plus or minus 0.5% by weight.
4.13 Mixing & Transportation of concrete
4.13.1 Mixing of Concrete

4.13.1.1 Machine mixing
Concrete shall always be mixed in mechanical mixer. Water shall not, normally,
be charged into the drum of the mixer until all other ingredients are already in the
drum and mixed for at least one minute. Mixing shall be continued until there is
uniform distribution of materials and the mass is uniform in colour and
consistency. The mixing time from the time of adding water shall be in
accordance with IS: 1791-1985 but in no case less than 2 minutes or at least 40
revolutions.
4.13.1.2 Hand mixing
When hand mixing is permitted by the Engineer it shall be carried out on a water
tight platform and care shall be taken to ensure that mixing is continued until the
mass is uniform in colour and consistency. In case of hand mixing 10% extra
cement shall be added to each batch at no extra cost to the Owner.
4.13.2 Transportation of concrete
4.13.2.1 Concrete shall be transported from the place of mixing to the place of placing
concrete as rapidly as practicable by such means which will prevent the
segregation or loss of any of the ingredients and maintain the required workability.
No water shall be mixed with the concrete after it has left the mixer.
4.13.2.2 Where concrete is transported over long distances, the Contractor shall provide
suitable means by which different grades of concrete are readily identifiable at the
place of final deposit.
4.13.3 Actions before placement of concrete
4.13.3.1 Programme of works
At the beginning of every fortnight, the contractor shall give his detailed
concreting programme for that fortnight to the Engineer. Such programmes, shall
specify all information such as the locations where concrete is to be poured,
type/grade of concrete, volume of concrete to be poured, number and Type of
vibrators proposed to be used as well as proposed to keep as standby, number of
skilled technicians and supervisors proposed to be engaged, the proposed time and
period of pouring etc.
4.13.3.2 Checking & approval
Before placement of concrete, the contractor shall get all the form works,
reinforcements, inserts, conduits, openings, surface preparation etc., checked and
approved by the Engineer. To facilitate such checking, the contractor shall
complete all his works according to the drawings and specifications well in
advance before placement of concrete at least 36 hours for all
major/important/complicated works and 24 hours for all minor/ordinary/simple
works. The checks are purely in the interest of the work and to draw the
contractor's attention to his contractual obligations to execute the works according
to the drawings/specification and do not relieve the contractor from his

responsibility in getting the end results for the quality & strength of concrete and
for maintaining the shape, level & dimensions of the finished concrete, as well as
the inserts, openings, other features within the tolerance limits.
4.14 Preparatory Works/Surface Preparation
4.14.1 For concrete directly on earth foundation
4.14.1.1 Earth foundation on which direct placement of concrete is specified, shall be

rammed and consolidated as directed by the Engineer such that it does not crumble
and get mixed with concrete during or after placement. If the foundation is quite
wet, the same shall be kept dry and then sufficiently consolidated, if necessary, a
thin top layer of the wet soil shall be removed and replaced by sand or other
suitable materials as directed by the Engineer without any extra cost to the Owner.
Care shall also be taken that earth from the sides also does not get mixed with the
concrete, during or after placement, before it has sufficiently set and hardened.
4.14.1.2 The earth foundation, over which concrete is to be placed direct, shall not be kept
abandoned at the specified level and concrete shall be placed immediately
following the final preparation of the formation otherwise suitable measures shall
be taken, as directed by the Engineer without any extra cost to the Owner.
4.14.2 For construction joints
All such joints shall have continuous square bond grooves to produce a substantial
and water-tight key. Where the placement of concrete has to be resumed on a
surface which has hardened, it shall be roughened, cleaned by wire or bristle
brushing, compressed air, water jet etc., and thoroughly wetted. For vertical
construction joints a neat cement slurry shall be applied on the surface immediate
before the placement of concrete. For horizontal joints the surface shall be
covered with a layer of freshly mixed mortar about 10 to 15 mm thick composed
of cement and sand in the same proportion as the cement and sand in the concrete
mix and applied immediately before placing of the concrete. On this surface (i.e.
on the surface of joints) a layer of concrete not exceeding 150 mm in thickness
shall first be placed and shall be well rammed against old work, particular
attention being paid to corners and close spots. To ensure water tightness, care
shall be taken to punn concrete properly against the old surface.
4.14.3 (a) On vertical surfaces of masonry
When the concrete is placed on the vertical surface of masonry (as in the case of
thin concrete fins projected from the vertical masonry surface), a groove of
dimension as directed by the Engineer shall be cut in the masonry to ensure a
proper bond and the surface shall be cleaned thoroughly. Before the placement of
concrete, the surface shall be kept moist by spraying water at least for the period
of 2 hours and a thick coat of cement slurry shall be applied immediately before
the placement of concrete.

b) Over walls
Building paper over average 12mm thick cement sand bearing plaster of 1:4 mix
with neat cement finish shall be provided at the bearings of slabs over walls as
directed by the Engineer.
4.14.4 Inside the formwork (cleaning, surface preparation etc.,)
The interior of the form works, where the concrete is to be placed, shall be
thoroughly washed by high pressure water jet or air jet to completely clean the
entire volume from all sort of dirts, grease/oil, foreign and deleterious materials
etc. The reinforcement shall be completely clean and free from all sorts of dirts,
grease/oil, rust, foreign/deleterious materials etc., Before placement of concrete,
the form works coming in contact with concrete, shall be coated with form oil or
raw linseed oil material or provided with any approved material to prevent
adhesion of concrete to the form work, but utmost care shall be taken so that such
oily material do not come in contact with the reinforcement.
4.15 Placing and Compaction of Concrete
4.15.1 The concrete shall be placed and compacted before setting commences & should
not be subsequently disturbed. No water shall be mixed with the concrete after it
has left the mixer. Method of placing should be such as to preclude segregation.
Approved mechanical vibrator shall be used for compacting concrete, and concrete
shall not be over vibrated or under vibrated.No concrete shall be placed until the
place of deposit has been thoroughly inspected and approved by the Engineer. all
inserts and embedments properly secured in position and checked and forms
properly oiled. No concrete shall be placed in the absence of the Engineer.
4.15.2 Concrete shall be placed on clean bed having the designed level. The bed shall be
cleaned of all debris and other objectionable materials. Seepage water, if any,
shall be controlled or diverted.
4.15.3 Concreting shall not be carried on during rains unless all precautions have been
taken by the Contractor and necessary permission has been given by the Engineer.
Suitable measures shall be taken to control the temperature of concrete.
4.15.4 Where plums are permitted in massive concrete, they shall be washed and
carefully placed. No stone shall be closer than 30 cm to an exposed face, nor
nearer than 15 cm to an adjacent stone.
4.15.5 Concrete shall not be dropped from a height of more than 2m except through a
chute, the design and type of which shall be subject to approval of the Engineer.
4.15.6 The concrete shall be placed, spread and compacted by approved mechanical
vibrator. Vibrators shall not be used for pushing concrete to adjoining areas.
4.15.7 For members involving vertical placing of concrete (eg. columns, walls etc.,),
each lift shall be deposited in horizontal layer extending the full width between

shuttering and of such depth that each layer can be easily and effectively vibrated
and incorporated with the layer below by means of compaction.
4.15.8 For member involving horizontal placing of concrete (e.g. slabs, beams etc.,) the
concrete shall be placed along the line of starting point in such quantities as will
allow members to be cast to their full depth along the full width between side
shuttering and then gradually brought towards the finishing point along its entire
front parallel to the starting line. Vibration and surface finish shall follow behind
the placement as closely as possible.
4.15.9 Utmost care shall be taken to avoid the displacement of reinforcements/embedded

parts or movement of formwork or damage to faces of the form work or transmis-
sion of any harmful vibration/shocks to the concrete which has not yet hardened
sufficiently.
4.15.10 All members shall be concreted at such a rate that no cold joint is formed and
fresh concrete is placed always against green concrete which is still plastic and
workable.
4.15.11 Should any unforeseen occurrence results in a stoppage of concreting for one hour
or such other time as might allow the concrete, already placed, to begin to set
before the next batches can be placed, the Contractor shall make at his own cost,
suitable tongue, and groove construction joint, as approved by the Engineer. Any
additional reinforcement required as directed by the Engineer shall also be
provided by the Contractor at his own cost. Before placement of new batches of
concrete over that construction joint, the surface preparation according to this
specification stipulated earlier, shall be done by the Contractor at his own cost.
4.15.12 The concrete shall be worked well up against whatever surface it adjoins and
compacted to such a degree that it reaches its maximum density as a homogeneous
mass, free from air and water holes and penetrates to all corners of moulds and
shuttering and completely surrounds the reinforcement. All measures shall be
taken to make the shape, size, and location of the finished concrete including its
embedments, holes, openings etc., well within the accepted tolerance limit.
4.16 Construction Joint & Cold Joints
4.16.1 Construction joints
4.16.1.1 Normally, the construction joints including crank inducing joints shall be
constructed as per locations and details indicated on the drawings.
4.16.1.2 Where the location of the joint is not specified in the drawings, it shall be in
accordance with the following guide lines:
(a) In Columns
(i) In case of Projection from basement slab, 300 mm from the top of base
slab or 75 mm from the top of the haunches whichever is higher.
(ii) In framing of beam at different elevation, 75 mm below the lowest soffit

of the beam and in case of projection from beams and slabs 75 mm from

the top surface of the beam/slab or at the top surface of beam/Slab

whichever facilitates formwork.
(iii) For columns under flat slabs 75 mm below the lowest soffit of the slab.
(b) In walls (horizontal construction joints)
(i) Walls projecting from : 300 mm from top of

base slab base slab
(ii) Walls supporting the : 75 mm from the

suspended slab lowest soffit of the
slab
Note :
In the case of water retaining structures and structures under the influence of
ground water, approved water bars of suitable size shall be provided to make the
joint completely water-tight.
(c) In beams
Beams shall be cast, as a rule, without a joint. But if provision of a joint is

unavoidable, the joint for simply supported beam shall be vertical and at
the middle of the span ; in continuous beam, the same shall be at the point
of minimum shear force.
(d) In suspended slabs
(i) In slab of small span, there shall be no construction joints.
(ii) In slabs of large span and continuous slabs, construction joint, if allowed
by the Engineer shall be vertical at the middle of span and at the right
angles to the principal reinforcement.
(e) In walls (Vertical construction joint)
As a rule, walls shall be cast monolithically without any vertical

construction joint, unless specified in the drawing. However, for a long
wall, the Engineer may allow vertical construction joint and the same
shall be at the place of minimum shear force. In water retaining structures
and in structures under the influence of ground water approved water bars
of suitable size shall be provided to make the joints completely water
tight.
(f) In slabs resting on ground
(i) For Plain concrete
Concreting shall be done in alternate panels not exceeding 10 sq.m in

area. The largest panel dimension shall be 5 m.

(ii) For nominally reinforced slab
The area of pour shall not exceed 40 sq.m and the maximum panel
dimension shall not exceed 8m.
For the basement slabs which act as structuralmember there shall be no

construction joint.
(g) In ribbed beam
The beams shall be cast monolithically with the slab in one continuous
operation.
4.16.1.3 In all construction joints the reinforcements shall pass through as per drawings and
the same shall not be disturbed in any way.
4.16.1.4 The vertical construction joints shall be provided by insertion of board keeping
provision for passage of reinforcement/fixtures / embedments. All construction
joints shall be made to form a tongue and groove joint.
4.16.2 Cold joint
An advancing face of a concrete pour, which could not be covered before expiry
of initial setting time for unexpected reasons, is called a cold joint. The
Contractor shall remain always vigilant to avoid cold joints. If however, a cold
joint is formed due to unavoidable reasons, the following procedures shall be
adopted for treating it :
(a) If the concrete is so green that it can be removed manually and if vibrators
can penetrate the surface without much effort, fresh concrete can be
placed directly over the old surface and the fresh concrete along with the
old concrete shall be vibrated systematically and thoroughly.
(b) In case the concrete has hardened a bit more than (a), but can still be
easily removed by a light hand pick, the surface shall be raked thoroughly
and the loose concrete removed completely without disturbing the rest of
the concrete in depth. Then a rich mortar layer of 12 mm thickness, shall
be placed on the cold joint and then the fresh concrete shall be placed on
the mortar layer and vibrated thoroughly, penetrating deep in to the layer
of concrete.
(c) In case the concrete at the joint has become so stiff that it cannot be
remoulded and mortar or slurry does not rise in spite of extensive
vibration, a tongue and groove joint shall be made by removing some of
the older concrete and the joint shall be left to harden at least for 12-24
hours. It will then be treated as regular construction joint and the surface
preparation of the same, before placement of concrete, shall be as
described in the appropriate clauses of these specifications.
4.17 Requirements for Concreting in Special Cases
4.17.1 Concreting in deep lifts

Placing of concrete in lifts exceeding 2 M in columns and walls is in the category

of deep lifts.
4.17.1.1 Before commencement of work, the contractor shall submit for the approval of the
Engineer, the details of the methods he proposes to adopt for concreting.
4.17.1.2 The placement of concrete shall preferably be by tremie, chute or any other
approved method.
4.17.1.3 In structures of heavy/complicated reinforcement or in complicated form works,

the contractor shall provide sufficient number of windows in the form works as
directed by the Engineer to check the placement and compaction of concrete in
different stages. Such windows shall be closed as soon as the concreting reaches
the bottom level of the same.
4.17.2 Concreting under water
When it is necessary to deposit concrete under water, the special requirements,

over and above those of this specification shall be in accordance with Clause 13.2
of IS: 456-2000.
4.17.3 Cold weather concreting
When conditions are such that the ambient temperature may be expected to be 4.5
C degree or below during the placing and curing period, the work shall conform to
IS: 7861 (Part-II)-1981.
4.17.4 Hot weather concreting
When concreting in very hot weather the Contractor shall take all precautions as
stipulated in IS: 7861 (Part-I)-1975 and stagger the work to cooler parts of the day
to ensure that the temperature of wet concrete used, specially in massive structure,
does not exceed 38 degree 'C'.
Positive temperature control by methods like pre-cooling, post cooling or cooling

of concrete by circulating cold water through small embedded pipe lines inside
concrete, if required, shall be specified and shall be undertaken.
4.18 Finishes to Exposed Surfaces of Concrete
The Contractor is to include in his quoted rate for concrete, the provision of
normal finishes in both formed & unformed surfaces as and where required by the
Engineer without any extra cost to the owner. Some common finishes are
indicated below:
4.18.1 Surface which do not require plastering
Surface in contact with casings shall be brought to a fair and even surface by
working the concrete smooth against casings with a steel trowel while it is being
deposited and also by working over the surface with a trowel immediately after the
removal of the casings or centerings, removing any irregularities and stopping air
holes, etc. Use of mortar plaster is not permissible for correcting levels, removing

unevenness etc. However, if, in the opinion of the Engineer, such plastering is
unavoidable then the thickness of plaster shall in no case exceeds 5 mm and the
plastering shall be in cement and sand mortar.(1:3).
4.18.2 Exposed surfaces which need plastering
Surfaces of beams/columns flushing with the block work or other structures where
intended to plaster, shall be hacked adequately as soon as the shuttering is
stripped off so that proper bond with the plaster can develop.
4.18.3 Surface for non-integral finish
Where a non-integral finish such as floor finish is specified or required, the

surface of the concrete shall be struck off at the specified levels and finished
rough.
4.18.4 For monolithic finish
Where no more finishing course is to be applied as in the case of basement floor,

industrial flooring or the screed concrete flooring etc, the concrete shall be
completed and struck off at the specified levels and sloped with a screed, board
and then floated with a wooden float. Steel troweling is then started after the
concrete has hardened enough to prevent the excess of fines and water to rise to
the surface but not hard enough to prevent proper finishing. Troweling shall be
such that the surface is flat, smooth and neatly finished.
4.19 Curing of Concrete
4.19.1 General
The purpose of curing is to prevent loss of moisture from the concrete itself so that
the cement inside the concrete is sufficiently hydrated which of course is slow and
prolonged process. As soon as the concrete has hardened sufficiently the curing
shall be started. To cure the concrete properly and sufficiently is also the sole
responsibility of the contractor.
4.19.2 Different methods of curing
Any one of the following methods may be used for curing as approved by the
Engineer.
(a) Curing by direct water.
(b) Curing by covering the concrete with absorbent material and kept damp.
4.19.3 Curing by direct water
This is done either by ponding or spraying water.
(a) Ponding

Ponding is widely used for curing slab and pavements. Earth bunds are formed
over the slabs and water is pumped or poured into them and the same is
replenished at interval to make up for the loss of evaporation. As this type of
curing is one of the best methods, 10 days of curing after final setting is sufficient.
(b) By spraying water
Curing is done by spraying water by suitable means at approved time intervals.

While spraying, it shall be ensured that the complete area is covered. In order to
avoid cracking, cold water shall not be applied to massive members immediately
after striking the form work, while the concrete is still warm. Alternate wetting
and over drying shall be avoided.
Curing by spraying water shall be continued at least for 18 days after final setting.
4.19.4 Curing of concrete with absorbent material kept damp
The entire concrete surface is covered either with hessian, burlap, sawdust, sand,
canvas or similar material and kept wet continuously for at least 12 days after final
setting.
4.20 Testing of Concrete
4.20.1 General
The Contractor shall carry out, entirely at his own cost, all sampling and testing in
accordance with the relevant I.S. standards and as supplemented herein. The
Contractor shall get all tests done in approved Laboratory and submit to the
Engineer, the test result in triplicate within 3 days after completion of the test.
4.20.2 Consistency test (tests of fresh concrete)
4.20.2.1 At the place of deposition/pouring of the concrete, to control the consistency,

slump tests and/or compacting factor tests shall be carried out by the Contractor in
accordance with I.S. 1199-1959 as directed by the Engineer.
4.20.2.2 The results of the slump tests/compacting factor tests shall be recorded in a
register for reference duly signed by both the Contractor and the Engineer. That
register shall be considered as the property of the Owner and shall be kept by the
Contractor at site in safe custody.
4.20.2.3 The results of the slump tests/compacting factor tests shall tally, within accepted
variation of plus or minus 12% with the results in the respective design mix, in
case of mix design concrete and with the values indicated in the table under clause
6.1 of IS: 456 in case of nominal mix concrete.
4.20.2.4 For any particular batch of concrete, if the results do not conform to the
requirements as specified in 4.20.2.3 or do not conform to any requirement of this
specification, the Engineer has the right to reject that batch and the Contractor
shall remove the same immediately from the site, at no cost to the Owner.

4.20.3 Strength test of concrete
4.20.3.1 While placing concrete, the Contractor shall make 6 nos. of 15 cm test cubes from
particular batches of concrete as desired by the Engineer. The frequency of
taking test cubes shall be either according to clause 14.2 of IS: 456-2000 or as
4.20.3.2 The cubes shall be prepared, cured and tested according to IS: 516-1959. Out of 6
nos. of test cubes 3 shall be tested for compressive strength at 7 days after casting
and the remaining 3 at 28 days after casting.
4.20.3.3 A register shall be maintained at site by the Contractor with the following details
entered and signed by both the Contractor and the Engineer. That register shall be
considered as the property of the Owner.
(a) Reference to the specific structural member

(b) Mark on cubes
(c) The grade of concrete
(d) The mix of concrete
(e) Date and time of casting
(f) Crushing strength at 7 days
(g) Crushing strength at 28 days
(h) Any other information directed by the Engineer.
4.20.4 Acceptance criteria for test cubes
The acceptance criteria of concrete on strength requirement shall be in accordance

with the stipulations under clause 15 of IS: 456-2000.
Non-destructive tests on hardened concrete
If there is doubt about the strength or quality of a particular work or the test results
do not comply with the acceptance criteria as stipulated under clause 5 of IS: 456-
2000, non-destructive tests on hardened concrete like core test and/or load tests or
other type of non destructive tests like ultrasonic impulse test etc. shall be carried
out, as may be directed by the Engineer, by the Contractor at entirely his own cost.
4.20.5.2 The core tests and load tests shall comply with the requirements of clause 16.3 and
16.5 of IS: 456-2000 respectively. In case of other types of special tests like
ultrasonic impulse test etc., the stipulation of clause 16.6 of IS: 456-2000 shall be
applicable.
4.20.6 Concrete below specified strength
In case of failure of test cubes to meet the specified requirements the Engineer
may take one of the following actions:-
1) Instruct the Contractor to carryout additional test and/or works to ensure

the soundness of the structure at Contractor's expense.
2) Reject the work and instruct that section of the works to which the failed
cubes relate shall be cut out and replaced at Contractor's expense and the

resultant structures affected due to such rejection shall be made good at

contractor's expense.
3) Modification/remedial measures if approved by the engineer to be carried
out at contractor's expense.
4) Accept the work with reduction in the rate in appropriate item subject to
the provisions of clause 15 of IS 456-2000 provided it is technically
acceptable. The reduction in the rate shall be as given below :-
i) When test strength of the sample is above 90% of the characteristic

strength, payment shall be made 10% less than the contract rate.
ii) When test strength of the sample is between 80-90% of the characteristic
strength, payment shall be made 25% below than the contract rate.
4.20.7 Concrete failed in non-destruction tests
In case the test results of the core tests or load tests in a particular work do not
comply with the requirements of respective clause (16.3 for core test and 16.5 for
load tests) of IS: 456-2000 the whole or part of the work concerned shall be
dismantled and replaced by the Contractor as may be directed by the Engineer at
no extra cost to the Owner and to the satisfaction of the Engineer. No payment for
the dismantled concrete including relevant form work, reinforcement, embedded
fixtures etc. shall be made. In the course of dismantling if any damage occurs to
the adjacent structure or embedded item, the same shall be made good, free of
charge by the Contractor, to the satisfaction of the Engineer.
4.21 Steel Reinforcement
4.21.1 Material
Material shall be as specified in the respective schedule of Items. The

specifications of materials shall be as per Part-I.
4.21.2 Storage
Steel reinforcement shall be stored in such a manner that they are not in direct
contact with ground. Bars of different classifications and sizes shall be stored
separately. In cases of long storage or in coastal areas, reinforcement shall be
stacked above ground level by at least 15 cm, and a coat of cement wash shall be
given to prevent scaling and rusting at no extra cost of the owner.
4.21.3 Bending and placing
Bending and placing of bars shall be in conformity with IS: 2502-1963 "Code of
Practice for Bending and Fixing of Bars for Concrete Reinforcement" and IS: 456
-2000 "Code of Practice for Plain and Reinforced Concrete".
4.21.4 Welding of Reinforcement

Welding of mild steel reinforcement bars conforming to IS:432 (Part-I)-1982 shall

be done in accordance with IS: 2751 -1979 "Code of Practice for Welding of Mild
Steel Bars used for Reinforced Concrete construction" with additional precaution
that for lap welded joints the throat thickness of weld beads shall be at least 3 mm
or 0.6 times the nominal size of weld (which is the radius of bar) whichever is
more.
Welding of cold worked high strength deformed bars conforming to IS: 1786-
2008 shall be done using electric arc welding process using low hydrogen
electrodes (Ferro Weld- I or Ferro Weld-II or equivalent). Oxy-acetylene welding
shall not be used.
Butt welding of bars upto 32 mm diameter for vertical splices shall be done either
by single bevel groove weld or double bevel groove weld, with bevel angle 45
degree. Butt welding of bars upto 32 mm diameter for horizontal splices shall be
done either by single Vee-groove weld or double Vee-groove weld with cham-
fered angle of 45 degree to 60 degree. The diameter of welded joint shall be 1.2
times the diameter of bar. Edge preparation for butt welding shall be done by
shearing, machining and grinding. Oxy-acetylene flame shall not be used for
cutting. Chamfered faces shall be smooth finished by hand file if required.
Lap welding of bars upto 20 mm diameter shall have a minimum bead length of
12 times the diameter of bar or 200 mm whichever is more arranged on one or
both sides. The throat thickness of weld beads shall be 5 mm or 0.75 times the
nominal size of weld (which is the radius of bar) whichever is more. In case of
unsymmetrical lap weld with weld bead on one side only, the maximum length of
each weld bead shall be 6 times the diameter of bar or 100 mm (whichever is
more), separated by an equal length in between weld beads. Splice bars used in
symmetrical weld joint shall have same diameter as the parent bars. Lap joint with
single splice bars shall have weld beads on both sides.
Lap welding of bars above 20 mm shall be done using splice plate or splice angle.
Thickness of splice plate shall not be less than 0,65 times the diameter of bar and
width shall not be less than twice the diameter of bar. The size of splice angle
shall be such that its area of cross section is at least 1.62 times the area of bar
being spliced.
More than one third of the bars shall not be welded at any one section and welded
joints shall be staggered at a distance of 50 times the diameter of bars. Welding
shall not be done at bends or curved parts of bars and it shall be located at least at
a distance of 50 times the diameter of bar from bends.
Tests
Test pieces of welded bars shall be selected and tested in accordance with the
provisions of IS: 2751-1979. The number of tests will be as laid down in IS:
2751-1979 or such larger number as the Engineer may decide having regard to the
circumstances.
4.21.5 Cleaning

All steel for reinforcement shall be free from loose scales, rust coatings, oil,
grease, paint or other harmful matters immediately before placing the concrete.
To ensure this, reinforcements with rust coatings shall be cleaned thoroughly
before bending/placement of the same.
4.21.6 Placing in position
All reinforcements shall be accurately fixed and maintained in positions as shown

on the drawings and by adequate means like mild steel chairs and/or concrete
spacer blocks as required. Bars intended to be in contact at crossing points, shall
be securely tied together at all such points by 20G annealed soft steel wire or by
tack welding in case of bars larger than 25 mm dia, as may be directed by the
Engineer. Binders shall tightly embrace the bars with which they are intended to
be in contact and shall be securely held. The vertical distance between successive
layers of bars shall be maintained by provision of mild steel spacer bars. They
should be spaced such that the main bars do not sag perceptibly between adjacent
spacers.
4.21.7 Clear cover
Clear cover shall be as specified in the drawings. If nothing is specified in the

drawing the clear cover shall be in accordance with the relevant clause of IS: 456-
1978.
Light structural work and embedded metallic parts, conduits
4.21.8.1 Fabrication of metallic parts & light structural works
Fabrication of all structural steel work shall be done in accordance with IS: 800 -
1984 "Code of Practice for use of Structural Steel in General Building
Construction". Workmanship shall match to the best practice in modern structural
shops. Greatest accuracy shall be observed in the manufacture of every part and
all identical parts shall be strictly inter-changeable. Steel work shall be shop fitted
and shop assembled as far as practicable to minimise site work and to meet
transport restrictions. All materials shall be straight and if necessary before being
worked shall be straightened of flattened by pressure and shall be free from twists.
Shearing or flame cutting may be used and the resulting edges shall be clean and
straight. Flame cut edges shall be planed/cleaned by chipping or grinding.
Sheared members shall be free from distortion at sheared edges. Welding and
welded work shall conform to IS: 816 -1969 "Code of Practice for use of metal arc
welding for General Construction in Mild Steel". Mild steel electrodes
conforming to IS: 814-1991 "Specification for covered electrodes for metal arc
welding of mild steel shall be used.
Transportation and Storages
All pieces shall be properly identified and bundled for transportation to work site.
Care shall be exercised in the delivery, handling and storage of material to ensure
that material is not damaged in any manner. Materials shall be kept free of dirt,
grease and foreign matter and shall be stored properly on skids or any other

suitable supports to avoid contact with ground, damage due to twisting, bending
etc.
4.21.8.3 Erection of light structural work
Erection of light structural work shall be carried out in accordance with the
provisions of IS: 800-1984. No component which is bend or twisted shall be put in
place until the defects are corrected. Components seriously damaged during
handling shall be replaced. No riveting, permanent bolting or welding shall be
done until proper alignment has been completed. Whenever field welding is to be
done it shall be in accordance with the requirements of shop fabrication. Shop
paints shall be removed before field welding for a distance of at least 50 mm on
either side of the joints.
4.21.8.4.1 Erection of embedded metallic parts, inserts, conduits
Bolts and inserts shall be securely fixed in position as shown in the drawings,
before commencement of concreting. Bolts shall be checked for accuracy in
alignment on both the axes. Limits of tolerance in alignment and level shall be as
shown in the drawing or described elsewhere in these specifications.
Where bolts are housed in sleeves, special care shall be taken after concreting is
over and has partly set to ensure that the bolts move within the sleeves. The
annular space of the sleeve shall be plugged with suitable stoppers to prevent the
ingress of water, grout, dust, rubbish or other foreign material into it, both during
and after concreting. Opened conduits shall be plugged similarlyand conduits laid
on earth shall suitably encased with Plain Cement Concrete Where channels,
Unshapely profiles or other similar inserts are required to be placed in concrete,
special care shall be taken to keep the grooves of such profiles free from the in-
gress of concrete, slurry etc., by suitable packing material, if necessary.
All threads for bolts and inserts shall be greased at intervals and kept covered to
prevent damage.
4.21.8.4.2 Necessary templates, jigs, fixtures, supports shall be used as may be specified or
required or directed by the Engineer free of cost to the Owner.
Exposed surfaces of embedded materials shall be painted with one coat of

anticorrosive paint or bituminous paint, as desired, without any extra cost to the
Owner. If welding is to be done subsequently on the exposed surfaces of the
embedded parts, the painting for a length of 50mm beyond each side of the weld
line shall be cleaned off.
4.22 Shuttering
4.22.1 General
All shuttering, formwork, supports and staging shall be designed by the Contractor
and be subject to approval by the Engineer. The Contractor shall submit drawings
and calculations to the Engineer for scrutiny when called upon to do so. The
shuttering shall be designed for a live load of 400 Kg/m2 in addition to the weight

of the green concrete, or such other load as the Engineer may specify. The
Contractor shall be responsible for the correctness and strength of the formwork
including its supports and centering and approval by the Engineer will not relieve
him of his responsibilities.
4.22.2 Material
The staging and supports may be of round or sawn timber or tubular or other
shapes in steel. Round timber shall preferably extend over the full height in one
piece. These shall be securely jointed or otherwise fastened and spaced at suitable
intervals as the design may warrant and shall be suitably braced at regular
intervals horizontally and diagonally.
The form work shall be of steel plate on steel frame, wooden boards with steel
sheet lining, or plywood or seasoned timber board. Where ornamental and curved
surfaces are required the material shall be very good seasoned timber or plywood
which can be shaped correctly.
4.22.3 Fixing
The shuttering shall conform to the shapes, lines, levels and dimensions shown in
the drawing. It shall be fixed in perfect alignment and securely braced so as to be
able to withstand, without appreciable displacement, deflection or movement of
any kind, the weight of all construction, movement of persons and plant. It shall
be so constructed as to remain rigid during the placing and compacting of concrete
without shifting or yielding and shall be sufficiently water tight to prevent loss of
slurry from the concrete.
All props shall be supported on sole plates and double wedges. At the time of
removing props these wedges shall be gently eased and not knocked out. The form
work shall be so designed that the sides are independent of the soffits and the side
forms can be removed easily without any damage or shock to the concrete.
4.22.4 Wrought shuttering
Wrought shuttering shall be such as to produce a first class fair face on the
concrete free from board marks or any other disfigurements. This shall be used
for exposed surfaces where specified or directed by the Engineer. It may be made
of heavy quality plywood or steel sheets having smooth, plain surface.
The joints in shuttering shall be arranged in a regular pattern approved by the

Engineer. Wrought shuttering shall be aligned within a tolerance of 3 mm.
4.22.5 Rough shuttering
Rough shuttering shall be used for all surface of concrete walls, footings etc.,
which are not exposed in the finished work or which are to receive plaster and as
directed by the Engineer. It may be made of timber, ordinary plywood or steel
sheets.

4.22.6 Special provision
4.22.6.1 Wherever concreting of narrow member is required to be carried out within

shutters of considerable depth, temporary openings in the sides of the shutters
shall, if so directed by the Engineer, be provided to facilitate cleaning, pouring and
consolidation of concrete.
4.22.6.2 In liquid retaining structures and structures below ground water level, through
bolts for the purpose of securing and aligning the form work shall not be used.
4.22.6.3 Forms shall be given an upward camber, if so desired by the Engineer, to ensure
that long beams do not have any sag. The camber may be 1 in 250 or as the Engi-
neer may direct.
4.22.6.4 The joints in form work shall be sealed by adhesive tapes or by other means, to
prevent any leakage of slurry or mortar if so directed by the engineer.
4.22.7 Preparation for concreting
Before any concreting is commenced the shuttering shall be carefully examined

for dimensional accuracy and safety of construction. The space to be occupied by
concrete shall be thoroughly cleaned out to remove rubbish, debris, shavings and
saw dust. The surface in contact with concrete shall be coated with an approved
substance such as mould oil or other non-staining mineral oil to prevent adhesion.
Where necessary the surface shall be wetted to prevent absorption of moisture
from concrete. Care shall be taken to avoid the reinforcements coming in contact
with shutter oil.
4.22.8 Removing
4.22.8.1 Removal of forms shall never be started until the concrete has thoroughly set and
aged to attain sufficient strength to carry twice its own weight plus the live load
that is likely to come over it during construction
4.22.8.2 Removal of forms shall not entail chipping or disfiguring of the concrete surface.
Shuttering shall be removed without shock or vibration and shall be eased off
carefully in order to allow the structure to take up its load gradually.
4.22.8.3 Under normal circumstances (generally where temperatures are above 21 degree
'C'), and where ordinary portland cement is used shuttering may be struck after the
expiry of the following periods :-
Walls, columns & vertical faces 24 to 48 hours as may be

Bottom of slab upto 4.5 m span 7 days
Bottom of slab above 4.5 m span, bottom of beam 14 days

and arch, rise upto 6 m span

Bottom of beam and arch rise over 6 m span 21 days
These periods may be increased at the discretion of the Engineer. Special care
shall be taken while striking the shuttering of cantilevered slabs and beams, portal
frames etc.,
4.22.8.4 Before removing the form work, the Contractor must notify the Engineer to enable
him to inspect the condition of the finished concrete immediately after the removal
of the form works.
4.22.9 Contractor's responsibility
Any damage resulting from faulty preparation, premature or careless removal of

shuttering shall be made good by the Contractor at his own expense.
4.22.10 Irrecoverable shuttering
In cases where the shuttering cannot be removed without damaging the structure
itself or where removal of shuttering is rendered impossible due to the nature of
construction or where the Engineer may so instruct, such shuttering shall be
classified as irrecoverable shuttering. However, such abandoning of shuttering
will be permitted only in situations where it will not remain exposed or otherwise
cause damage of any kind.
4.22.11 Metal Forms
Where permanently left-in-place metal forms or deck are shown in drawings or

otherwise ordered to be provided by the Engineer, they shall satisfy the
requirements with regard to load carrying capacity. The metal forms shall be
obtained from a reputed manufacturer, whose performance guarantee shall be
obtained and submitted to the Engineer. Designs and drawings giving full details
shall be submitted to the Engineer in advance for approval.
4.23 Damp Proof Course Concrete
4.23.1 Thickness
It shall be as specified in the drawings or in the items.
4.23.2 Mix
The grade of mix shall be as specified in the drawing or schedule of quantities. If

nothing is specified, the mix shall be 1 part of cement : 1 1/2 part of coarse sand :
3 parts of stone chips. The stone chips shall be 12 mm down graded.
Approved water proofing admixture shall be mixed with cement as per

manufacturer's specifications. The water cement ratio shall be as low as possible
to increase the impermeability of concrete and in no case more than 0.5.

4.23.3 Preparation of base surface
The base surface shall be well roughened by chipping and brushing with steel
brush and shall be cleaned of all dirt, dust, grease, oil and all other foreign &
deleterious materials. Then the surface shall be well moistened with water.
4.23.4 Placing and compaction
Just prior to placement of D.P.C. Concrete, a thick coat of cement slurry shall be
applied on the base surface. The placement shall be as specified for the concrete
in beams. The concrete shall be well compacted to make it dense.
4.23.5 Finishing
When the concrete has set enough but remains still green, the top surface shall be
marked in regular pattern by steel trowel so as to have proper bond with the future
work.
4.23.6 Curing
The D.P. course shall be kept continuously moist at least 10 days.
4.24 Grout
4.24.1 Scope
The scope covers the grouting under base plates, grouting between the joints of
precast concrete, grouting the pockets/holes/opening etc.
4.24.2 Grouting under base plates
Grouting under base plates of equipments/structures shall be of cement mortar 1:2

for thickness upto 25 mm. For thickness exceeding 25 mm, concrete of grade
specified in the drawing or minimum M-20 grade using 10 mm down graded
aggregates shall be used. The grout shall be placed in position well rammed until
the whole space is completely filled with concrete. No vibrators shall be used.
Quick setting cements shall be used in the preparation of mortar or concrete,
where so specified.
The grout shall either be "dry" concrete or mortar or "wet expanding" concrete or
mortar as the Engineer may direct. A dry grout shall have a slump not exceeding
6 mm. It shall be rammed under the horizontal surface with the aid of suitable
tools. A "wet expanding" grout shall have a slump of at least 125 mm but not
exceeding 225 mm. To this shall be added an expanding admixture approved by
the Engineer and in accordance to the Manufacturer's instructions.
4.24.3 Grouting the pockets/holes in concrete
Depending upon the size of the pockets/holes in the concrete, the mix of the grout
shall be either of concrete or of cement sand mortars. Normally the grade of such
concrete/mortar shall be M-20 unless specified otherwise. In filling the holes of

foundation bolts and expanding admixture of approved type shall be used as per
manufacturer's specification.
4.24.4 Workmanship
4.24.4.1 The surface of the concrete over which grouting is to be applied shall be
thoroughly prepared to provide a clean rough surface. If necessary, chipping shall
be carried out on such surface to make it completely rough. Then the surface shall
be wetted. Bolt pockets shall be cleaned immediately before the base plate is
placed in position. Before grouting the surface shall be thoroughly cleaned with
compressed air/water jet.
4.24.4.2 Before placement of grout, the surfaces (except in the case of bolt holes) shall be
wetted with cement slurry. In case of bolt holes/pockets water from such pockets
shall be thoroughly removed by some suitable means and no cement slurry shall
be applied.
4.24.4.3 Hand mixing is not permitted and the grout shall always be machine mixed. If
however in some special cases where the quantity of grout is so small that it
cannot be machine mixed, hand mixing may be allowed but the same shall be done
under the strict supervision of an experienced supervisor of the Contractor.
4.24.4.4 The grout shall be placed within 30 minutes of being mixed. The grout shall be
poured and then worked into position by suitable means until the space is com-
pletely filled. The Contractor shall take all possible measures during grouting so
that the grout fills the space completely and thoroughly. Where the gap is very
small or unapproachable for the placement of concrete, the Contractor shall grout
by pressure grouting and in that case the mix may be of cement sand mortar of the
appropriate grade but in any case the water cement ratio shall be as low as
possible. Neither "Dry" grout (having slump 6mm or less) nor expanding wet
grout shall be grouted with any type of vibrating machine
4.24.5 Curing
After 10 hours of grouting, the same shall be covered with wet gunny bags and the
surface shall be kept continuously moist at least for 10 days.
4.25 Concreting in Water Retaining Structures
General requirements
The basic specifications as regards 'mix' design, placing, compacting, curing etc.
shall conform to the requirements as specified herein before in this Chapter. Over
and above the materials and workmanship shall conform to the stipulations of IS:
3370 (Part-I & II)-1965 to make dense and impervious concrete. As specified
herein before all the construction joints shall be provided with approved Chemical
treatment. The expansion and construction joints, if any, shall be provided with
the requirements as specified in the drawing or as directed by the Engineer.

4.26 Application of Live Load
The designated live load shall be allowed on any structure only after 28 days, after
proper curing is carried out on the last concrete poured in structure.
4.27 Foam Concrete
This shall be of average 50mm thickness or as specified or as shown on the

drawings. This may be laid in in-situ in suitable panels or in precast blocks. The
insulating properties shall be such that the thermal conductivity shall not exceed
0.125 Kcl m/m2h/degree C. The weight of the insulating material shall be from
0.5 to 0.75 gm/cm3, strength not less than 5 Kg/sq.cm or (0.5N/sq.mm.). In
general, the main ingredients of Foam Concretes are cement, fly ash and foaming
agent and the work shall be carried on by specialised Agencies/Companies. Before
starting the laying of foam concrete sample shall be prepared at site and got tested
for approval of the Engineer.
The foam concrete laid shall be sufficiently strong to take the usual work loads
and standard loads expected on the roof. Any damaged portion shall be removed
and replaced forthwith. Approval of the Engineer shall be taken before laying the
waterproofing over the insulation.
While laying the foam concrete, sample batches of mix shall be kept for test if so
desired by the Engineer.
5.0 Maonry
5.1 eneral
This specification deals with masonry and allied works in foundation, plinth and
superstructure.
5.2 Mterials
For specifications of materials Part-I shall be referred.
5.3 Selection of Mortars
Mortar for masonry shall conform generally to IS: 2250-1981 "Code of Practice
for Preparation and Use of Masonry Mortars", and proportion shall be as specified
in the drawing or in the Schedule of Items.
5.4 Cement Mortar
5.4.1 Cement mortar shall be prepared by mixing cement and sand in specified
proportion. It is convenient to take unit of measurement for cement as a bag of
cement weighing 50 Kg equivalent to 0.035 cubic metre. Sand is measured in
boxes of suitable size (say of 40 x 35 x 25 cm). It shall be measured on the basis
of dry volume. In case of damp sand, the quantity shall be increased suitably to
allow for bulkage in accordance with IS:2386-1963 (part-III) or by any approved
method.

5.4.2 The mixing of the mortar shall be done preferably in a mechanical mixer. This
condition may be relaxed by the engineer taking into account the nature,
magnitude and location of the work.
If mixed in the mixer, cement and sand in the specified proportion shall be fed in
the mixer and mixed dry thoroughly, water shall be then added gradually and wet
mixing continued for at least 3 minutes. In case of hand mixing also after mixing
dry on a water-tight masonry platform, water shall be added and the mortar turned
over and over, backward and forward several times.
5.4.3 Fresh mixed mortar, in case becoming stiff due to evaporation of water may be
retempered by adding water as frequently as needed to restore the requirement of
the consistency but this shall be permitted only upto a maximum of 2 hours from
the time of addition of cement in the mortar.
5.5 Brick Work ( Specification of fly ash bricks added in annexure)
5.5.1 Storage and handling bricks
Bricks shall not be dumped at site. They shall be carefully handled and carefully
stacked in regular tiers to avoid breakage and defacement of bricks and prevent
contamination by mud or other materials. The supply of bricks shall be so
arranged that as far as possible at least two days' requirement of bricks is available
at site at any time. Bricks selected for different situations of work shall be stacked
separately.
5.5.2 Soaking & Cleaning bricks
Bricks required for masonry shall be cleaned to be free from dirt, dust and sand
and fully soaked in clean water by submerging in vats before use, till air bubbling
ceases. The bricks shall not be too wet at the time of use. After soaking they shall
be removed from the tank sufficiently early so that at the time of laying they are
skin dry and stacked on a clean space.
5.5.3 Setting out
The building lines shall be set out by the Contractor as per clause 7 of IS: 2212-
1991 and got checked by the Engineer.
5.5.4 Laying of bricks
5.5.4.1 Brickwork in general shall be as per IS 2212-1991. Bricks shall be laid in English
bond, unless otherwise specified, with frogs upward over a full bed of evenly laid
mortar, and slightly pressed and tapped into final position to the lines levels and
shape as shown in the drawing fully embedded in mortar. All joints including
inside faces shall be flushed and packed. Not more than 8 courses shall generally
be laid in a day. The first course itself shall be made horizontal by providing
enough mortar in the bed joint to fill up any undulations. The horizontality of
courses and the verticality of wall shall be checked very often with spirit level and
plumb bob respectively.

5.5.4.2 Horizontal joints shall be truly horizontal and vertical joints shall line up in every
alternate course. The joints shall not exceed 10 mm in thickness and shall be well
finished and neatly struck. The joints shall be kept uniform throughout the brick
work. All the brick joints of the face works shall be neatly raked out to a
minimum depth of 15 mm with the help of raking tools and the faces of brick wall
cleaned with wire brush to remove any splashes of mortar before the close of the
day's work, while the mortar is still green and the last brick layer shall be cleaned
with wire brush and the frogs free from mortar.
5.5.4.3 Walls coming in contact with R.C.C. structures shall perfectly be bonded with
M.S. inserts or lugs where shown on drawings and the sides butting against the
R.C.C structures neatly and efficiently flashed and packed with rich mortar &
cement slurry at no extra cost (cost of M.S. inserts or lugs used shall be measured
and paid separately under relevant items). Where such lugs are not required to be
provided, brick work shall be built tightly against columns, slabs or other
structural parts, around door and window frames with proper distance to permit
caulked joint. Where drawings indicate structural steel column or beam to be
partly or wholly covered with brick work, bricks shall be built closely against all
flanges and webs, with all spaces between steel and brick work filled solid with
mortar not less than 10 mm thick.
5.5.4.4 Damaged or broken brick or brick bats shall not be used in brick work. Cut bricks
may be used to complete bond or as closers or around irregular openings.
5.5.4.5 Bricks shall not be thrown from heights to the ground, but shall be handled
carefully and put gently in position to avoid damaging their edges.
5.5.4.6 Selected bricks of regular shape and dimension shall be used for face work.
5.5.4.7 Making of grooves, sleeves and chases shall be done, during the construction, to
the lines, levels and position as shown in the drawing or as instructed by the
Engineer. Such sleeves shall slope outward in external walls so that their surface
cannot form channels for the easy passage of water inside.
5.5.4.8 Fixtures, plugs, frames,pipes, inserts etc., if any, shall be built in at the right places
to the lines & levels as shown in the drawings while laying the course and not later
by disturbing the brick work already laid.
5.5.4.9 Brick walls of one brick thick or less shall have one selected face in true plane and
walls more than one brick thick shall have both the faces of wall in true plane.
5.5.4.10 All connected brick work shall be carried out simultaneously with uniform heights
throughout the work, and in exceptional cases, with the approval of the Engineer,
the brick work built in any part of the work may be lower than another adjoining
wall/connected wall by a maximum of one metre and the difference in height of
adjoining wall/connecting wall shall be raked back according to bond by stepping
at an angle not steeper than 45 degree, without sacrificing the necessary bond,
horizontality of layers, verticality of joints and the wall. Toothing shall not be
allowed in brick work, for raking back. The top layer just below the R.C.C slab or
beam shall be laid with frogs down over a layer of mortar on full width.

5.5.4.11 Openings in brick work
Openings shall be made in brick work, which may be of any shape, size, at all
levels, heights or depths, including round openings, as shown in the drawing or as
directed by the Engineer, maintaining the necessary bond using a minimum of cut
bricks. Openings in external face walls, the sills, jambs, soffits of opening may be
rebated and the sill shall be sloped slightly for drainage of rain water.
5.5.4.12 All exposed brick work shall be rubbed down, thoroughly washed, cleaned and
pointed as specified. Where face bricks of specific quality are used the same shall
be rubbed with carborundum stone.
5.5.5 Half-brick masonry
5.5.5.1 Half-brick work shall be done in the same manner as for brick work except that all
courses shall be laid in stretchers. Both faces shall be true to plane and the joints
raked on both faces.
Where reinforcement is considered necessary or specified and shown in drawing,

M.S. bars or hoop iron shall be provided as stipulated in the Schedule of Items or
as directed by the engineer. The reinforcement shall be cleaned of rust and loose
scale with a wire brush, and shall be laid straight on the mortar and lapped with
the dowel bars provided in the column, securely anchoring them at their ends
where the half-brick wall butts. The batching of mortar usually shall be in the
proportion of 1:4 or as stipulated in the Schedule of Items. Half of the mortar for
the joints shall first be laid and the other half laid after the reinforcement is laid in
position, so that the reinforcement is fully embedded in position.
5.5.6 Brick on edge masonry
The work brick on edge masonry wall in superstructure shall be done in the same
manner as mentioned for brick work except that it shall always be reinforced with
wire mesh netting of approved variety as specified in the item and embedded in
cement mortar at interval as specified in the Schedule of Items. The wire netting
shall be continuously laid and securely anchored with the dowel bars provided &
projecting from the walls/RCC structure or steel structures at their ends where
brick on edge wall butts. The batching of mortar usually shall be in the proportion
of 1:3 or as stipulated in the Schedule of Items.
5.5.7 Protection of brick work
The brick wall shall be protected and covered with gunny bags or water proof
sheets from the effects of inclement weather, rain, frost, etc., during the
construction and until the mortar sets. Care shall be taken during construction that
the edges of jambs, sills and soffits of openings are not damaged.
5.5.8 Curing
All brick works shall be kept moist for 10 days after laying.

5.5.9 Scaffolding
5.5.9.1 Necessary and suitable scaffolding shall be provided at all heights to facilitate the
construction of brick wall. Scaffolding shall be sound, strong and all supports
and other members shall be sufficiently strong and rigid, stiffened with necessary
bracings and shall be firmly connected to the walls securing them against swing
or sway. Planks shall be laid over the scaffolding at required levels. Scaffolding
shall preferably be of tubular steel, although the Engineer may permit other
material, depending upon the circumstances.
5.5.9.2 Scaffolding shall be double, having two sets of vertical supports, particularly for
the face wall and all exposed brick work. Single scaffolding may be used for
buildings upto two storeys high or at other locations, if permitted by the Engineer.
In such case the inner ends of horizontal members shall rest in holes provided in
header course only. Such holes shall not be allowed in pillars under one metre in
width, or immediately near the skew backs or arches. The holes thus left in
masonry shall be filled with bricks set in rich mortar and the surface made good on
removal of scaffolding.
5.5.9.3 If for any reason the Contractor is required to erect scaffolding in property other
than that belonging to the Owner, including municipal corporation or local bodies,
necessary permission shall be obtained by the Contractor from the appropriate
authorities and necessary licensing fees if any shall have to be borne by him.
5.5.9.4 All scaffoldings once erected shall be allowed to remain in position, efficiently
maintained by the Contractor, till all the finishing works required to be done are
completed and shall not be removed without the approval of the Engineer.
The Contractor shall allow workmen of other trades to make reasonable use of the
scaffolding without any extra cost.
5.6 Stone masonry
5.6.1 General
All aspects of the work shall be in conformity with the "Code of Practice for
Construction of Stone Masonry, IS: 1597 (Part-I & II)-1992. Relevant clauses
under brick work, such as setting out, making chases, openings, fixing frames and
plugs, protection, curing, scaffolding etc., shall apply to stone masonry and
concrete block masonry.
5.6.2 Mortar
The mortar used shall be as specified in the Schedule of Items or drawing.
5.6.3 Holes and Plugs
Holes in stone walls shall be left for water supply, plumbing, sanitation,
electrification, etc., where shown on drawings or ordered by the Engineer as the
work proceeds. These holes shall, on completion, be made good to match with the

adjoining wall. The Contractor shall provide and fix wooden plugs, water supply
piping and electric conduit pipes etc. where so specified.
5.6.4 Random rubble masonry
5.6.4.1 Laying
All stones shall be wetted and cleaned of all dust and loose materials before
laying. Stones shall be laid on their natural beds, fitted carefully to the adjacent
stones to form neat and close joints fully packed with mortar and chips and spalls
of stone may also be used wherever necessary to avoid thick mortar bed or joints.
Walls shall be carried to plumb or to the specified batter. Stones may be brought
to level course at plinth, window sills and roof levels and the leveling shall be
done with concrete comprising of 1 part of the mortar as used for the masonry and
2 parts of 20 mm down graded hard stone chips at no extra cost. Bond shall be
provided by fitting in closely the adjacent stones and by using bond stones running
through the thickness of wall in a line from the face to back with at least one bond
stone, or a set of bond stones, for every 0.5 sq.m. of the wall surface. Face stones
shall extend and bond well into the backing. These shall be arranged to break
joints as much as possible, and to avoid long vertical lines of joints.
5.6.4.2 Quoins
Quoins shall be of selected stones, neatly dressed with hammer or chisel to form
the required angle and laid header and stretcher alternately. No quoin stone shall
be smaller than 0.025cum (25dcum in volume and it shall also not be less than
300mm in length, 25% of them being not less than 500 mm in length).
5.6.4.3 Joints
The stones shall be so laid that the joints are fully packed with mortar and chips
and face joints shall not be more than 20 mm thick. When plastering or pointing
is not required to be done, the joints shall be struck flush and finished at the time
of lying, otherwise the joints shall be raked to a minimum depth of 20 mm by
raking tool during the progress of work, when the mortar is still green.
5.6.5 Coursed rubble masonry - First sort
5.6.5.1 Laying
All stones shall be wetted before use. The walls shall be carried up truly plumb or
to specified batter. All courses shall be laid truly horizontal and all vertical joints
shall be truly vertical. The height of each course shall not be less than 15 cm nor
more than 30 cm.
Face stones shall be laid alternate headers and stretchers. No pinning shall be
allowed on the face. No face stone shall be less in breadth than its height and at
least one third of the stones shall tail into the work for length not less than twice
their height.

The hearting or the interior filling of the wall shall consist of stones carefully laid
on their proper beds in mortar, chips and spalls of stone being used where
necessary to avoid thick beds of joints of mortar and at the same time ensuring that
no hollow spaces are left anywhere in the masonry. The chips shall not be used
below the hearting stone to bring these upto the level of face stones. The use of
chips shall be restricted to the filling of interstices between the adjacent stones in
hearting and these shall not exceed 10% of the quantity of stone masonry. The
masonry in a structure shall be carried up regularly but where breaks are
unavoidable, the joints shall be raked back at an angle not steeper than 45 degree.
Toothing shall not be allowed.
5.6.5.2 Bond Stones
Bond stone or a set of bond stones shall be inserted 1.5 to 1.8 metres apart, in
every course.
5.6.5.3 Quoins
The quoins, shall be of the same height as the course in which these occur. These
shall be at least 45 cm long and shall be laid stretchers and headers alternately.
These shall be laid square on the beds, which shall be rough-chisel dressed to a
depth of at least 10 cm. In case of exposed work, these stones shall have a
minimum of 2.5 cm wide chisel drafts at four edges, all the edges being in the
same plane.
5.6.5.4 Joints
All bed joints shall be horizontal and all side joints vertical. All joints shall be
fully packed with mortar, face joints shall not be more than one cm thick.
When plastering or pointing is not required to be done, the joints shall be struck
flush and finished at the time of laying. Otherwise, the joints shall be raked to a
minimum depth of 20 mm by raking tool during the progress of work, when the
mortar is still green.
5.6.6 Coursed rubble masonry - Second sort
5.6.6.1 Laying
Shall be as specified in 5.6.5.1 except that the use of chips shall not exceed 15% of
the quantity of stone masonry, and stone in each course need not be of the same
height but more than two stones shall not be used in the height of a course.
5.6.6.2 Bond stone, quoins
Shall be as specified for first sort respectively.
5.6.6.3 Joints
All bed joints shall be horizontal and all side joints vertical. All joints shall be
fully packed with mortar, face joints shall not be more than 2 cm thick.

When plastering or pointing is not required to be done, the joints shall be struck
flush and finished at the time of laying. Otherwise, the joints shall be raked to a
minimum depth of 20 mm by raking tool during the progress of work, when the
mortar is still green.
5.7 Hollow concrete block masonry
5.7.1 Construction of hollow concrete masonry shall be done in accordance with

procedures laid down in IS: 2572-1963. General procedures for construction shall
conform to IS: 2212-1991 except for the following :
5.7.2 Storage, handling and preparation
The blocks shall be stored in stable stacks over planks or other supports with
sufficient care taken to prevent ingress or moisture.
Blocks shall be handled carefully to avoid cracking. All damaged units shall be
rejected and removed from site.
Blocks need not be wetted before or during placement. Unless the climatic
condition so require, the top and sides may be slightly wetted.
5.7.3 Mortars
Mortar for use in hollow concrete block masonry shall be made from cement,
slaked lime and sand unless otherwise specified. The mix preparation shall be as
recommended in Table-I of IS: 2572-1963. Preparation of mortar shall be in
accordance with IS: 2250-1981.
5.7.4 Laying
Laying of block for first and subsequent courses and requirements of horizontal
and vertical joints shall be as described in IS: 2572-1963. Use of hollow blocks in
foundations shall be avoided. Use of blocks filled with sand and blocks filled with
1:3:6 concrete for foundation courses, plinths and basements shall be done with
approval of Engineer. Closure blocks of superstructure shall have all openings
battered with mortar. A course of solid concrete block masonry shall be provided
under door and window openings or a 10 cm thick precast concrete sill block shall
be provided under windows. This course shall extend at least 20 cm beyond the
openings on either side. Solid blocks or hollow blocks filled with 1:3:6 concrete
shall be used for jambs or fixing of hold fasts etc., Similarly solid blocks or U-
shaped blocks filled with 1:3:6 concrete shall be used for roof course. They shall
be finished smooth at top with 1:3 cement mortar and covered with a coat of crude
oil, craft paper or oil paper for free roof movement.
5.7.5 Bond
Wherever two walls intersect, bond between at least 50% of the units intersecting
shall be provided. If intersecting walls are laid separately pockets shall be left in
the first wall at a maximum vertical spacing of 20 cm for the corresponding course
of second wall to be built into these pockets.

Pilasters shall be of twice the thickness. Hollow blocks shall not be used for
isolated piers unless they are filled with 1:3:6 concrete.
6.0 Plastering and pointing
6.1 Materials
The specification of materials shall conform to the requirements as specified in

Part-I.
6.2 Plastering
6.2.1 General
Plastering shall be done in accordance with provisions of IS: 1661-1972. Mix

proportions of mortar for plastering and thickness of plaster shall be as given
either in the drawing, or as per Schedule of Items or as directed by the Engineer.
For special plaster work, necessary admixtures shall be added to mortar in
required proportion as per manufacturer's specifications or as specified herein. The
thickness mentioned in the Schedule of Items shall be minimum thickness.
6.2.2 Preparation of surface
The surface to be plastered shall be cleaned of all extraneous matter and rubbish.
In masonry the joints shall be raked to a minimum depth of 12 mm and cleaned
with wire brush. Concrete surfaces to be plastered shall be roughened and hacked
to form key for plastering. All plastered surfaces shall be finished smooth with a
wooden float in one plane and all internal angles shall be finished slightly
rounded. If desired by the Engineer, any unevenness shall be rubbed down by
carborundum stones. The surface to be plastered shall be wetted evenly before the
application of plastering. Trimming of projections on brick/concrete surfaces
wherever necessary shall be done.
For one coat plastering the plaster shall be laid slightly thicker than the specified
thickness and the surface then leveled with flat wooden float to the required
thickness. For two coat plaster work, the first coat (usually half of total thickness)
shall be applied as detailed above except that the surface shall be left rough and
keys formed for the application of second coat. The second coat shall be laid on
with a wooden float to the specified thickness and shall be applied a day or two
after the first coat has set, but has not dried up.
Cement mortar for plastering work shall be used within 30 minutes after adding
water to cement and should be kept agitated at intervals of 20 minutes.
If specified cement punning shall be done over the plastered surface by sprinkling
neat cement powder evenly on the surface and rubbed smoothly with a trowel to
give a fine coating. The plaster shall be kept wet for at least seven days and
protected from extreme temperature and weather during this period
The arises of doors and windows shall have richer mortar 1:3 in a width of 75 mm
on either side or as required at respective location.

6.2.3 Concrete beams, slabs, columns etc. framing into masonry are to be plastered
along with masonry walls with these edges wrapped with chicken wire mesh of
gauge 24. Overlapping of mesh shall be minimum 75 mm on either side of the
edge of the concrete element. Minimum lap for chicken wire mesh shall be 50
mm.
6.3 Cement Pointing
6.3.1 Where shown on drawing, Schedule of Items, or as directed by the Engineer,

exposed brick faces shall be cement rule pointed. The mortar shall be raked out of
the joints to a depth of 12 mm. The dust shall be brushed out of the joints and the
wall well wetted.
Unless otherwise specified the pointing shall be made with cement and sand
mixed in proportion 1:3. The joints of the pointed work shall be neatly finished
truly vertical and horizontal or as directed and the lines shall be kept wet till the
cementing material has set and become hard. If required, the whole brick face
shall be rubbed and polished with fine grade of carborundum stones. Particular
care shall be taken to see that no brick face or brick edge is damaged during this
work.
6.3.2 Flush pointing
The mortar shall be pressed into the joints and shall be finished flush and levelled.
The edges shall be neatly trimmed with trowel and straight edges.
6.3.3 Ruled pointing
The joint shall be initially formed as for flush pointing and then, while mortar is
still green, a groove of required shape and size shall be formed by running a
forming tool straight along the centre line of the joint till a smooth and hard
surface is obtained. The vertical joints shall also be finished in similar way. The
pointing line shall be uniform in width and truly horizontal in case of floors and
ceilings.
6.3.4 Cut or weather struck pointing
The mortar shall first be pressed into joints. The top of the horizontal joints shall
then be neatly pressed back by about 3mm with the pointing tool so that the joint
is sloping from top to bottom. The vertical joint shall be ruled pointed. The
junctions of vertical joints with the horizontal joints shall be at true right angles.
6.3.5 Raised and cut pointing
This type of pointing shall project from the wall facing with its edges cut parallel
so as to have a uniformly raised band about 6mm raised and width 10mm or more
as directed. The pointing shall be finished to a smooth but hard surface. the
superfluous mortar then shall be cut off from the edges of the lines and the surface
of the masonry shall also be cleaned off all the mortar.
Curing

The pointing shall be kept wet for 7 days. During this period it shall be suitably
protected from all damages.
6.3.6 Pointing on brick flooring
Specification for this shall be conforming to under sub head "Pointing".
6.3.7 Pointing on random rubble stone masonry
In such pointing, the mortar shall be simply struck off with a trowel and the work
left showing the natural irregularities in line and surface of the stones themselves.
Other specifications shall remain same as per para 8.3 under sub head "Pointing".
6.4 Rough Cast Concrete Facing
6.4.1 The surface shall be prepared as for Cement plaster and then 2 cm backing coat of
cement sand mortar 1:3 shall be applied. Subsequently, when the backing coat is
in plastic state, a top coat 12 mm average thick cement and stone chips mixture in
proportion 1:3 (stone chips 10 mm size and below) shall be applied by dashing the
mixture on top with trowel to produce uniform rough texture. The mix shall again
be dashed over the vacant spaces if any. The surface shall afterwards be cured for
10 days. After curing, the surface shall be brushed with hard wire brush to remove
loose chips from the surface. A coat of cement wash shall then be applied, the
cost of which shall be included in the rate of the item.
6.4.2 Rendered sand faced cement plaster
The surface shall be prepared as for cement plaster. The backing coat shall be 12
mm thick of cement plaster proportion 1:4 (1 cement and 4 sand) and keys shall be
formed on the surface. After curing this coat sufficiently, the finishing coat 6 mm
thick consisting of grey cement and screened coarse sand to required gradation
(1:3) shall be applied and finished to the desired te texture to the satisfaction of the
Engineer. The surface afterwards shall be cured for 7 days.
6.4.3 Plaster moulding
Where specified, plaster moulding shall be strictly as per drawings and details, and
shall run clean and true from proper templates and moulds, to the entire satis-
faction of the Engineer. Rates shall include for brick or concrete cores and for any
necessary dabbing in cement mortar or brick or metal lath curing and final finish
as desired. Where desired, all angles in internal moulding work shall be covered
to a radius of 50 mm or as directed without any extra charges.
6.4.4 Floating coat with neat cement
When the plaster has been brought to a true surface with the wooden straight edge,
it shall be uniformly treated over its entire area with a paste of neat cement and
rubbed smooth so that whole surface is covered with neat cement coating. Smooth
finishing shall be completed with a trowel immediately and in no case later than
half an hour of adding water to cement.

6.4.5 Pebble dash plaster
Specification shall be same as that for rough cast concrete facing vide 8.4.1 except
that pebbles or graded crushed stone, of size 10mm to 20mm or as
specified/directed by the Engineer, shall be well washed and drained and then
dashed/thrown wet on the plaster surfaces while it is still plastic, using strong
whipping motion at right angles to the face of wall, pressed flat and filling uncover
parts by hand so that finished surface represents homogeneous look. The finished
surface shall be lightly tapped with a trowel to ensure good bond.
6.5 Punning with Lime or Plaster of Paris
6.5.1 Lime Punning
Lime punning shall be carried out with best quality approved lime. Lime shall be
properly stirred, tempered with water to form a homogeneous mass and strained
through fine cloth. The punning shall be laid and rubbed and troweled to an
uniform smooth even finish using special trowels. Any unevenness shall be
rubbed down with fine sand paper. The plaster must be dry before the lime
punning is applied. The punning shall be kept wet for a period of 7 days. The
lime paste shall be kept wet until use and no more quantity than can be consumed
in 10 days shall be prepared at a time. No portion of the surface shall be leftout
initially to be patched up later on.
6.5.2 Plaster of Paris punning
This shall be provided by using the best quality of plaster of Paris from approved
manufacturer. Unless otherwise specified same procedure as for lime punning
shall be followed for getting uniform smooth finish.
7.0 Flooring, paving & facing
7.1 Scope
Flooring, Paving and facing includes flooring, skirting and dado of various types
encountered in plants, buildings, pavements etc. as described under respective
heads. For the items which have not been covered up in this chapter completely or
covered up only partly, specifications suggested by the manufacturers for the
materials, surface preparation, workmanship and all other byeworks etc., shall be
strictly followed. In addition to this the entire job will have to be carried out as per
direction of the engineer, which shall be final.
7.2 Materials
Materials shall conform to Part-I of this series.
7.3 General
Flooring, skirting & dado may have to be done in discontinuous strips or areas to
suit the needs of erection and commissioning of equipment. Flooring shall be done
in close co-ordination with erection of equipment or other services and shall keep

pace with the demands in respect of commissioning of individual equipment. No

claims for extra shall be tenable for reasons of discontinuity of work or delay in
having areas available for work.
Unless otherwise specifically included in the Schedule of Quantities or stated in

the description of work, no extra shall be payable for works such as forming coves
at internal angles, nosing at plinths, steps, window sills and stair treads, dishing in
bath rooms, toilet & other places and cutting to line and fair finish to top edge of
skirting and dado. Thickness mentioned shall be the minimum.
7.4 Sub-base
Flooring at ground level having sub-base of sand or earth as specified shall be laid
in layers of 15 cm, watered and consolidated by rolling with hand roller or
ramming with iron rammer and with butt ends of the crow bars. When filling
reaches the required level, the surface shall be flooded with water for 24 hours,
allowed to dry and then rammed and consolidated to avoid any settlement later.
The thickness of the sub-base shall be as specified either in the drawing or in the
Schedule of Items.
7.5 Subgrade
The surface shall be brought to the desired level before subgrade is laid, loose
pockets shall be filled up and whole surface shall be consolidated by tamping.
Vegetable growth and other decomposed matter, rubbish etc., shall be removed.
7.5.1 Hard core subgrade
Where hardcore subgrade is specified, stone/slag boulders/laterite boulders shall

be laid closely stacked together, the longer edge being laid vertically. All
interstices shall be filled with smaller particles of the same material or with gravel
or red earth. The top surface shall be spread with loose moorum sufficient to
cover the gap and to achieve uniform top surface. The surface shall then be ade-
quately watered and rolled by roller.
Hard core shall be laid to form the desired slope in the finished floor.
7.5.2 Brick Khoa subgrade
Over burnt bricks shall be used for getting brick khoa as per sizes described in
Schedule of Items. The khoa shall be laid uniformly and rammed in dry and wet
conditions so as to get a uniform compact surface.
7.6 Cement Concrete Flooring with Integral Finish
Cement concrete shall be mixed, laid, consolidated and cured as described in

Chapter "Concrete". Laying of concrete shall be done in alternate panels. The
size and division of panels shall be as per direction of Engineer. The mix or grade
of concrete shall be as specified in Schedule of Items.

The finished surface may be rendered smooth by trowel finishing to provide an

appearance of fine and smooth textured surface and in panels or in geometric
pattern as specified in Schedule of Items or as directed by Engineer.
Concrete Flooring with Granolithic Finish (Artificial Stone Flooring)
Granolithic finish shall either be laid monolithically over base concrete or

separately over hardened base concrete. The subgrade shall be either brick
khoa/lime concrete/cement concrete, as specified. Flooring shall be laid and
finished according to IS: 5491-1967.
7.7.1 Thickness
Unless otherwise mentioned the thickness of flooring including topping shall be

either 25 mm or 40 mm or 50 mm as shown on drawing/Schedule of Items. The
net thickness of topping shall be 6 mm for 25 mm thick floor, 10 mm for 40 mm
and 12 mm for 50mm thick floor. An additional allowance of 2mm in thickness of
topping shall be made for cutting and grinding margin wherever polishing is
specified in the item. The rate of the item will be inclusive of this.
7.7.2 Mix
For base or under bed course, the mix shall be 1:2:4 concrete, unless specified
otherwise. The mix of the topping shall consist of 1 part cement :1 part coarse
sand : 1 part coarse aggregated by volume or 1 part cement and 1 part stone chips.
The coarse aggregate shall very hard like granite and well graded and size of chips
shall be 3mm for 6mm topping & 6mm to 3mm for 10mm or more thick topping.
Minimum quantity of water to get workability shall be added.
7.7.3 Laying
a) Laying of monolithic topping

The concrete base or underbed shall be laid as per specification "Cement
Concrete" and levelled upto the required grade. The surface shall remain
sufficiently rough to take the finish.
To prevent construction cracks, the panels shall be divided in square or rectangular

pattern. For floor finish of 40mm thickness or above, the maximum panel area
shall be 2.5 sq.m. with none of the sides exceeding 2.5m, however for lesser
thickness these shall be 1.5sq.m. and 2.5m respectively. The dividing strip may be
aluminium or glass or as specified and shall have the same depth as that of floor.
Within about 2 to 3 hours of laying the base while it is still fully 'green' the
topping shall be laid evenly to proper thickness and grade. The topping shall be
pressed firmly and rigorously to form full bond with the base/underbed.
The laitance brought to the surface during compression shall be removed carefully
without disturbing the stone chips. The surface shall then be lightly troweled to
remove all marks and shall be left for sometime till moisture disappears from it.
Fresh quantity of cement @ 2.2 Kg per sq.m. of the flooring shall be mixed to
form a thick slurry and spread over the surface while concrete is still green. The
cement slurry then shall be floated even & smooth. Polishing, if specified, shall be

done with polishing machine and the portion where machine cannot be used
manually to the satisfaction of the Engineer. If specified so the surface of the
flooring shall be finished ribbed, chequered or laid in slope without any extra cost
unless specified so in the item. On completion, the floor shall be kept flooded with
water for 10 days and shall be adequately protected before it is sufficiently hard.
(b) Laying of topping separately on hardened base
The sub base shall be laid as in clause 7.7.3. The surface of the base concrete shall
be thoroughly brushed and cleaned free from all dirt, mortar droppings and
laitance etc.. Where the surface has hardened too much, chipping or hacking of
the surface may be necessary. The surface shall then be wetted with water for
several hours and surplus water mopped. Neat cement slurry at 2.75Kg/sq.m. of
surface shall be brushed into the clean surface. The topping then shall be laid as
described in clause 7.9.3.
7.7.4 General
The junction of the floors with all plaster dado or skirting shall be rounded of with
1:1 cement sand mortar & polished, if specified or shown in drawing.
7.7.5 Curing
Immediately after laying, the finish shall be protected against rapid drying. As
soon as the surface had hardened sufficiently, it shall be kept continuously moist
for at least 10 days by means of wet gunny bags or ponding of water on the
surface. The floor shall not be exposed to use during this period.
7.7.6 Grinding & finishing
Where grinding is specified, it shall start only after the finish has fully set. The
grinding shall be done with carborundum stone of No. 60, then No. 80 and then
120 as per the method as specified in in-situ mosaic flooring. After final
polishing, the floor shall be rubbed with oxalic acid and then wax polished.
7.8 Dado & Skirting Work (Grey Cement Skirting/Dado)
A backing coat of 12 mm thick and 15 mm thick shall be applied on walls after

proper dabbing of the surface for a finished thickness of 18 mm and 21 mm thick
respectively, with cement plaster of proportion 1:4 (1 cement and 4 approved
quality sand) or as specified. Over this a top coat 6mm/7mm thick consisting of
one cement to one stone chips 3 mm nominal size shall be applied. If grinding
and polishing specified, the same shall be done as per granolithic flooring with
carborundum stones.
Flooring & Facing with Redoxide of Iron

(Red Artificial Stone Flooring)
It shall consist of an underbed or base course and topping over already laid &
matured concrete subgrade.

7.9.1 Thickness
Unless otherwise specified the total thickness of the flooring shall be either 40 mm
or 25 mm of which the topping shall not be less than 6 mm (net) for 25 mm
thickness and 10 mm (net) for 40 mm thickness. The topping shall be of uniform
thickness, the underbed may vary in thickness to provide necessary slopes. For
vertical surfaces the total thickness shall be 18 mm, of which the topping thickness
shall be 6 mm (net). Where grinding (cutting) & polishing is specified a minimum
allowance of 2 mm shall be kept for cutting & polishing so that the net specified
top thickness is achieved. All junctions of vertical with horizontal shall be
rounded neatly to uniform radius of 25 mm or as shown in the drawing.
7.9.2 Mix
i) Course or base course
The underbed for floors and similar horizontal surfaces shall consist of a mix of 1
pert cement, 2 parts coarse sand and 4 parts 10 mm down graded stone chips by
volume. For vertical and similar surfaces the mix shall consist of 1 part cement to
3 or 4 parts coarse sand by volume as specified in the item.
ii) Topping course
For the topping white cement and red oxide of iron pigment powder shall be dry
mixed thoroughly (generally 10:1 by weight) to produce the desired colour when
laid. The mix shall then be prepared with 1 part white cement (mixed with
pigment) and 3 parts coarse sand by volume. The whole quantity required for
each visible area shall be prepared in one batch to ensure uniform colour.
7.9.3 Laying
The underbed shall be laid in panels of maximum area 2.5 sq.m. each and no side
shall be more than 1.5m long. For outdoor locations the maximum area shall be
2.0 sq.m. or as specified. The forms for the panels shall have perfectly aligned
edges to the full depth of the total thickness of finish. Aluminium or glass
dividing strips shall be used as forms. The underbed shall be laid compacted,
levelled and brought to proper grade with a screed or float. The topping shall be
placed after about 24 hours while the underbed is still somewhat 'Green' but firm
enough to receive the topping.The surface of the underbed shall be roughhead
for better bonding. The topping shall be rolled for horizontal areas and thrown
and pressed for vertical areas to extract all superfluous cement and water to
achieve a compact dense mass fully bonded with the underbed. The topping shall
then be levelled up by troweling and finished smooth with a slurry made with
already prepared cement and pigment mixture. About 2.0 kg of the mixture shall
be consumed/per sq.m. for horizontal surface, and 1.0 kg for vertical surface.
7.9.4 Grinding & polishing
Where grinding & polishing specified, the same shall be done 36 hours after
laying when the surface has hardened sufficiently. It shall be polished with
polishing stone, in sequence of different grades of carborundum stones (first No.

60, then No. 80 & then No.120) till a smooth shiny surface to the satisfaction of
the Engineer is achieved. After final polishing, the finished areas shall be rubbed
with oxalic acid and then wax polished.
7.10 Terrazzo Flooring & Facing
General
The terrazzo work shall be done by approved firm or specialists. Marble chips
used for facing coat of terrazzo work shall be of best quality (from Dehradoon or
other approved source) and of uniform tint and colour and shall be approved by
the Engineer before using in the work. All terrazzo work shall be polished on
completion followed by a final wax polish of approved quality.
Terrazzo work shall be done either cast-in-situ or with precast tiles as specified in
the Schedule of Quantities Unless otherwise specified thickness for cast-in-situ
terrazzo work shall be 25 mm including base course and for tiles 20 mm excluding
mortar bed.
7.10.1 Cast-in-situ terrazzo flooring
It shall consist of an underbed and a topping laid over an already matured

concrete subgrade.
7.10.1.1 Thickness
Unless specified otherwise, the total thickness of the finished flooring shall be
either 25 mm or 40 mm of which the topping shall be minimum 6 mm (net) for 25
mm and minimum 10 mm net for 40 mm flooring. A minimum allowance of 2
mm in the topping shall be kept for grinding and polishing so as to achieve the
minimum specified thickness of topping. All junctions of vertical with horizontal
planes shall be rounded neatly to uniform radius of 25 mm or as shown in the
drawings.
7.10.1.2 Mix
i) Underbed course
The underbed for floors and similar horizontal surface shall consist of a mix of 1
part cement, 2 parts sand and 4 parts stone chips by volume. The sand shall be
coarse. The stone chips shall be 10 mm down well graded. Only minimum water
to be added to give a workable consistency.
ii) Topping
Topping shall consist of cement (grey or white) as specified with or without

colour pigment, marble powder and marble chips. The proportion of cement and
marble powder shall be 3 parts of cement to one part of marble powder by weight.
The proportion shall be inclusive of any pigments added to the cement. The
proportion, to which pigments are mixed with grey or white cement to obtain
various shades for the binder, shall be as specified in Table-I of IS: 2114-1984.

The proportion of marble chips and cement marble powder mix shall be 7 parts of
marble chips to 4 parts of cement marble powder mix mixed by volume. Care
shall be taken to ensure an even and uniform disposition of the marble chips.
7.10.1.3 Laying
i) Laying of underbed
The underbed shall be laid in panels in the same manner as that for artificial stone
flooring. The panels shall not be more than 2 sq.m. in area of which no side shall
be more than 2.0 m long. Cement slurry @ 2.75 kg/sq.m. shall be applied before
laying over cement concrete/RCC surface/ plastered surface.
Dividing strips made of aluminium or glass shall be used for forming the panels.
The strips shall exactly match the total depth of underbed plus topping. In case of
in-situ dado work, the sections shall not be more than 60 cm x 60 cm and the
aluminium, glass or any other material strips provided similarly.
ii) Laying of topping
After laying, the underbed shall be leveled compacted and brought to proper grade
with screed or float. The topping shall be laid after about 24 hours while the
underbed is still somewhat 'green' but firm enough to receive the topping. A
slurry of the mixture of cement and pigment already made shall be spread evenly
and brushed in just before laying the topping. The topping shall be rolled for
horizontal areas and thrown and pressed for vertical areas to extract all
superfluous cement and water and to achieve a compact dense mass fully bonded
with the underbed. The terrazo surface shall be tamped, troweled and brought true
to the required level by straight edge and steel floats in such a manner that
maximum amount of marble chips come up and are spread uniformly over the
surface and no part of the surface is left without the chips. Excessive troweling
should be avoided in early stages lest too much cement may come up the surface
leading to surface cracking and requiring more grinding to expose marble chip.
7.10.1.4 Curing
The surface shall be left dry for air curing for about 12 to 18 hours and then cured
by allowing water to stand on the surface or by covering with wet sack for seven
days.
7.10.1.5 Grinding & polishing
Grinding and polishing shall be done either by hand or by machine. In case of

manual grinding, the process of grinding shall begin after 2 days while in case of
machine grinding the process shall start after seven days after completion of
laying. First grinding shall be done with carborundum stone of 60 grit size. The
floor shall then be washed and cleaned to remove mud and grindings, a grout of
cement and colouring pigment in same proportion of the topping shall be applied
to cover the pin holes. The surface shall be cured for 5 to 7 days and then ground
with machine fitted fine grit blocks (No. 120). The surface shall be again cleaned
and repaired as mentioned above and shall be cured for 3 to 5 days. Finally the
third grinding shall be done with machine fitted with fine grit blocks (No. 320) to

get even and smooth surface without pin holes. The finished surface should show
the marble chips evenly exposed.
Where use of machine for polishing is not feasible/ possible rubbing and polishing
by hand shall be done in the same manner as specified for machine polishing
except that carborundum of coarse grade (No. 60, 80 and 120) for first, second &
final polishing. After the floor is polished to the satisfaction of the Engineer, it
shall be rubbed with oxalic acid and finally wax polished with 'Mansion' or similar
approved floor polish to the entire satisfaction of Engineer. For good result, wax
polishing shall be applied on the surface with the help of soft linen over a clean
and dry surface and then the polishing machine fitted with bobs shall be run over
it. Clean saw dust shall be spread over the floor surface and the polishing machine
again operated so as to remove excess wax and leave glossy surface. Floor shall
not be left slippery.
7.10.2 Terrazzo cast-in-situ facing, skirting and dado
The work shall be carried out in the same manner as that for terrazzo cast-in-situ
floors except that the base or bedding course shall consist of 1:3 cement mortar (1
cement & 3 medium sand) of 12 mm or 15 mm or 20 mm thickness for total
thickness 18 mm or 21 mm or 26 mm respectively. As specified earlier, the
bedding course shall be laid in panel (not more than 60 cm x 60 cm) divided by
glass/ aluminium strips. The topping shall be of 6 mm thick finished and shall be
laid when the backing plaster is still green. Special care shall be taken to see that
the surface are properly cured.
7.10.3 Terrazzo tile finished flooring/facing
The work will consist of manufactured terrazzo tile and an underbed.
7.10.3.1 Thickness
Unless otherwise specified, the total (net) thickness including the underbed shall
be 40 mm for flooring and other horizontal surface and 32 mm for vertical sur-
faces like dado/skirting. The necessary allowance for cutting and grinding shall be
kept to have the specified finished thickness.
7.10.3.2 Tiles : Terrazzo
The tiles shall, unless specifically permitted in special cases, be machine made
under quality control in a shop and shall be subjected to minimum hydraulic
pressure of 140 kg. per sq. cm.
The tiles shall be composed of a backing and topping. The finished thickness of
upper layers shall not be less than 5mm for size of marble chips upto 6m size and
not less than 6mm for size of marble chips upto 20mm size.
The ingredients for topping shall be same as cast-in-situ terrazzo. The thickness
of the topping, as specified above, shall be net after grinding & polishing. First
grinding shall be given to the tiles at the shop before delivery.

The manufacturer shall supply along with the tiles the grout mix containing
cement and pigment in exact proportions as used in topping of the tiles.
7.10.3.3 Mix : Underbed
The underbed for floor and similar horizontal surfaces shall be 1 part lime putty : 1
part surkhi : 1 part coarse sand or 1 part cement : 3/4 parts coarse sand mixed with
sufficient water to form a stiff workable mass. The thickness of underbed for the
flooring shall be 20mm unless otherwise specified. For skirting and dado and all
vertical surface it shall be about 12 mm thick and composed of 1 part cement 3
parts coarse sand.
7.10.3.4 Laying
The underbed mortar shall be evenly spread and brought to proper grade and
consolidated to a smooth surface. The base surface shall be roughened for better
bond. Before laying the underbed, over the base/subgrade, a coat of cement
slurry shall be applied over the subgrade. Before the underbed has time to set and
while it is still fairly moist but firm, cement shall be hand dusted over it or cement
slurry applied at 4.4Kg of cement per sq.m. and the tiles shall immediately be
placed upon and firmly pressed by wooden mallet on to the underbed until it
achieves the desired level. The tiles shall be kept soaked for about 10 minutes just
before laying. The joints between tiles shall be as close as possible and not more
than 1.5 mm wide.
Special care shall be taken to check the level of the surface and the lines of the
joints frequently so that they are perfect. When tiles are required to be cut to
match the dimensions these shall be sawn and edges rubbed smooth. The location
of cut tiles shall be planned in advance and approval of the Engineer taken.
At the junction of horizontal surface with vertical surface the tiles on the former
shall enter at least 12 mm under the latter.
After fixing, the floor shall be kept moistened allowed to mature undisturbed for 7
days. Heavy traffic shall not be allowed. If desired dividing strips as specified
under Cl. 7.10.1.3 may be used for dividing the work into suitable panels.
7.10.3.5 Grinding and polishing
Procedure shall be same as in-situ terrazzo finished flooring. Grinding shall not
commence earlier than 14 days after laying of tiles.
7.11 Glazed Tile Finished Flooring & Facing
This finish shall be composed of glazed earthen tiles with an underbed laid over a
concrete or masonry base.
7.11.1 Thickness
Unless specified the total thickness shall be 21 mm for flooring & 18 mm for
dado/skirting for the underbed.

The necessary cutting into the surface receiving the finish, to accommodate the
specified thickness shall be done.
7.11.2 Tiles : Glazed
These shall conform to the requirement of IS : 777. The tiles shall be of

earthenware, covered with glazed white or coloured, plain or with designs, of 149
mm x 149 mm or 99mm x 99mm nominal sizes and 5,6 & 7 mm thick unless
otherwise specified. Specials like internal and external angles, beads, covers,
cornices, corner pieces etc., shall match. The top surface of the tiles shall be
glazed with a gloss or matt unfading stable finish as desired by the Engineer. The
tiles shall be flat and true to shape. The colour shall be uniform, and fractured
section shall be fine grained in textures, dense and homogeneous.
The coloured tiles, when supplied, shall preferably come from one batch to avoid
difference in colour.
7.11.3 Mix : Underbed
The mix for the underbed shall consist of 1 part cement and 3 parts coarse sand
mixed with sufficient water or any other mix if specified and shall be 12mm thick
minimum or as specified.
7.11.4 Laying & finishing
The underbed mortar shall be evenly spread and brought to proper grade and
consolidated to a smooth surface. Before laying the underbed, over the
base/subgrade a coat of cement slurry shall be applied over the subgrade. Before
the underbed has time to set and while it is still fairly moist but firm, cement shall
be hand dusted over it and the tiles shall immediately be placed upon and firmly
pressed by wooden mallet on to the underbed until it achieves the desired level.
The joints shall be practically invisible and filled with non-staining white
cement/white cement mixed with pigment for coloured tiles. Internal angles shall
be provided with `specials'. Drains shall be provided with `specials'. The tiles
shall be thoroughly cleaned after completion. The tiles shall be laid to the slope
specified in the drawings and truly vertical on walls when used as skirting.
7.11.5 Curing & cleaning
After flush pointing the joints, the surface shall be cured for 7 days by keeping it
wet. The surface shall be then cleaned with soap or suitable detergent, washed
fully and wiped with soft cloth to prevent scratching before handing over.
7.12 Marble Flooring
7.12.1 Thickness
Unless specified otherwise the underbed shall be average 20 mm for flooring and
12 mm thick for vertical surfaces. The slabs may be 20 mm, 25 mm, 30 mm or 40
mm thick as specified.

7.12.2 Marble slab
The slabs shall be made from selected stock which are hard, sound, homogeneous
and dense in texture and free from flaws, angles and edges shall be true, square,
free from chipping and surface shall be plane. The slabs shall preferably be
machine cut to the required dimensions. Tolerance of plus or minus 5 mm in
dimensions and plus or minus 2 mm in thickness will be allowed. Unless
specified the slabs shall be minimum 300 mm x 300 mm. The stone slabs shall
come from specific regions and in specified quality with top surface fine chisel
dressed. All sides shall also be fine chisel dressed to the full depth to allow finest
possible joints.
The slabs shall be delivered to the site well protected against damages and stored
in dry place under cover.
7.12.3 Mix: Underbed
The underbed, unless specified otherwise for floor and similar horizontal surfaces
shall be 1 part lime putty : 1 part surkhi : 1 part coarse sand or 1 part cement : 4
parts coarse sand mixed with sufficient water to form a stiff workable mass and
shall be on 20mm thick bed. For skirting and dado and all vertical surfaces it shall
be 12 mm thick and composed of 1 part cement and 3 parts coarse sand.
7.12.4 Laying
The sides and top surface of the slabs shall be machine rubbed with coarse sand
stone and washed clean before laying. The underbed mortar shall be evenly
spread and brought to proper level on the area under each slab. The slab shall be
laid over the underbed, pressed and tapped down with wooden mallet to the proper
level. The slab shall then be lifted and the underbed corrected as necessary and
allowed to stiffen a little. Next, a thick cement slurry at 4.4 Kg of cement per
sq.m. shall be spread over the surface. The edges of the slab shall be buttered with
slurry of cement, grey/ white/mixed with pigment matching the colour of the stone
slabs. The slab shall be gently laid and tapped with wooden mallet to bed properly
to a very fine joint and to the required level. All surplus cement slurry shall be
removed and the surface mopped clean with wet soft cloth. The laid finish shall
be cured for 7 days by keeping it wet.
7.12.5 Polishing, finishing
Fine chiseling shall be done to remove the slight undulations that usually exist at
the joints. The polishing and finishing shall be done as specified under terrazzo
flooring. However, the joints shall be so fine in the case of stone slabs that
grouting shall not be called for.
7.13 Marble in Facia or Dado
Marble tiles of approved shade, variety, size and thickness as specified in the item
shall be used. They shall be of selected quality, dense, uniform and homogeneous
in texture and free from cracks or other structural defects. The exposed face shall
have no unsightly stains, veins and defects. They shall have uniform milky white

or coloured shade or patterns of colours approved by the Engineer before ordering

the tiles. The surface shall be fine polished and sides machine cut, true to square.
When a single course of marble slab is to be fixed as in dado etc., the slabs shall
be fixed as described below:
Mortar pads of 1:3 C.M. (1 cement : 3 coarse sand) of uniform width shall be
stuck on to the wall at close intervals and the marble slabs shall be pressed on to
them firmly. The remaining cavities if any shall then be filled with thin grout of
cement mortar of the same proportion. The sound coming, on gently tapping of
the slab, will indicate if there are hollows. When the hollow cannot be filled with
grout and the finished slab continues to give a hollow sound on tapping, the slab
shall be removed and reset. For the facia work where more than one course is
required the marble slabs shall be of matching stand and veins to form
architectural pattern as per drawings and shall be fixed in the same way as
described above except for the horizontal joints of the slabs, where adjacent slabs
shall be held together by a brass pin passing through a hole drilled into the slabs.
In addition, wrought iron/dowels shall be provided to anchor the slabs to the wall.
The metal cramps shall be counter sunk into the joints of the slab and it shall be
located about a metre apart subject to a minimum of one for each slab for each
horizontal joint.
The facing shall be fixed truly in plumb and in perfect line or curves as shown on
the plans. The courses and joints shall be as directed by the Engineer. The
surface shall be protected from sun and rain and cured for 10 days and shall be
finally polished with carborundum stones as for skirting & dado of cast-in-situ
terrazzo.
7.14 Flooring/Paving with Hardener like Ironite
This will consist of a topping (incorporating iron particles) to bond with concrete
base while the latter is 'Green'.
7.14.1 Thickness
Unless otherwise specified in the Schedule of Items, the total thickness of the floor
with metallic hardener finish shall be 40 mm or 50 mm of which the topping shall
be 10 mm (net) for 40 mm & 12 mm (net) for 50 mm
7.14.2 Material (metallic hardener)
The hardening compound shall be uniformly graded iron particles free from non-
ferrous metal impurities, oil, grease, sand soluble alkaline compounds or other
injurious materials. When desired by the Engineer, actual samples shall be tested.
7.14.3 Mix
Unless otherwise specified, the mix for underbed shall be of 1:2:4 concrete and
stone chips shall be 12 mm down grade. For topping the proportion of the
metallic hardener shall be as specified or as indicated by the manufacturer.
However, in absence of any such direction 1 part metallic hardener shall be mixed
dry with 4 parts cement, by weight. To this mixture 6 mm nominal size stone

chips shall be added in proportion of 1 part cement (mixed with hardener) to 2

parts of stone chips by volume and uniformly mixed. Minimum quantity of water
shall be added to make it workable.
7.14.4 Laying & finishing
The under bedding course of base course shall be laid as per specification of
laying underbed for Red artificial stone flooring. The surface shall be roughened
by wire brush as soon as possible. The finish top coat shall be laid while the
concrete base is still fairly 'green' within about 3 hours of laying of the later. The
finish shall be of uniform and even dense surface without trowel marks, pin holes
etc. This topping layer shall be pressed firmly and worked vigorously and quickly
to secure full bond with the concrete base. Just when the initial set starts the
surface shall be finished smooth with steel trowel.
7.14.5 Curing
The finished floor shall be cured for 7 days by keeping it wet.
Chemical Resistant Tiles Flooring / Facing

(Either of natural stone or prepared tiles)
This shall include all varieties of special tiles used for specific chemical resistance
function and an underbed over already laid concrete or masonry. The Contractor
shall get it done by specialised manufacturer & get guarantee of its performance.
7.15.1 Tiles
The chemical resistant tiles as detailed in the Schedule of Items shall be of the best
indigenous manufacture unless otherwise specified and shall be resistant to the
chemical described in the Schedule of Items. The tiles shall have straight edges,
uniform thickness, plain surface, uniform non-fading colour and textures.
Usually the chemical resistant tiles shall not absorb water more than 2% by
weight. The tiles shall have at least compression strength of 700 kg/cm2. The
surface shall be abrasion resistant and durable.
7.15.2 Laying
The mortar used for setting or for underbed the tiles shall be durable and strong.
The grout which shall be to the full depth of tile shall have same chemical
resistant properties as that of tiles. Joints shall be pointed if so desired. The
setting and fixing shall be according to the manufacturer's specification approved
by the Engineer.
7.16 Chemical Resistant in Situ Finished Flooring/Facing
Chemical resistant in situ finish shall be as called for in the Schedule of Items.
About its performance the Engineer shall have to be fully satisfied by test results
and examination of similar treatment already in existence. The Contractor shall
get it done by a specialised manufacturer, get guarantee of performance from the
organisation and pass it on to the owner in addition to his own guarantee.

The Contractors shall satisfy the Engineer specially for the workmanship
of the following finished floor :
(a) Level, slope, plumb as the case may be

(c) Alignment of joints, dividing strip etc.
(d) Colour, texture
(e) Surface finish
(f) Thickness of joints including the workmanship in joints.
(g) Details at edges, junctions etc.
(h) Performance
(i) Precautions specified for durability.
8.0 Wood work
8.1 General
Wood work shall be neatly and truly finished to exact dimensions and details as
per drawings, without patching or plugging of any kind. Rebates, roundings and
mouldings as shown in drawings shall be made before assembling. Exposed work
shall be finished smooth with well planed faces.
All assembly of shutters of doors, windows, ventilators and frames thereof shall be
exactly at right angles. In the case of frames, the right angle shall be checked
from the inside surfaces of the respective members.
All door and window frames shall be clamped together so as to be square and flat
at the time of delivery. Door frames without sills shall be fitted with temporary
stretchers.
Horns of frames and other parts that go into or butt against the masonry, shall be
protected against moisture and decay with two coats of coal tar or other approved
protective material.
All surfaces of the door, window and ventilator frames and shutters which are
required to be painted ultimately shall be covered evenly by brush with a priming
coat of approved primer. In the case of doors to be polished or varnished, a
priming coat of approved polish or varnish shall be given before delivery. No
primer shall be applied to the wood work until it has been inspected and passed by
the Engineer.
8.2 Joinery
All heads, posts, transoms and mullions etc., of doors, windows and ventilators
shall be made out of single pieces of timber only. The heads and post shall be
through- tenoned into the mortices of the jamb posts to the full width of the latter
and the thickness of the tenon shall be not less than 1.25 cm. The tenons shall be
close fitting into the mortices and pinned with corrosion resisting metal pins not
less than 8 mm diameter or with wood dowels not less than 10 mm diameter. The

depth of rebate in frames for housing the shutters shall in all cases be 1.25 cm and
the rebate in shutters for closing in double shutter doors or windows shall be not
less than 2 cm. Unless otherwise specified, all joints shall be mortice and tenon
joints with the ends of the tenons exposed to view. Joints shall fit truly and fully
without fillings. The contact surfaces of tenons and mortices shall be treated,
before putting together, with an approved adhesive conforming to I.S :848- 1974
and 851-1978.
8.3 Shrinkage & Tolerance
The arrangement, joining and fixing of all joinery work shall be such that
shrinkage in any part and in any direction shall not impair the strength and ap-
pearance of the finished work.
The tolerance on overall dimensions shall be within the limits prescribed in IS :

1003 (Part 1 & 2)-1983 to 1991.
8.4 Fixing
Door and window frames shall generally be built in at the time the walls are
constructed. Alternatively, where permitted by the Engineer, the frames may be
subsequently fixed into prepared openings for which purpose holes to
accommodate the holdfasts shall be left at the time of construction. Where the
frames are subsequently fixed into prepared openings in the wall such openings
should be 25 mm more than the overall width of the door, window or ventilator
frame to allow minimum 12mm plaster on each jamb. The height of the
unfinished opening shall depend upon whether a threshold is required or not.
While fixing the door care shall be taken to see that at least 6 mm space is left
between the door and the finished floor. The M.S. clamps fixed to the frame shall
be inserted in the holes and jammed in cement concrete M-15 or (1:2:4 mix) with
20 mm down graded stone chips after holding the frame in proper position to the
line, level and plumb.
The size of the concrete block shall be 250 x 125 x 85mm unless otherwise
specified.
8.5 Tarring
Timber in contact with earth, concrete, plaster or masonry shall be treated with
boiling coal tar or 2 coats of wood preservative treatment like hot solingnum or
creosite oil etc. before fixing the frame in position.
8.6 Fittings
Unless otherwise specified, three holdfasts shall be fixed on each side of a door
frame, one at the centre point, and the other two at 30 cm from the top and the
bottom of the door frames. In the case of windows and ventilators, a pair on each
side shall be fixed at quarter points of the frames. Unless otherwise specified the
hold-fasts shall be of mild steel plate 40 x 3 x 225 mm long, fish tailed at one end
and screwed to the frame in the formed rebates.

Generally, each door shutter shall be fixed to the frame with three hinges of
approved manufacture, one at the centre and the other two approximately 24 cm
from the top and bottom of the shutter. Each window shutter shall be fixed to its
frame with two hinges at the quarter points.
Locks, handles, door closers, stoppers etc., shall be fitted as shown in drawing or
described in the Schedule of Items.
8.7 Doors, windows & ventilators etc.
Dimensions of the various components of doors, windows and ventilators shall be

in accordance with IS : 1003 (Part 1&2)-1983 to 1991 Table- III or as shown on
the drawings. The work shall be carried out as per detailed drawing. The wooden
members shall be planed, smooth and accurate. They shall be cut to the exact
shape and size without patching or plugging of any kind. Mouldings, rebates,
curves and roundings etc. shall be done as shown in the drawing before the pieces
are assembled into the shutter.
The thickness of stiles and rails etc shall be as per IS: 1003 (Part 1&2)-1983 to
1991 unless otherwise specified in the item of works. These shall be properly and
accurately mortised and tenoned. Rails which are more than 180mm in width shall
have 2 tenons. Stiles and rails shall be made out of single piece upto 200mm in
width. In case more than one piece of timber is used for members exceeding
200mm width, they shall be joined with a continuous tongued and grooved joint,
glued together and reinforced with rust proof metal dowels or headless pins. The
tenons shall pass clear through stiles. the stiles and rails shall have a 12mm
groove, unless otherwise shown in the drawing, to receive the panel. In case of
double shutters the rebate at the closing junction of the two shutters shall be as
per clause 5.5 of IS: 1003-1991 or as shown in the drawing. Primer coat shall not
be put before shutters are passed by the engineer.
8.8 Panelled Shutters
These shall conform to IS: 1003 (Part I)-1991. Timber panelled shutters shall be
constructed in the form of timber frame work of stiles and rails with panel inserts
of timber, plywood, block board, veneered particle board, hard board or asbestos
cement board.
Stiles, rails and panels in door shutters shall be of the same species of wood.
Timber panels shall be of minimum width of 150mm. When made from more than
one piece, the pieces shall be jointed with a continuous tongued and grooved
joint, glued together and reinforced with metal dowels. No single panel shall
exceed 0.5 m2 in area. Timber panels shall be fixed only with grooves but
additional beadings may be provided either on one side or both sides.
Unless otherwise specified thickness of panel for 35mm thick shutter shall be
15mm and for 40mm and above thick shutter, it shall be 20mm. For 25mm thick
shutter, panel thickness shall be 12mm.

Apart from timber panels other materials like plywood, Block board, particle
board, Hard board and Asbestos cement may also be used for panelling purpose
and shall be fixed with grooves or beading or both as per provisions made in
IS:1003 (Part-1)-1991.
Timber suitable for manufacture of door shutter have been grouped under class
a,b,c & d in Table 1 of IS: 1003 (Part-1)-1991.
8.9 Glazed Shutters
The openings for glazed shutters shall be rebated and moulded out of solid timber.
Plain sheet glass for panels shall be of approved quality as specified. Wherever
specified, ground glass or frosted glass of approved quality shall be used in place
of plain sheet glass. Unless otherwise specified glass panes shall be fixed by
means of moulded beads and suitable MS panel pins. A thin layer of putty shall be
applied between glass panes and sash bars and also between glass panes &
beading.
8.10 Flush Door Shutters
Unless otherwise specified, flush door shutters shall have a solid/cellular core, a
teak wood frame, and shall be faced with approved quality of plywood on both
faces. The core and stock shall be made from well seasoned approved timber and
treated with approved preservatives. The plywood faces shall be glued on to the
solid/cellular core with waterproof glue under pressure and heat. The construction
of flush doors shall be such that no difficulty should arise in fixing mortice locks,
hydraulic door closers etc. The shutters shall be rebated in the case of the double
leaf doors. Where specified flush doors shall be provided with vision panels,
rectangular/ round or louvered.
If specified so, the flush door shall be solid block board core or solid particle
board core construction. The workmanship and overall finish shall be of very high
standard and shall conform to IS:2191 (Part 1&2)-1983 & 2202 (Part 1&2)-1983
to 1991. The shutters shall be procured from approved manufacturer bearing IS
certification mark only.
8.11 Other types of shutters
8.11.1 Wooden hand rails
Wooden hand rails shall be of approved quality teak wood fixed to concrete or
metal balustrade with concealed steel or metal lugs and bolts as per drg. Joints will
be made with concealed crews and dowels. All bends, mitres, coves, moulds etc.
will be strictly to proper profile and finally smoothened by sand paper. The hand
rail shall be finished with wax or french polish or painting as per direction of the
engineer.
8.11.2 Hardware fittings for door, windows & ventilators
All mortice or rim locks, latches, cabinet and wardrobe locks, hydraulic door
closers, floor springs etc. shall be of Godrej, Everite make or of similar approved

make. The rate shall include for all necessary screws, other adjuncts, fixing in
position and is for the completed work. the finish shall be as specified in the
schedule of quantities. Door, window and ventilator fittings shall be as per
specifications already described. The rates for doors, windows and ventilator
shutters shall include the cost of fixing the fittings, with the necessary screws to
the shutters and the frame. The cost of fittings only shall be paid separately.
Where specified in the schedule of quantities, the cost of fittings shall be included
in the rates for doors, windows and ventilators shutters. In such case the contractor
shall supply and fix the various fittings strictly to the standard laid down in the
schedule of hardware fittings and no separate payment for this shall be made.
8.12 Inspection
The Contractor shall provide all facilities to the Engineer for the inspection of the
goods at his premises. No primer shall be applied until the wood work has been
inspected and passed by the Engineer. The Engineer shall have the option of
rejecting any article or asking for replacement of any article found to be defective
or not complying with the requirements of this specification and the relevant
Schedule of Items.
9.0 Metal doors, windows and rolling shutters
9.1 General
Doors, windows and ventilators etc., shall be truly square and flat, i.e. free from
twist and warp. The general fabrication shall conform to IS:1038-1983 & IS :
1361-1978 as applicable.
9.1.1 Frames shall be constructed of sections which have been cut to length and mitred.
They shall be morticed, reinforced, drilled and tapped for hinges and lock and bolt
strikes. Where necessary, frames shall be reinforced for door closers. Flash butt
welding or any other suitable method which gives the desired requirement, with
mitred corners shall be used. Rubber door silencers shall be furnished for the
striking jamb. Loose "T" masonry anchors shall be provided. Frames shall finish
flush with floor and adjustable floor anchors shall be supplied. Frames shall be
brought to site with floor ties/weather bars installed in place. All frames shall be
square and flat. Door thresholds shall be provided as shown on drawing. Doors
without threshold shall have bottom tie of approved type.
9.1.2 The Contractor shall first submit for the approval of the Engineer, the name and
address of the manufacturer whose metal casements and doors and windows he
intends to use, together with typical drawings and specifications, describing the
details of construction for each type of door/window/ventilator etc.
9.1.3 All steel doors, windows and ventilators shall be either galvanised or painted. All
steel surfaces shall first be thoroughly cleaned free of rust, scale or dirt and mill
scale by pickling or similar process and then shall be painted with one coat of an
approved primer conforming to IS : 102-1962 before despatch. Alternatively they
may be galvanised by the "Hot Dip" zinc spray or electro- galvanizing process as
described in IS : 1361-1978.

9.2 Fixing
Doors, windows and ventilators shall not be built in at the time the walls are
constructed but shall be subsequently fixed into prepared openings, as laid down
in IS : 1081-1960. Holes to accommodate the fixing lugs are to be left or cut, and
the casements fixed after all the rough masonry and plaster work have been
finalised. The lugs of the casement shall be jammed in cement concrete (15C
Mark)/(1:2:4) mix after holding the casement in proper position, line and level.
The width of the clear unfinished opening in the wall should be 25 mm more than
the overall width of the door frame to allow for plaster on each jamb. The height
of the unfinished opening shall depend upon whether a threshold is required or
not. While fixing the door, care shall be taken to see that at least 6 mm space is
left between the door and the finished floor.
9.3 Fittings
Hardware shall be fixed as late as possible, preferably just before the final coat of
paint is applied. It shall be fitted in a workmanlike manner, so that it may not
work loose and in such a way that screws and pins are not marked and mutilated
by hammers and screw drivers. It shall be tested for correct operation. Where
specified, doors shall be fitted with a three-way bolting device which can be
operated from outside as well as inside, and a locking system, which can similarly
be operated from either side. Solid steel bolt handles shall be provided, one on the
outside and one on the inside of each shutter. In case of doors provided with a
service door, the lock shall be fitted on the service door. All materials shall be the
best procurable and shall be approved by the Engineer.
9.4 Normal Steel Plate Doors
Steel doors may be of the hinged type or sliding/ folding type, single shutter or
double shutter, and of single-walled or double walled construction, as specified on
the drawings or Schedule of Items. All doors shall be provided with a sturdy
frame and hold fasts for fixing into the wall. Unless otherwise specified, the
frame shall be prepared from mild steel angles of size not less than 65 x 65 x 6
mm electrically welded at the corners and the shutter shall be made from flat steel
sheet of 18 gauge or 1.25mm thickness with a frame of mild steel angles not less
than 50 x 50 x 6 mm all round, suitably braced. The whole shutter shall be of
welded construction and shall be hung at the sides by means of three or four
hinges as specified.
9.4.1 Double Plate flush door shutters
Door shutters shall be 45 mm thick, completely flush design and shall comprise of
two outer sheets or 18G or 1.25mm thick steel sheets, rigidly connected and
reinforced inside with continuous vertical 20G or 0.99mm thick stiffeners, spot
welded in position at not more than 150 mm on centres. Both edges of doors shall
be joined and reinforced full height by steel channels placed immediately inside
and welded to the door faces. Top and bottom of doors shall be reinforced
horizontally by steel channels running full width of door. Doors shall not have
more than 2.5 mm clearance at jambs and head, shall have proper level on lock

stiles and rails and shall be reinforced at corners to prevent sagging or twisting.
Pairs of double doors shall have meeting style edges bevelled or rebated. Where
shown on drawing, or in the Schedule of Items, the doors shall be sound-deadened
by filling the inside voids with mineral wool or other suitable approved materials.
Doors shall be mortised, reinforced, drilled and tapped in shop for hinges, locks
and bolts. They shall also be reinforced for closers, push-plates and other surface
hardwares where necessary. Any drilling and tapering required for surface
hardware shall be done at site. Where shown in drawing, provisions, shall be
made for fixing glazing, vision panels, louvres etc. Glazing mouldings shall be of
18G or 1.25mm thick steel or extruded aluminium sections with profiles shown in
drawing and suitable for fixing 6 mm glass. Louvre blades shall be V or Z shaped
sections.
9.4.2 Single sheet door shutters
Single sheet doors shall be made from best quality 18g/1mm mild steel sheets,
and shall present a flush surface on the outside. The inside shall be stiffened with
a semi-tubular edge and central stiffening rail which shall convey the lock and
other fixture. The frames shall be made from best quality steel sections.
Wherever required or shown on drawings, provision for fixing glass panes,
louvres etc., shall be made.
The manufacturing shall done as specified in "Double Plate Flush Door Shutters".
9.5 Pressed Steel Doors
All pressed steel doors shall be obtained from an approved manufacturer. The
frame and shutters shall be fabricated from cold rolled or pressed steel sections.
Unless otherwise specified, the thickness of all sheets used for frames shall be not
less than 5 mm. The shutters shall be made of sheet steel of 2 mm thickness for
single shutter doors and double shutter doors with or without service door. The
plates shall be adequately stiffened with suitably placed stiffeners
The double-walled door shutter shall consist of two plates each 2.5 mm thick,
separated by a gap of 33 mm in between making an overall thickness of 38 mm or
as shown in drawing. The plates shall be adequately stiffened by means of
suitably spaced horizontal steel stiffeners.
9.6 Steel Windows, Sashes, Ventilators, etc.
These shall conform to IS : 1038-1983 and IS : 1361-1978 as appropriate and as

shown in drawings. The details as called for in the above codes shall be
applicable for coupling mullions, transoms, weather bars, pivot arrangements for
ventilators, etc.
9.6.1 Where composite unit openings are shown in drawings, the individual window
units shall be joined together with requisite transoms and mullions. Where
aluminium glazing beads are specified, they shall be extruded aluminium channel
9.5 mm x 1.6 mm (Indal Section No. 2209) unless otherwise shown in drawings.

All welds at the corner of casement shall be done by flash butt welding process or
any other suitable method which gives the desired requirement and dressed flush
on all exposed and contact surfaces.
9.7 Collapsible Gate (Steel)
Mild steel collapsible gates shall be obtained from an approved manufacturer.

These shall be of mid bar type made out of double channels each 20 x 10 x 2 mm
with 20 x 5 mm diagonals and shall be top hung with roller bearings, and fitted
with locking arrangement.
Collapsible gates under 3.0 metre height shall generally have 3 sets of lattices and
those over 3.0 metre height, 4 sets of lattices. Guide tracks shall be fitted at the
top and bottom, of T-iron 40 x 40 x 6 mm with 40 mm dia bearings in every fourth
double channel
9.8 Steel Rolling Shutters and Grills
Unless otherwise specified the shutters shall conform IS:6248-1979. Laths for
rolling shutters shall be made from tested bright cold rolled, annealed M.S. strips,
not less than 0.9 mm thick for shutters upto 3.5 M wide and not less than 1.25 mm
thick for shutters above 3.5 M wide and machine rolled at 75 mm rolling centres,
interlocking with each other. The profile will be such as to prevent excessive
deflection under specified wind load.
Rolling grills shall be constructed out of 6/8 mm dia rods at 35 mm on centres

running horizontally flexible connected with vertical links spaced not more than
200 mm centres. Alternatively, rolling grills shall be made from perforated laths
of approved design reinforced with 6 mm dia rods. End locks shall be heavy type
and shall be provided at each end of alternate laths unless specified otherwise.
Bottom bars shall be finished with two angles not less than 6 mm thick for
external shutters. When shown in drawings, a flexible weather strip shall be
applied to make tight contact with the floor. Guides shall be of such depth as to
retain the shutter under a wind pressure of 150 kg/sq.m. or as specified. Shafts
shall be of steel pipe of sufficient size to carry the torsional load with a maximum
deflection of 1/360 th of span. Grease packed ball bearings or bushings shall be
provided for smooth trouble free operation.Hoods shall be formed of not less than
20 gauge or 0.90 mm thick sheet mild steel, suitably, reinforced to prevent sag.
Locks shall be slide bolt and hasp, or cylinder lock operable from both sides.
Provision for securing hand chain with padlock, removable handle for hand cranks
etc, shall be made as described in scheduled of items and as directed by the
Engineer.
9.8.3 Laths for rolling shutters shall be made from tested bright cold rolled, annealed
M.S. strips, not less than 0.9 mm thick for shutters upto 3.5 M wide and not less
than 1.25 mm thick for shutters above 3.5 M wide and machine rolled at 75 mm
rolling centres, interlocking with each other. The profile will be such as to prevent
excessive deflection under specified wind load. Rolling grills shall be constructed
out of 6/8 mm dia rods at 35 mm on centres running horizontally flexible
connected with vertical links spaced not more than 200 mm centres.

Alternatively, rolling grills shall be made from perforated laths of approved design
reinforced with 6 mm dia rods.
End locks shall be heavy type and shall be provided at each end of alternate laths
unless specified otherwise. Bottom bars shall be finished with two angles not less
than 6 mm thick for external shutters. When shown in drawings, a flexible
weather strip shall be applied to make tight contact with the floor. Guides shall be
of such depth as to retain the shutter under a wind pressure of 150 kg/sq.m. or as
specified. Shafts shall be of steel pipe of sufficient size to carry the torsional load
with a maximum deflection of 1/360 th of span. Grease packed ball bearings or
bushings shall be provided for smooth trouble free operation. Hoods shall be
formed of not less than 20 gauge or 0.90 mm thick sheet mild steel, suitably,
reinforced to prevent sag. Locks shall be slide bolt and hasp, or cylinder lock
operable from both sides. Provision for securing hand chain with padlock,
removable handle for hand cranks etc, shall be made as described in scheduled of
items and as directed by the Engineer.
9.8.5 Manually operated shutters/grills
Manually operated shutters shall be easily operable by one person. The speed of
operation shall be about 0.3 metres per second. In general, manually operated
shutters shall be push pull type for openings upto 9 sqm in area. Larger shutters
shall be either chain and gear operated or crank and gear operated. The
crank/handle shall be removable. All shutters shall be lockable from one or both
sides as described in Schedule of Item or as desired by the Engineer.
9.8.6 Priming coat of shop coat
Shutters shall be painted with one coat of red lead or zinc chromate primer after
they are inspected and found in order and acceptable. Where specified, doors shall
be galvanized and subsequently painted one coat of zinc chromate for adhesion of
field coat.
9.8.7 Erection
Door shall be installed by the manufacturer or his authorised representative and all
work shall be as per manufacturer's instructions. Any drilling or cutting to
concrete, masonry etc., shall be made good after erection of shutters and all
abrasion to shop coat shall be touched up. All electrical work shall be in strict
accordance with prevailing Indian Electricity Rules.
9.8.8 Inspection
After completing the manufacture of the different components of the rolling

shutter, an arrangement for shop inspection by the Engineer shall be made to
check the conformity with approved shop drawings.
9.8.8.1 Field inspection
After installing the shutters, the Contractor shall test the performance of the
shutter in the presence of the Engineer. The doors shall be smoothly operable

under all ambient conditions. All control and locking devices shall give fault-free
performance.
9.9 Guarantee
The Contractor shall give one year's guarantee for the successful operation of the
shutters. This shall be supported by a separate and unilateral guarantee from the
manufacturer of the shutters.
9.10 Aluminium Doors, Windows, Frames
9.10.1 Anodised tubular aluminium doors shall be of approved make and shall be of size
and design as per relevant drawing. Unless otherwise specified, the door frame
shall be of 101.4mm x 44.6mm and shutter of 50mm tubular extrusions, 3mm
thick. The opening arrangement shall be single action or double action as shown
in drawing with spring hinges in floor. The glazing shall be 5.5mm thick plain
glass panes fixed with necessary gaskets and aluminium beading strip. The door
shall be provided with one security lock. The shutters shall be provided with
1.6mm thick 300x150mm push plates and 1.6mm thick 300mm wide kick plate of
anodised aluminium for full width of door inside and outside.
The door frames shall be polished and anodized with approved colour. The
average thickness of anodic coating shall not be less than 15 microns as per IS:
1868-1982. Door frame shall be provided with approved anchors @ 90 cm c/c
maximum for fixing.
9.10.2 Aluminium windows
Aluminium windows and ventilators shall conform to IS:1948-1961 or equivalent

as approved by the Engineer. Fixed frame shall be manufactured from aluminium
alloy conforming to ISS-HE-9 WP. The fixtures like handles, stoppers, stays, etc.,
shall also be anodized aluminium and shall be of approved make. Glazing shall be
4mm thick plain glass and shall be fixed with glazing clips and metal putty. It
shall conform to IS:1081-1960. Average anodizing coating to windows,
ventilators and fixtures shall not be less than 15 microns as per IS : 1868 - 1982.
9.10.3 All work shall be fitted and shop assembled to a first job, and ready for erection.
Shop joints shall be made to hair lines and then welded or braced by such method
as will produce a uniform colour throughout the work. Wherever possible, joints
shall be made in concealed locations and on edges of doors. Field connections of
all work may be made with concealed screws or other approved type of fasteners.
Glazing beads shall be shape fit type without visible screws and shall be of sizes
to accommodate glazing. All work shall be adequately braced and reinforced as
necessary for strength and rigidity.
10.0 Glazing
10.1 General
Glazing shall be done with plain, frosted, ground glass or wired cast glass,
laminated safety glass or toughened glass etc. as shown on drawings, described in

the Schedule of Items or approved by the Engineer. The method of glazing

adopted shall be such that movement of the structure, to which the securing is
done, does not transmit strain to windows, doors or ventilators as the case may be.
The work shall generally conform to IS:1081-1960 "Code of Practice for Fixing
and Glazing of Metal Doors, Windows & Ventilators". The material for putty
shall consist of whiting and linseed oil, raw-mixed in such proportion as to form a
paste conforming to IS : 419-1967.
10.2 Doors, Windows and Ventilators
Windows and ventilators shall be designed for putty glazing fixed from outside
and glazed doors for fixing from inside. In addition, spring type glazing clips shall
be provided at intervals of 30 cm, or as shown otherwise on drawings or described
in the Schedule of Items. These shall be inserted into holes drilled in the shutters
or frames as the case may be.
All glazing shall be puttied to the shutters of frames with good quality putty in
addition to glazing clips. Glass panes shall not be placed directly against the
metal/timber. A thin layer of putty shall be even spread over the glazing rebate and
the glass pressed firmly against it. It shall be secured in position by means of teak
wood beads for wooden shutters. Glass panes shall be set without springing &
shall be bedded in putty and back puttied, except where moulding or gasket are
specified. Putty etc. shall be smoothly finished to even lines. Figured glass shall
be set with smooth side out. After completion of glazing work, all dirt stains,
excess putty etc., shall be removed and the glass panes shall be left in perfectly
acceptable condition. All broken cracked or damaged glass shall be replaced by
new ones at the Contractor's cost.
10.3 Northlight Glazing
This shall consist of aluminium or steel glazing bars as shown on drawings or

described in the Schedule of Item and be subject to approval of Engineer.The
glazing parts shall be securely fixed in their frame and shall be weather-proof. All
glazing shall be flashed to the surrounding so as to be weather-proof. Glass shall
be fixed to the a astragals with glazing clips and putty.
11.0 White washing, colour washing and painting
11.1 Scope
This chapter deals with white washing, colour washing, distempering, cement
washing, emulsion painting, silicate painting etc., to concrete and masonry
surfaces and painting to the wood works and steel works. For the items which
have not been completed or partly covered in this chapter, specifications suggested
by the manufacturers for the materials, surfaces preparation, workmanship and all
bye works shall be strictly followed and shall be carried out as per direction of the
Engineer.
11.2 Materials
Materials shall conform to Part - I

11.3 White Washing, Colour Washing
11.3.1 General
Wherever scaffolding is required/necessary, it shall be erected on double support

tied together by horizontal pieces, over which the scaffolding planks shall be
fixed. No part of it shall rest on or touch the surface which is being
washed/painted. Where ladders are used, pieces of old gunny bags shall be tied on
their tops to avoid damage or scratches to walls. For white washing the ceiling,
proper stage scaffolding shall be erected. The surface on which wash is to be
applied shall be thoroughly brushed free from mortar droppings and foreign
matter.
11.3.2 White Wash
The wash shall be prepared from fresh stone white lime of approved quality and
shall be thoroughly slaked on the spot mixed and stirred with sufficient water to
make a thin cream. This shall be allowed to stand for 24 hours and then shall be
screened through a clean coarse cloth. 4 Kg of gum dissolved in hot water shall be
added to each cubic metre of the cream.
The approximate quantity of water to be added in making the cream will be 5 litres
of water to 1 Kg of lime. Indigo/ultramarine blue upto 3 gm per kg of lime
dissolved in water shall then be added and wash stirred well. Water shall then be
added at the rate of about 6 litres per kg of lime to produce a milky solution. The
white wash shall be applied with approved brushes to the specified number of
coats. The operation for each coat shall consist of stroke of brush given from the
top downwards, another from the bottom upwards over the first stroke and
similarly one stroke horizontally from the right and another from the left before it
dries. The white washing on ceiling shall be done prior to that on walls.
Each coat shall be allowed to dry before the next one is applied and shall be
subjected to inspection and approval by the Engineer. No portion of the surface
shall be left out initially to be patched up later on.
The finished dry surface shall not show any signs of cracking and peeling nor shall
it come off readily on the hand when rubbed. Doors, windows, floors and such
other parts of the building not to be white washed shall be protected from being
splashed upon.
11.3.3 Colour Wash
A priming coat of white wash with lime shall be applied before applying two or
more coats of the colour wash (as specified). Entire surface should represent a
smooth and uniform finish. Sample of colour wash shall be duly approved by the
Engineer before application. Same specification as that of white wash shall be
followed for colour wash also using necessary amount of colouring ingredient of
approved tint.
11.3.4 White Washing with Whiting

Whiting (ground white chalk) shall be dissolved in sufficient quantity of warm

water and thoroughly stirred to form a thin slurry which shall then be screened
through a clean coarse cloth. 2 Kg of gum and 0.4 Kg of copper sulphate
dissolved separately in hot water shall be added for every cum. of slurry which
shall then be diluted with water to the consistency of milk so as to make wash
ready for use. Other specification remains same as per white washing with lime.
11.4 Cement Primer Coat
The surface shall be thoroughly cleaned of dust, mortar, droppings etc., and shall
be allowed to dry for at least 48 hours. It shall then be rubbed thoroughly be sand
paper to give a smooth and even surface. Any unevenness shall be made good by
applying putty, made of plaster of paris mixed with water on the entire surface
including filling up the undulation and then sand papering the same after it is dry.
The cement primer shall preferably be applied by brushing and not by spraying.
Horizontal strokes shall be given first and vertical strokes shall be applied
immediately, afterwards. This entire operation will constitute one coat. The
surface shall be finished as smooth as possible, leaving no brush marks.
11.5 Water-proof cement paint
The prepared surface shall be thoroughly wetted with clean water before water
proof cement paint is applied. The paint shall be prepared strictly as per
manufacturer's specifications, in the absence of which it shall be mixed in two
stages. The first stage shall comprise of 2 parts of water proof cement paint and
one part of water stirred thoroughly and allowed to stand for 5 minutes. Care shall
be taken to add the paint gradually to the water and not vice versa. The second
stage shall comprise of adding further one part of water to the mix and stirring
thoroughly to obtain a liquid of workable and uniform consistency. The paint
shall be mixed in such quantities as can be used up within an hour of its mixing.
Paint shall be applied with brushes or spraying machine The solution shall be
kept well stirred during the period of application. It shall be applied as far as
possible on the surface which is on the shady side of the building so that direct
heat of the sun on the surface is avoided. Painted surfaces shall be sprinkled with
water 2 or 3 times a day. This shall be done between coats and for at least 2 days
following the final coat. The curing shall be started as soon as paint has hardened
so as not to damage by sprinkling of water say about 12 hours after the
application. A uniform shade should be obtained after application of paint.
Cement paint shall not be applied on surfaces already treated with white wash,
colour wash, distemper, varnish paint etc., and on gypsum, wood and metal
surfaces.
11.6 Synthetic washable distemper
The surface shall be prepared as for Cement Primer Coat. A primer coat of
cement or distemper primer shall be applied as specified in the description of the
item. Unevenness in the plaster shall be made good by applying plaster of Paris
putty mixed with distemper of the colour to be used on the entire surface including
filling up the undulations. The surface shall then be rubbed down with a fine
grade sand paper and made smooth. After the primer coat has dried for at least 48
hours, the surface shall be lightly sand papered to make it smooth, taking care not

to rub the priming coat out. All loose particles shall be dusted off. One coat of
distemper properly diluted with thinner, shall be applied with brushes/rollers in
horizontal strokes followed immediately by vertical ones which together constitute
one coat. The subsequent coats shall be applied in the same way. Two or more
coats of distemper as are found necessary shall be applied to obtain an even shade.
A time interval of at least 24 hours shall be allowed between consecutive coats.
The brushes shall be of 15 cm. double bristled type. They shall be maintained in
proper condition and those that are dirty or caked will not be allowed to be used.
The finished surface shall be even and uniform without patches, brush marks,
distemper drops etc. Sufficient quantity of distemper shall be mixed to finish one
room for applying one coat in one operation.
11.7 Dry Distemper
The surface shall be prepared in the same manner as for synthetic washable
distemper. A primer coat using approved whiting shall be applied over the
prepared surface. Distemper prepared as per manufacturer's direction shall be
applied and each coat shall be allowed to dry before subsequent coat is applied.
The finished surface shall be free from chalking when rubbed, even, uniform and
shall show no brush marks.
11.8 Plastic emulsion paint
The surface on which plastic paint has to be laid must be thoroughly cleaned and
prepared and all defects rectified and finally prepared in the same manner as for
synthetic washable distemper. The surface shall be dry and rubbed smooth by
means of sand paper to the satisfaction of the Engineer. One coat primer and two
coats of plastic emulsion paint are to be applied. The work is to be carried out
under direct guidance and instructions from the manufacturers whose expert
advise and supervision are to be made available in order to achieve the high grade
finish. The painters employed for this work must be capable of producing the
highest standard of workmanship required. If the finish is of doubtful nature, the
contractor shall have to rectify at his own cost to the entire satisfaction of the
Engineer.
11.9 Bitumen painting
Bitumen painting to concrete surface shall be done as follows :
(i) Hot application
The surface shall be cleaned of all mud etc., before painting. The honey-combs
and other defects of concrete surfaces to be painted shall be rectified properly.
Any projection of binding wire shall be cut to keep it 10 mm inside the concrete
surface and then filled with mortar. Before application the surface shall be
absolute dry.
Bitumen of standard quality as specified shall be heated to the temperature

specified by the maker and then applied hot with brushes on the prepared surface.
The surface shall be allowed to cool before applying the second coat.
(ii) Cold application

The surface shall be prepared in the same way as for hot application. The bitumen
emulsion of approved quality shall be applied with special brushes. Where acid
resistant treatment is specified such surface shall be covered with approved acid
resisting coating to the satisfaction of the Engineer. Before the coating is applied,
the surface shall be properly cleaned and prepared in the manner described above.
11.10 Tarring
(i) Timber surfaces in contact with earth/concrete/ plaster shall be treated

with one coat of hot tar or as specified in schedule before fixing.
(ii) If required steel work in holdfasts and the like shall be treated as above
and sanded in addition before being fixed in position.
11.11 Painting to Timber & Steel Surface
11.11.1 General
The priming coat for steel/wood work shall be applied after the surface has been
prepared. After the priming coat has dried, all nails, screw holes and cracks shall
be filled with putty and surface smoothened with sand paper.
All surfaces must be thoroughly dry before painting work is started and painting in
exterior/exposed parts shall not be taken up in wet/humid or otherwise unfa-
vourable weather.
All stains of paint to glasses, walls, fittings and fixtures etc. shall be cleaned
thoroughly by applying required turpentine or thinner. The contractor's rate shall
include all these.
11.11.2 Painting to timber
(i) Unless otherwise specified, all timber surfaces shall be treated with one
priming coat, one under coat and one finishing coat. Under coat and
finishing coat shall be synthetic enamel or as specified. Priming coat shall
be of approved primer. In case the surface is to be polished or varnished,
a priming coat as approved or specified shall be given. No primer shall
be applied to wood work until it has been inspected and passed by the
Engineer.
(ii) Polishing
The surface to be polished shall be prepared in the same manner as

specified under painting.
(iii) French Spirit Polish
After preparation of the surface it will be well dusted and then the pores of
the wood shall be filled up with a filler made of a paste of whiting in
water or methylated spirit with a pigment if so required. The spirit polish
shall be prepared by dissolving pure shellac in methylated spirit, @ 0.75

Kg of shellac to 5 litres of spirit, with the addition of pigment if so

required.
Te polish shall be applied with a pad consisting of cotton wool inside a

clean white cloth. Several coats shall be applied with light sand papering
from time to time and cleaning the dust before applying next coat except
the final coat. The final coat of the polish shall be rubbed thoroughly until
the wood feels perfectly dry when touched and gives a satisfactory smooth
shining.
(iv) Wax Polishing
After preparation of surface wax polish will be applied. The polish shall
be prepared by heating together 2 parts of pure bees wax and boiled
linseed oil each over a slow fire. When the wax is completely dissolved
the mixture shall be cooled till it is just warm and one part of genuine
turpentine is to be added and entire mixture shall be well stirred.
Polish shall be applied in the same manner as specified for spirit polish.
11.11.3 Painting to Steel Surface
11.11.3.1 General
All surfaces shall be thoroughly cleaned of all dirt, grease, rust and mill scale.
Areas which become inaccessible after assembly shall be painted before assembly
after cleaning the surfaces as described above. The surfaces shall be perfectly dry
before painting.
Wherever shop primer painting is damaged, the surfaces shall be thoroughly

cleaned and touched up with corresponding primer.
Site painting shall not be done in frosty or foggy weather or when humidity is
such as to cause condensation on the surface to be painted.
11.11.3.2 Steel Structures
Unless otherwise specified all structures shall be painted with two coats of primer.
One coat shall be applied at shop and the second coat at site. All structures after
erection shall be given two coats of finishing paint and shall be of synthetic
enamel of approved colour. The under coat shall have different tint to distinguish
from the finishing coat.
11.11.3.3 Galvanized Iron Sheets
All plain and CGI sheets requires surface pre-treatment or use of other patented
primer to ensure adhesion of paint to zinc coated surfaces. Such pre-treatment
shall be as per manufacturer's specifications. Where pre-treatment is adopted one
coat of primer paint of suitable quality shall be applied. Unless otherwise
specified the finishing coats shall consist of an under-coat of an aluminium paint
having blue tint and a second coat of aluminium paint having aluminium colour.

11.11.3.4 Structures embedded
Exposed surfaces of embedded parts shall be given two coats of red lead graphite
primer at shop and finished with two coats of anti-corrosive paint at site after
embedment. Type of paint and procedure of painting shall be as per
manufacturer's specification. Surfaces to be field welded shall have no paint
applied within 100 mm of the welding zone.
12.0 Internal water suppply plumbing, drainage & sanitation
12.1 Scope of Work
The work comprises supply, laying testing, commissioning etc. of water supply,
plumbing, drainage & sanitation.
The work includes the following activities connected with the job :
i) Supply and delivery of all required pipes and other materials.
ii) Earthwork in excavation for trenches, pits/chambers/manholes etc.
iii) Civil works connected with the laying/erection of pipe lines such as
making holes in the wall etc. and repairing them after pipe erection,
construction of pipe supports, valve chambers, manholes, bedding and
covering of pipe laying wherever required.
iv) Laying and jointing of pipe lines as specified in this chapter
v) Testing of pipe lines after laying as per standard tests specified in this
chapter.
vi) Back filling of trenches after successful and satisfactory testing.
vii) Disinfection of the complete piping system in the case of water supply.
viii) Commissioning of entire network.
ix) Safe custody of the pipes/materials/equipment/work and other obligation

stated elsewhere in the specification.
x) Any other activities which are not mentioned above but essential and
required.
12.1.1 Materials
The materials shall conform to Part-I of this series.
12.2 Water Supply & Plumbing
12.2.1 General
12.2.1.1 General Requirements

The Contractor shall lay all the pipes and fittings in the best workman like manner
by skilled workmen and experienced plumbers in conformity with the regulations
and requirements of the local appropriate authorities and to the satisfaction of the
Engineer. Unless otherwise specified water supply works in buildings shall be
carried out in accordance with IS:2065-1983 "Code of Practice for Water Supply
in Buildings" & IS:2064-1993 "Code of practice for selection, installation and
maintenance of sanitary appliances".
12.2.2 Installation
All works like earth work, masonry, concrete, steel work, cutting holes, chases in
brick, concrete & RCC works, cutting of roads, repairs and rectifications
associated directly with the installation of water supply system shall come under
the scope of the contractor and shall be governed by the specification of the
relevant chapter.
12.2.3 Laying
Before lowering down for laying in the trenches, the pipes shall be checked
against crack by means of light hammering and for any other damage. All fixing
shall be carefully aligned and spaced at a distance from the main structure to give
reasonable all round access for maintenance and inspection and laid true to line
plumb and level. Any deviation shall need approval of the Engineer. Meticulous
care shall be taken to avoid chances of airlock and water hammer.
Pipes shall be laid on continuous unyielding surface holder or on reliable supports

at least one near each joint and spacings as directed by the Engineer. The support
must be strong, neat and shall have provisions for securing the pipes in every
direction and easy maintenance. If situation requires, pipes shall be encased or
concealed in masonry or concrete if shown on drawing or directed by the
Engineer. Pipes embedded in floors and wall shall be securely bound so as not to
allow any movement due to expansion and contraction. adequate width shall be
provided to lay the pipes as per standard practice.
Excavation below the required level is not permitted. The contractor shall make
good any excess excavation as directed by the Engineer.
Soft spots in the bottom of beds for pipe lines in rock shall be leveled with sand or
soft soil or concrete as approved by the Engineer and the thickness of the layer
shall not be less than 100mm.
12.2.4 Excavation for pipe lines in trenches
Excavation shall comply with chapter 2. The sides of pits and trenches shall be
adequately supported at all times, except where otherwise directed by the
Engineer.
12.2.5 Underground piping in and around building
Underground piping shall be laid at such a depth that it is not likely to be damaged
by traffic and other loads and frost, where applicable, and as shown in the drawing

and instructed by the Engineer. The thrust blocks shall be provided wherever
required.
The size and depth of the trench shall be as approved by the Engineer. Backfilling
in trenches shall be done with selected fine earth, unless otherwise permitted, in
150mm layers and carefully consolidated and well treated so that it does not set as
a drainage channel. Special care shall be taken while filling in the vicinity of the
pipe to avoid damages. Before backfilling the laid pipe shall be fully tested and
approved.
12.2.6 Concealed piping
Where desired by the Engineer or shown on the drawings the pipes shall be
concealed in masonry or concrete of the adjoining structure by making chases in
walls/floors and these shall be secured by hooks and the chases filled with
concrete 1:2:4 (1 cement, 2 sand and 4 aggregate). The contractor will rectify, if
required the chases, openings and pipes, supplement and make good after laying
and testing of the concealed pipelines.
12.2.7 GI.Piping
The pipes shall be fixed in longest lengths possible with all necessary
bends, tees, couplings, reducing ockets, short piece, jamnut and tees etc. in
perfect straight lines both vertically and horizontally.
12.2.7.2 All exposed GI pipes shall be fixed at least 15mm clear of wall face with holder
bat clamps at suitable places not exceeding (2.5 metres) centre to centre. Where
the pipes are laid in chases in walls as shown in the drawing, these shall be
secured to walls by hooks. Chases in walls and floors shall be filled in with
cement concrete 1:2:4. Where the pipes are to be run underground these may be
laid at least 60 cm below ground level.
12.2.7.3 The joints of pipes and fittings shall be sealed with red lead paint and fine spun
yarn. Joints must be perfectly water tight when put under maximum test pressure.
12.2.7.4 Unless otherwise specified the exposed portion of pipes and fittings shall be given
two coats of approved synthetic enamel paint over a coat of approved priming.
Pipes laid underground or concealed in walls/floors shall be treated with two coats
of bituminous paint.
12.2.8 Jointing of pipes
The interior of all pipes and joints shall be cleaned before jointing commences.
Jointing of pipes shall be done in such a manner as to render them completely leak
proof and durable. Instruction of the manufacturer shall be followed unless desired
otherwise by the Engineer. However, the general norms and recommended
practices for different types of pipes are given below for guidance :
(a) Cast Iron
i) Spigot and socket joints :

Interior surface of bells and exterior surface of smooth ends of pipes shall
be cleared of redundant insulating cover and other foreign materials
particularly of oil, burning off materials from bells and smooth pipe ends.
Sharp rises on interior bell surface shall be smoothed out.
Bells should be lined up, in compliance with direction of pipe. Laying

work shall be started from lower points.
ii) Lead and Flanged Joint :
ead joints shall be made as per Sl. 15.4.6.1 and flanged joints as per Sl.
15.4.6.2 of chapter 15.
b) Steel Pipes
Plain ended steel pipes may be jointed by welding. Screwed and socketed
joints shall be carefully tightened. Care shall be taken to remove burring
from the ends of the pipes. Jointing compound, if used, shall be lead free
and approved by the Engineer.
c) G.I Pipes
Threads shall be cut with, sharp tools, and before jointing all scale shall be
removed from pipes by suitable means. The screw threads of the pipe shall
be cleaned out and the joint made by screwing the fitting after treating the
threads with approved pipe jointing compound. Once a joint has been
screwed up it shall not be backed off unless threads are recleaned and new
compound applied.
d) Asbestos cement pipes
Socket and spigot ended pipes shall be jointed by caulking with tarred
gaskets and grouted with 1:3 cement sand mortar.
12.2.9 Precautions
a) All water supply pipes shall be so laid and so fixed and maintained as to
be and remain completely water tight.
b) During installation open ends of each pipe shall be protected by suitable

covers or plugs so that the ends, thread, sockets or spigot are not damaged
and no foreign materials can make its way into the pipe line.
c) Due care should be taken to ensure that there shall be no cross connection
whatsoever between a pipe or fitting for conveying or containing
wholesome water and a pipe or fitting containing impure water or water
liable to contamination or of an uncertain quality of water which has been
used for any other purposes.
d) Fittings and fixtures liable to be stolen shall be fitted and fixed just before
testing and handing over.

Painting
When mentioned in the schedule of item underground steel and cast iron pipes
shall be treated with 2 coats of anticorrosive bituminous paint on the outside
surface after cleaning the surface from soil, dust, moisture, rust, scales soot etc.
When painting is to be done for pipes above ground, G.I. pipes shall be given a
coat of zinc chromate primer, C.I. & M.S. pipes shall be given one coat of red lead
or zinc chromate primer over which at least 2 coats of paint of best quality and
manufacture as approved by the Engineer shall be provided or as specified in the
schedule of item.
12.2.11 Ferrule and stop cock box with chamber
Square cast iron surface box 15 cm square and 22.5 cm deep weighing not less
than 4.54 Kg with hinged lid shall be provided in masonry chamber. Top of box
shall be made flush with the finished level of the chamber. The chamber 25cm x
25cm inside shall be with half brick wall in cement mortar 1:4 over a cement bed
concrete of 75mm thick in proportion 1:4:8 with stone chips. The inside wall faces
shall be plastered with 12mm thick cement mortar 1:4 finished smooth with a
floating coat of neat cement.
The exposed surfaces of cast iron box and cover shall be treated with two coats of
bituminous paint.
12.2.12 Inspection, Testing and Acceptance
12.2.12.1 Pipes, fittings and fixtures before laying
All pipes, fittings and appliances shall be inspected, before delivery at the site to
see whether they conform to accepted standards. The pipes and fittings shall be
inspected on site before laying and shall be sounded to disclose cracks. Any
defective items shall be clearly marked as rejected and forthwith removed from
the site.
12.2.12.2 Testing of pipes after laying
General
a) The contractor shall ensure the safety of the pipe work under test and
provide all necessary stoppers, testing apparatus etc. that are required for
testing.
b) The contractor shall be responsible for any damage done to pipe work and
ancillary work while testing and shall replace any pipe or fitting which
does not satisfactorily withstand the test.
c) The contractor shall give written notice of the times at which tests are to
take place. On completion of each test two copies of the complete records
shall be given to the Engineer.

d) The work will not be considered complete until the tests are found
satisfactory and a certificate issued by the Engineer.
After laying and jointing, the main shall be slowly and carefully charged with
water, so that all air is expelled from the main by providing a 25mm inlet with a
stop-cock, allowed to stand full of water for a few days if time permits and then
tested under pressure. The test pressure shall be 6Kg/cm2 or double the maximum
working pressure, whichever is greater The pressure shall be applied by means of
a manually operated test pump, or in the case of long mains or a large diameter,
by a power driven test pump, provided that pump is not left unattended. In either
case due precaution shall be taken to ensure that the required test pressure is not
exceeded. Pressure gauges shall be accurate and shall preferably have been re-
calibrated before the test. The pump having been stopped, the test pressure shall
maintain itself without measurable loss for at least five minutes. The end of the
main shall be closed by fitting a water-tight expanding plug and the plug shall be
secured by struts to resist the end thrust of the water pressure in the mains.
12.2.12.3 Testing of service pipes and fittings
The service pipes shall be slowly and carefully charged with water allowing all air
to escape avoiding all shock or water hammer. The service pipe shall then be
inspected under working conditions of pressure and flow. When all draw-off taps
are closed, the service pipes shall be absolutely watertight. All pipings, fittings
and appliance shall be checked for satisfactory support and protection from
damage, corrosion and frost.
12.2.13 Storage Tank
12.2.13.1 Pressed steel tank
Pressed steel water storage tanks shall be of nominal size and capacity as
mentioned in the Schedule of Item and fabricated with all flanges external /
internal or bottom flange internal and side flanges external, as shown on drawings
or schedule of items. Inlet, overflow, vent pipes and manholes shall be arranged
and provided as shown in drawing or mentioned in the schedule. Unless otherwise
specified, the outlet pipe shall be 50mm above the bottom of the tank and there
shall be 150mm free board at the top of the tank. The fabricator shall supply 5
prints of fabrication drawing to the Engineer for prior approval showing thickness
of plates, method of jointing the plates. All supports, stays, gussets etc. Pads,
cleats etc., required for supporting the tanks shall also be supplied by the
manufacturer.
All tanks shall be supplied with mosquito-proof top with manhole not less than
450mm diameter. Tanks deeper than 1.00 Metre shall be provided with M.S.
internal access ladder adjacent to the manhole. Meter level indicator shall be
provided if asked for. Two coats of anticorrosive paint over a suitable primer shall
be applied to both internal a external surface of tanks. The paint shall be so
selected as not to impart any taste or odour of water and be of lead free
composition.
12.2.13.2 G.I. Water Tank

G.I. water tanks shall be procured from a reputed manufacturer. The design shall
be good enough to withstand the loads safely. Galvanized iron water storage tank
shall be made of minimum 16 gauge galvanized iron sheet. Unless otherwise
specified plain sheets shall be fixed at the corner to angle iron frames by means of
6 mm rivets at 40 mm pitch for tanks upto 1000 litres capacity and 8 mm rivets at
35 mm pitch for tanks above 1000 litres capacity. Tanks above 1000 litres shall
have 20 mm dia. galvanised iron stays, one fixed to angle framing at topand two in
the body of the tank for extra strength. Holes for rivetting shall be drilled and not
punched. Lead shall be applied to the joints before rivetting.
Tanks shall have 400 mm dia. holes at the top with hinged covers. The covers
shall be made of galvanised iron sheet with angle iron frame. The cover shall be
just loose but close fitting to keep out dust and mosquito and will not be airtight.
It shall be complete with lockable arrangement.
Tanks unless otherwise specified shall be provided with rising main inlets of 40
mm dia. galvanised iron pipe or as shown on drawing and 40 mm dia. G.I. over-
flow pipe and 25 mm washout with plug. If specified the rising main shall be
connected to the tank with a ball valve near the top which disconnects the supply
when tank is full up to the point of overflowing.
The ball valve shall permit the entry of water when the tank is empty and
disconnect the supply when the tank is full. It consists of a hollow floating ball
made of copper, plastic or hard rubber, 110 mm in diameter attached to an arm
which is so pivoted that the end near the pivot close the orifice of the main when
the ball is raised to the required height of water in the tank and opens the main as
soon as the ball drops with the fall of water level as it is drawn off through the
distribution. The ball valve shall be fixed to the tank in such a position that the
body of the ball valve submerge when the tank is full upto the water line. The ball
valve shall be so adjusted as to limit the level of the water in the tank below the lip
of the over-flow pipe, and above the maximum water filled level shall be as per
the standard norms for GI water tank.
Water reservoirs made of concrete or masonry shall be governed by the

specification in the relevant chapter. It shall have, inlet, outlet, overflow and wash
out with plug and a top MS/CI cover as per schedule of items and drawings.
12.3 Drainage and Sanitation (Internal)
12.3.1 Scope
This section covers the layout and construction of drains for waste water, surface
water and sewage together with all fittings and fixtures inclusive of ancillary
works, such as connectins, manholes and inspection chambers used within and
around the building and the connection to a public sewer upto treatment work,
septic tank and soak pit. All sewerage and drainage works shall be executed in
accordance with specifications given for different works. All sewerage and
drainage works shall be executed by a licensed plumbing supervisor or a licensed
plumber and in accordance with IS : 1742-1983 "Code of Practice for Building
Drainage" unless otherwise specified.

12.3.1.1 Installation
All pipe lines, locations of fittings and fixtures, etc. shall be as per drawings or as
directed by the Engineer. Correctness of lines, plumbs, orientation, symmetry and
levels shall be strictly ensured. All items shall be fully secured against movement
in any direction and shall be located so as to allow easy maintenance.
All pipelines, fittings and fixtures shall be installed leakproof; when the works
under scope of this specification are linked up with works executed by others, the
connections shall be such as to prevent any splashing or spilling or emission of
foul odour and gasses.
12.3.2 Rainwater downcomers
Rainwater downcomers shall be standard cast iron or asbestos cement pipes. In

case where specifically desired, M.S. pipes may also be used. M.S. pipes shall be
painted outside with two coats of anticorrosive paint over a coat of primer. Rain
water downcomers shall run along and be secured to walls columns, etc. Where
desired by the Engineer these may have to be installed in chases cut in the
structure. All pipes shall be well secured and supported by adequately strong
brackets. The brackets may be wrought iron clamp type, split ring type or
perforated strap iron type as approved by the Engineer. For vertical runs each pipe
shall hang freely on its brackets fixed just below the socket. Suitable spacer
blocks shall be provided against the vertical surface to which the pipe is fixed.
Roof and floor drains and yard gullies shall be installed, if required, by cutting
into the structure and grouted with 1:2:4 cement concrete. All gutters shall be
provided with removable gratings. All horizontal pipes shall have a minimum fall
of 1 in 100.
12.3.3 Gutter
The gutters shall be made of G.I. or A.C. Gutters shall be supplied by reputed
specialised firms. Each section shall be sufficiently rigid, edges and corners
straight and the slopes perfectly uniform. GI gutters shall have the edges
strengthened by suitable means. The joints may be made by rivetting, bolting or
soldering.
Unless specified otherwise the gutters shall have a minimum fall of 1 in 120.
Adequate number of string supports shall be provided so that there is no deflection
even when the gutter is full. Each joint must have a support. Unless otherwise
specified the supports shall be fabricated of MS brackets. All junctions shall be
thoroughly watertight. The joints may be made by rivetting, bolting or soldering.
All joints between successive lengths of gutters shall have an overlap of at least 5
cm. The drop in the overlap shall always be in the direction of the fall of the
gutter. Ends of gutters shall be closed watertight. Junction with rainwater
downcomers shall be made fully watertight and secured.
12.3.4 Soil and Drainage Pipes
Gradients

If not specified the minimum gradients of soil and drainage pipe line shall be as
follows :
100 mm nominal dia : 1 in 35

Relation with water supply pipe lines
Unless specifically cleared by the Engineer, under no circumstances shall drainage
and soil pipes be allowed to come close to water supply pipelines.
12.3.4.3 Laying
Each separate pipe shall be individually set for lines and levels. Where lengths of
sewer or drain pipes are laid in trench, properly painted sight rails shall be fixed
across the trench at a height, equal to length of the boning rod to be used, above
the required invert level of the drain or sewer at the point where the sight is fixed.
More sight rails shall be required at manholes, change of gradient and intermediate
positions if the distance for sighting is more than 16 m apart. The excavation shall
be boned in at least one in every 2 m. The foot of the boning rod shall be set on a
block of wood of the exact thickness of the wall of the pipe. Each pipe shall be
separately and accurately boned between sight rails.
12.3.4.4 Support and protection on pipelines
All pipes shall be laid with sockets leading uphill. Preferably the pipe shall rest on
solid and even foundations for the full length of the barrel. However, the pipe
manufacturer's instruction as approved by the Engineer shall be followed in the
matter of support and jointings.
Where pipes are not bedded on concrete, the bed shall be left slightly high and
carefully placed so that the pipe barrels rest on undisturbed ground. If anywhere
the excavation has been carried too low packing shall be done in concrete. Where
laid on rock or very hard ground which cannot be easily excavated to a smooth
surface, the pipes shall be laid on a cradle of sand or gravel as desired by the
Engineer. PVC or similar pipes shall be laid directly on stable soil and packed
with selected soil.
The minimum support and protection for glazed stoneware pipes shall be as
follows :
a) When cover is less than 1 metre and where pipes are unavoidably exposed
above ground surface, the pipes shall be completely encased surrounded
with concrete as per IS:4127-1983.
b) Where pipes are laid on soft soil with the maximum water table laying at
the invert of the pipes, the sewer shall be bedded on concrete 1:4:8 mm
with 20mm down aggregates as per IS:4127-1983.
c) Where the pipes have to be laid on soft soil with the maximum water table
rising above the invert of the pipe, but below the top of the barrel, the pipe

sewer shall be haunched with concrete 1:4:8 mm with 20mm down

aggregates as per IS:4127-1983.
d) Where maximum water table is likely to rise above the top of the barrel
the pipe sewers shall be completely encased/surrounded with 1:4:8
concrete with 20mm down aggregate as per IS:4127-1983.
Vitrified clay pipes shall be laid on a bed of 150mm thick cement concrete (1:3:6)
nominal mix by volume.
Cast iron pipes and concrete pipes may be supported on suitable concrete or brick
support, where specified. The support shall be unyielding and strong enough. At
least one support shall be located close to ends. Spacing of intermediate supports
shall be as decided by the Engineer. Pipes shall be secured to the supports by
approved means.
Anchoring of pipes where necessary shall be achieved by suitable concrete

encasing designed for the expected thrust.
12.3.4.5 Entry into structures
For entry of the pipes lines into any building or structure suitable conduits under
the structure or sleeves shall be used. The conduits and sleeves shall be such as to
allow easy repairs and replacement of the pipes. Where openings or chases are
required to be made in the structure for entry of pipe lines, locations and sizes
shall be marked and checked by the Engineer. After laying of the pipeline, the
openings and chases shall be mended.
12.3.4.6 Traps and Ventilating pipes
a) Pipes carrying the sewage from water closets and waste water and
overflow water from baths, wash basins, sinks shall be trapped
immediately beneath such fixtures. Traps shall have minimum water seal
of 50mm and shall be ventilated whenever such ventilation is necessary to
maintain water seal of the trap. Ventilating pipes shall be carried up
vertically from the drain to a height of at least 600mm above the outer
covering of the roof top of the building or as shown on drawings. All
vertical ventilating, anti-siphonage and similar pipe shall be covered on
top with a cowl. The cowl shall be made of C.I. unless desired otherwise
by the Engineer.
Connecting to existing sewer lines shall be through a manhole.
b) Sand Cast Iron Spigot and Socket pipe and fittings
All soil waste and vent pipes and fittings used in the work shall be cast iron and
shall conform to IS:1729-1979. The pipes shall have spigot and socket ends, with
bead on spigot end and shall be with or without ears. The pipes shall be free from
cracks and other flaws. The interior. of the pipes and fittings shall be clean and

smooth and painted inside and outside with Dr. Angus Smith's solution or other
approved anticorrosive paint. Fittings shall include bends, offsets, branches of
various types, junctions etc. as required for the work which shall be provided
according to drawings and directions of the engineer.
The fittings shall be provided with access doors where so specified or directed by
the engineer. The access door fittings shall be of proper design so as not to form
cavities in which the filth may accumulate. Doors shall be provided with 3mm
thick rubber insertion packing, and when closed and bolted they shall be
watertight. The access doors shall have MS studs and bolts or screws or bolts and
nuts.
Fixing
The pipes and fittings shall be fixed to wall by means of MS holder bats clamp of
approved type and steel bolts or by pipe nails, bobbins etc. as the case may be,
keeping the pipe clear from the finished surface of the wall. The holder bat nails
shall be fixed to the wall in wooden block. The soil pipe shall be supported at the
foot upon a bed of cement concrete of proportion 1:3:6 and firmly attached to the
wall.
The pipes shall be laid truly vertically or along the line as shown in the drawing.
Connection between main pipe and branch pipe shall be made by using branches
and bends with access door for cleaning.
All vertical soil waste, ventilating and anti-siphonage pipes shall be carried up
above the roof and provided with suitable C.I. cowl on top.
Pipes outside the building shall be laid underground for which trenches shall be
excavated as required for the work. The trenches shall be back-filled with exca-
vated material after the drainage system has been tested and passed.
Jointing (Lead Caulked Joint)
Unless otherwise specified, the pipes and fittings shall be jointed with lead joints
as described below :
The annular space between the socket and spigot will be first well packed in with
tarred gasket or hemp yarn leaving 25mm from the lip of the socket for the lead.
The joint may be leaded by using proper leading rings or if they are not available
by wrapping a ring of hemp rope covered with clay round the pipe at the end of
the socket, leaving a hole through which lead shall be poured in (for pipes with
sockets facing a upwards 15mm high small clay band on socket edge may be
used).
The lead shall be rendered thoroughly fluid and each joint filled in one pouring.
Before caulking, the projecting lead shall be removed by flat chisels and then the
joint caulked round with proper caulking tools and a hammer of 2 to 3 pounds in
weight in such manner as to make the joint quite sound. After being well set up
the joint is to be left flush neat and even with the socket.
Lead for caulking shall conform to IS: 782-1978.

Painting
All the exposed CI pipes and fittings shall be painted to match the colour of the
surroundings. The surface of the pipes and fittings to be painted shall be cleaned
thoroughly and painted 2 coats with approved paint over and including 1 coat of
approved primer. Pipes laid underground shall be painted with 2 coats of anti-
corrosive paint.
12.3.4.7 Cutting of pipes
Manufacturer's instructions shall be followed for cutting of pipes where necessary.

Suitable and approved tools shall be used for the cutting so as to leave surface
clean and square to the axis of the pipe.
12.3.4.8 Jointing
Jointing of laid pipes shall be so planned as to avoid completely any movement or

strain to the joints already made. If any joint is suspected to be damaged it shall be
opened out and redone.
All joints between pipes, pipes and fittings and manholes shall be gas tight when
above ground and watertight when underground. Method of jointing shall be as
per instructions of the manufacturer and as approved by the Engineer. However,
in the absence of any instruction available from the manufacturer the methods as
detailed hereunder shall be used.
(a) Sand Cast Iron Pipes
Jointing of cast iron pipe shall be done as described in Sl. No. 12.3.4.7(b).
(b) Concrete pipes
i) Spigot & Socket Joint
The opening of the joint shall be filled with stiff mixture of cement mortar 1:2 (1
cement : 2 fine sand) which shall be rammed with caulking tool.
ii) Collar Joint
Joint shall be done by slipping the collar over and clear of the end of the pipe. The
recess at the end of the pipe shall be filled with jute braiding dipped in hot
bitumen. Care shall be taken that no off-set of the jute braiding shall be visible
either outside or inside the pipe. The collar shall be then set up over the joint
covering equally both the pipes and leaving an even caulking space all round.
cement and sand mortar (1:1.5) shall then be well punched or pressed home with a
caulking tool.
c) Glazed stoneware pipes
Tarred gasket or hemp yarn soaked in thick cement slurry shall first be placed
round the spigot of each pipe and the spigot shall then be placed into the socket of

the pipe previously laid. The pipe shall then be adjusted and fixed in the correct
position and the gasket caulked tightly so as not to fill more than 1/4 of the socket.
The reminder of the socket shall be filled with a stiff mixture of cement mortar of
1:1 proportion. When the socket is filled, a fillet shall be formed round the joint
with a trowel, forming an angle of 45 degree with the barrel of the pipe. The
newly made joints shall be protected, until set, from sun and rain and shall be
covered with damp sacking or other suitable materials.
12.3.5 Trenches and other excavations
Excavation shall be carried out according to chapter-2, Earthwork.
Width of the trench at the bottom shall be such as to provide 200 mm clearance on
either side of the pipe for facility of laying and jointing.
Excavated material shall be stacked sufficiently away from the edge of the trench.
The spoil bank shall not be allowed to endanger the stability of the excavation.
Spoil may be carted away and used for filling the trench behind the work. Turf,
top soil or other surface material shall be set aside, turf being carefully rolled and
stacked for use in reinstatement. All excavations shall be properly timbered,
where necessary. Efficient arrangements for dewatering during excavation and
keeping it dry till back filling shall be made to the satisfaction of the Engineer.
Sumps for dewatering shall be located away from the pipe layout.
Where the excavation proceeds through roads necessary permissions shall be

secured by the contractor from the appropriate authorities.
Special care shall be taken not to damage underground services, cables etc. These
when exposed shall be kept adequately supported till the trench is backfilled.
The backfilling shall be done only after the pipeline has been tested and approved
by the Engineer. Special care shall be taken for packing with selected material in
areas 300 mm around the pipe. At least 300 mm over the pipe shall also be filled
with soft earth or sand.
Consolidation shall be done in 150 mm layers. The surface water shall be

prevented from getting into the filled up trench. Traffic shall not be
inconvenienced by heaping up unduly the backfilling material to compensate
future settlement. All settlements shall be made good regularly to minimise
inconvenience or traffic where applicable.
12.3.6 Installation of fittings & fixtures
12.3.6.1 General
All fittings & fixtures shall be laid out as per drawings and in proper line, level
and shall be firmly secured to floors with screws and ditto fix and to walls with
wall plugs and screws. Unless otherwise specified only C.P. Brass screws shall
be used for fixing sanitary fittings to wall plugs and floors.
12.3.6.2 European pattern WC

Water closet shall be fixed with floor by means of 75 mm long, 6.5 mm diameter
counter sunk bolts & nuts embedded in floor using rubber or fibre washers so as
not to allow any lateral displacement.
12.3.6.3 Indian Patttern W.C.
The water closet pan shall be sunk into the floor and embedded in a cushion of
average 150 mm cement concrete 1:4:8 (1 cement, 4 sand and 8 broken brick
ballast of 40 mm size). The concrete shall be left about 125 mm below the top
level of the pan so as to allow for flooring and its bed concrete. The joint between
the pan and trap shall be made with C.M. 1:1 and joint between trap and CI soil
and waste pipe to be made with lead. All the joints shall be leak proof. The WC
floor shall slope towards the pan. The foot rest shall be set in cement mortar 1:3
(1 cement : 3 sand).
The cast iron cistern, brackets and flush pipe etc. shall be painted with two coats
of approved paint, over and including a coat of approved priming.
12.3.6.4 Wash basin
Wash basin shall be fixed to C.I./R.S. brackets fixed in cement mortar 1:3 (1
cement :3 sand). The brackets shall be fixed to approved wooden wall plugs with
screws. C.P. brass trap and union shall be connected to waste pipe if specified.
12.3.6.5 Urinals
The urinal shall be fixed to the walls with C.P. Brass screws fixed to wooden wall
plugs. Urinal partitions shall be fixed to walls by making chases in walls and
grouting the same in 1:2:4 cement concrete.
12.3.6.6 Mirror
Fixed type mirror shall be screwed to wall plugs with CP brass screws and shall
have a backing of asbestos or similar material as specification in the item.
Swivel type mirror shall be fixed with C.P. brackets which shall be fixed to wall
plugs with CP brass screws
12.3.6.7 Soap tray / toilet paper holder
This shall be of flush mounting design and shall be housed in walls by making
chases and grouting the same in cement mortar 1:3 unless otherwise specified. All
other fittings shall be fixed with screw or as per manufacturer's specification
12.3.6.8 Towel rail & Toilet glass-shelf unit
This shall be fixed with CP Brass screws which shall be fixed to wall plugs.
12.3.6.9 Gully trap
This shall be fixed on 100 mm thick bed and encasement of size 600mm x 600mm
x full height of trap shall be provided with cement concrete of proportion 1:4:8

with 40mm stone aggregate. The gully outlet shall be jointed to the branch drain as
specified or directed by the Engineer.
12.3.6.10 Masonry chamber for Gully Trap
After fixing and testing gully and branch drain, a brick masonry chamber 300mm
x 300mm x 450mm deep or as specified (internal dimensions) in cement mortar
1:4 (1 cement and 4 sand) shall be built with half brick thick wall round the gully
trap from the top of the concrete. The internal faces of the chamber shall be
finished smooth with 15 mm thick cement plaster (1:4) and neat cement finish.
Brick wall exposed to outside shall be finished with 12 mm thick cement plaster
1:4. P.C.C. (1:2:4) band 100 mm thick shall be provided over the brick work with
suitable grooves for accommodating R.C.C. cover to be supplied as per drawing
and made water tight by providing suitable beading in the band.
12.3.6.11 High level flushing cistern - (fixing flush pipe & cistern)
The W.C. pan shall be connected to the cistern by G.I. 32mm dia or 40mm (O.D)
high density polythene flush pipe with holder clamp and brass coupling.
12.3.6.12 Low level flushing cistern
Unless otherwise specified, it shall be connected to the closet by means of 40mm

dia white porcelain enameled flush bend using rubber adaptor joints.
12.3.7 Septic tank and effluent disposal
12.3.7.1 Septic tank
Septic tank shall consist of the tank itself with inlet and outlets therefrom
complete with all necessary earthwork and backfilling. The details of septic tank
shall be as shown on drawing. This item shall also include ventilating pipe of at
least 100mm dia whose top shall be provided with a suitable mosquito proof wire
mesh and cowl. Generally ventilating pipe shall extend to a height of about 2
metres when the septic tank is at least 15 metres away from the nearest building
and to a height of 2 metres above the top of building when it is located closer than
15 metres. Ventilating pipes can be connected to the normal soil ventilating
system of the building where allowed.
12.3.7.2 Effluent disposal
The effluent from the septic tank shall be disposed by allowing it into an open
channel or a body of water if the concerned authority approves or into a soak pit
for absorption by soil or shall be allowed to be absorbed by soil through open
jointed S.W pipes laid in a trench filled with broken bricks.
12.3.7.3 Soak Pit
Shall be complete as shown on drawing. In absence of a detailed drawing it shall

consist of a 900mm dia pit 1000mm in depth below the invert level of the inlet
pipe. The pit shall be lined with stone, brick or concrete blocks with dry open
joints backed with at least 75 mm of clean coarse aggregate. The lining above the

inlet level shall be set in cement mortar (1:6). The pit shall be filled with brick
bats. Inlet pipe shall be taken down to a depth of 900mm from the top as an anti-
mosquito measure.
12.3.7.4 Open jointed S.W pipes
Minimum dia of the S.W pipes shall be 200mm nominal. The trench for laying the
pipes shall be minimum 600x600mm. The joints of the pipes shall be left un-
sealed.
12.3.7.5 Commissioning septic tank
After the septic tank has been proved water-tight and the sewage system is
checked, the tank shall be filled with water to its outlet level before the sewage is
let into the tank. It shall be seeded with well digested sludge obtained from septic
tank or sludge digestion tank. In the absence of digested sludge a small quantity of
decaying organic matter such as digested cow dung may be introduced.
12.3.8 Manhole/Inspection chambers
Necessary excavation as required for the manhole shall be done true to dimensions
and levels as shown in the drawing. The manhole chamber shall be built with brick
work in C.M. 1:4 with minimum one brick thick on a base of 100mm thick
cement concrete 1:4:8 with 40mm down aggregate or as specified. The concrete
bed shall extend beyond the external face of brick work on all sides by at least
75mm . The thickness of wall shall be as indicated. The work shall be carefully
built in English bond, the jointing faces of each brick being wall buttered with
cement mortar before laying so as to ensure a full joint.
The inside of the walls shall be plastered with 15mm thick cement mortar 1:4 and
finished with a floating coat of neat cement and outside shall be plastered with
12mm thick C.M. 1:4.
The channels and benching shall be done in cement concrete 1:2:4 with 20mm
down stone aggregate and finished with 12mm thick cement plaster in C.M. 1:3.
The channels shall be semicircular in the bottom half and of diameter equal to the
sewer. Above the horizontal diameter the top edge shall be suitably rounded off.
The Branch channels shall also be similarly constructed with respect to benching
but at their junction with the main channel an appropriate fall suitably rounded off
in the direction of flow of the main channel shall be given. The benching at the
sides shall be carried up in a slope of 1 in 3.
All angles shall be rounded to 75mm radius with cement mortar 1:4 and shall be
rendered smooth. The internal surfaces shall have a hard impervious finish
obtained by using a steel trowel.
The manhole chamber shall be covered on top with RCC (1:2:4) slab with
necessary reinforcement as per drawings. Unless otherwise specified circular type
light duty M.H. cover with single seal weighting 25 kg. will be provided in each
RCC cover.
12.3.9 Testing and acceptance

12.3.9.1 Inspection before installation
All pipes, fittings and fixtures shall be inspected, before delivery at the site to see
whether they conform to accepted standards. The pipes shall again be inspected on
site before laying by sounding to disclose cracks. All defective items shall be
clearly marked and forthwith removed from the site.
12.3.9.2 Testing of pipelines
Comprehensive tests of all pipe lines shall be made by simulating conditions of

use. The method of actual test shall be decided by the Engineer. All test data shall
be recorded and submitted to the Engineer for review and instruction. The
Engineer's discretion regarding tolerance shall be final.
General guidance for the tests are given below :
12.3.9.3 Smoke Test
Soil, waste, vent and all other pipes, when above ground, shall be tested for gas
tightness by a smoke test conducted under a pressure of 25mm water gauge and
maintained for 15 minutes after all trap seals have been filled with water. The
smoke is produced by burning oily waste or tar paper or similar material in the
combustion chamber of a smoke machine. Chemical smokes are not satisfactory.
12.3.9.4 Water Test
For pipes other than cast iron Glazed ware and concrete pipes shall be subjected to
a test pressure of at least 1.5m head of water at the highest point of the section
under tests. The tolerance figure of two litres per centimetre of diameter per
kilometre may be allowed during a period of 10 (ten) minutes. The test shall be
carried out by suitably plugging the low end of the drain and the end of con-
nections, 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 the 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
required head is obtained and fixed suitably for observation.
Subsidence of test water may be due to one or more of the following causes
a) Absorption by pipes and joints.

b) Sweating of pipes or joints
c) Leakage at joints or from defective pipes
d) Trapped air
Allowance shall be made for (a) by adding water until absorption has ceased and
after which the test proper should commence. Any leakage and the defective part
of the work shall be cut and made good.

12.3.9.5 For cast iron pipes
Cast iron sewers and drains shall be tested as for glazedware and concrete pipes.
The drain plug shall be suitably strutted to prevent their being forced out of the
pipe during the test.
12.3.9.5.1 For straightness
i) By inserting at the high end of the sewer or drain a smooth ball of a

diameter 13mm less than the pipe bore. In the absence of obstruction, such
as yarn or mortar projecting through the joints, the ball will roll down the
invert of the pipe and emerge at the lower end and;
ii) By means of a mirror at one end of the line and lamp at the other. If the
pipe line is straight, the full circle of light may be observed. The mirror
will also indicate obstruction in the barrel if the pipeline is not straight.
12.3.9.6 Testing septic tank
The septic tank shall be tested for water tightness. It shall be filled up with water
and allowed to soak for 24 hours. Then, it shall be topped up and allowed to stand
again for 24 hours and loss of level recorded. The fall shall not be more than
15mm.
12.3.9.7 Fixtures etc.
All fixtures and fittings shall be connected by watertight joints. No dripping shall
be accepted.
13.0 External sewerage & drainage
13.1 Scope of Work
The work comprises supply, laying, testing, commissioning etc., of sewerage &
drainage network as specified.
The work includes the following activities connected with the job.
Supply and delivery of all required pipes and other materials including erection.
ii) Earth work in excavation for trenches and pits/ manholes.
iii) Civil works connected with the laying/erection of pipe lines such
as making holes in the walls etc., and repairing them after pipe
erection, construction of pipe supports, brick / concrete manholes,
preparation of concrete bedding and covering for pipe laying
wherever required etc.
iv) Laying and jointing of the pipelines as specified in this chapter

v) Testing of the pipelines after laying as per standard tests as

specified in this chapter.
vi) Back filling of the trenches after successful and satisfactory

completion of tests for the pipeline laid.
vii) Cleaning, painting/coating and wrapping etc of pipes and fittings

etc.
viii) Commissioning of entire network laid.
ix) Safe custody of pipes/material/equipment/work and other

obligations stated elsewhere in the specification.
x) Any other activities which are not mentioned above but essential
and required.
xi) If specified, at road crossing the pipe shall be laid in encasing

pipes, wrapped & coated M.S pipes shall be used as encasing
pipes. The encasing pipe shall project beyond the berm or both
sides of the road. The encasing pipe shall be supported on P.C.C
saddles if the site condition warrants so.
13.2 Materials
The materials shall conform to part-I of this series. Sewerage net work in
Township shall generally be of R.C.C/S.W.G pipes, R.C.C pipes being used
normally for pipe sizes of 400mm dia and above. In plant area, at road crossings
etc Cast Iron Pipes may be used.
13.3. Excavation of trenches & pits
Excavation shall be carried out according to Chapter of Earthwork.
Before starting earth work in excavation, temporary drainage arrangement shall be

provided to prevent surface water entering the trenches and pits at the cost of
Contractor.
Excavation of trenches and pits for pipelines shall be carried out in shortest
possible time so as to avoid sinking of ground and consequent damage to the pipe-
lines.
Excavation of trenches for pipelines and surface drains, shall be in exact

accordance with the plans and section, alignment, levels and gradients as indicated
on the drawings or as directed at site by the Engineer. The final bed must be
dressed, levelled or trimmed to proper gradient and rammed with sprinkling of
sand and got passed by the Engineer. No excavation shall be made below the
specified levels without written permission of the Engineer. Should any exca-
vation be taken below the specified level due to carelessness of the Contractor, he
will fill in such excavation at his own expense as specified in clause 2.12.

13.4 Cast Iron Pipes
I.S 3114-1985 has to be followed in general for Laying and jointing of pipes
unless otherwise specified.
13.4.1 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 trenches to the level of the center line of
the pipe.
ZONE-"B" From the level of the center line of the pipe to a level 300 mm
above the top of the pipe.
ZONE-"C" From a level 300 mm above the top to the top of the trench.
Trenches shall not be back filled until the pipe joints have been tested, alignment
and gradient passed by the Engineer but back filling shall be done, at least from
the bottom of the trench to the level of the center line of the pipe (ZONE "A")
leaving 450 mm on either side of the joints uncovered, with earth till testing is
completed. These joints should however be kept covered with mats, gunny,
straws etc., to avoid damage to joints by temperature effects.
While back filling care should be taken to ensure that no damage should be done
to the pipeline. All back fill materials shall be free from cinders, ashes, slag,
refuse, rubbish, vegetables or organic material, lumpy or foreign material,
boulders, rocks or stones or other materials which in the opinion of the Engineer is
unsuitable or deleterious. However, materials containing stones up to 20 cm as the
greatest dimension may be used in Zone-"C" unless specified otherwise herein.
Backfilling in Zone-"A" shall be done by hand with sand, fine gravel or other
approved material placed in layers of 80 mm and compacted by tamping. The
back filling material shall be deposited in the trench for its full width of each side
of the pipe, fitting and appurtenances simultaneously.
Backfilling in Zone-"B" shall be done by hand or approved mechanical methods.

Special care being taken to avoid injuring or moving the pipes. The type of back
fill materials to be used and the method of placing and consolidating shall be
prescribed by the Engineer to suit individual locations.
Back filling in Zone-"C" shall be done by hand or approved mechanical methods.

The type of back fill materials and method of filling shall be as prescribed by the
Engineer.
Paving and metaling shall be reinstated in as good order as before removal and the
Contractor shall do adequate ramming and watering of under layers to guard
against subsequent settlement all at his cost.
13.4.2 Custody of pipes

The Contractor shall remain responsible for the safe custody of pipes, specials and
other materials supplied by him/issued to him either free or on cost recoverable
basis till these are laid installed, tested, back filled etc., and handed over to the
Engineer.
The Contractor shall verify the conditions of the pipes, specials etc., at the time of
receipt from sources and shall be responsible for all damages during handling,
transporting, laying, installing, testing etc., and the cost of such damages shall be
borne by the Contractor.
13.4.3 Erection/laying of pipelines
i) Erection of all equipment shall be carried out with highly skilled

workers.
ii) The pipelines shall be laid and supported properly and it shall be
deemed as a contractual obligation that the lines are not thrown
out of alignment or lifted off during commissioning and
subsequent operation.
13.4.4 Pipeline erection
All the underground pipelines shall be laid in accordance with IS : 3114-1985.
13.4.5. Handling of pipes & fittings
Unloading of pipes & fittings
While unloading, pipes shall not be dropped down from trucks on hard surface.
This should be done with the help of a steadying rope and timber skids. Pipes
should not be dragged, specially to the spigot end along hard surface.
Lowering of pipes & fittings
Proper implements, tools etc. shall be provided and used by the contractor while
lowering pipes & fittings in the trenches and in no case these should be dropped.
Pipes over 300mm dia shall be handled with the help of chain pulley blocks with
tripod supports.
Detection of cracks in pipes and fittings
The pipes and fittings shall be inspected for defects and cracks by ringing with a
light hammer preferably while suspended. Smearing the outside with chalk dust
helps location of the crack. If doubt persists, pouring a little Kerosene on the
inside of the pipe at the suspected spot will confirm it as it will seep through.
Cleaning of pipes and fittings
All foreign materials shall be cleaned from the socket and spigot ends both from
inside and outside. Every precaution shall be taken to prevent foreign material

from entering the pipe while it is being laid. When pipe laying is not in progress,
the open ends of the pipe shall be closed suitably.
Cutting of pipe
The cutting of pipe for inserting valves, fittings or closure pieces shall be done in a
neat manner without damage to the pipe. Pipe cutting machine may be used for
this purpose and in case it is not available, for large diameter pipes electric arc
cutting method using a carbon or steel rod may be adopted. The pipes can be cut
by using chisels also depending on the circumstances.
Permissible deflection at socket and spigot joints
Direction
On level ground the socket ends should face the upstream. When the line runs
uphill the socket ends should face the upgrade.
Permissible deflection
In case it becomes necessary to deflect pipe from a straight either in the vertical or
horizontal plane, due to obstructions or where long radius curve is permitted, the
following norms shall be adhered to:- Lead joint 2.5 degrees Rubber joints
for nominal bore 80 to 300mm 5 degrees

Anchor and thrust blocks
Suitable concrete thrust blocks shall be installed, wherever the thrust is

appreciable, specially at dead ends and bends. In case of unbalanced also this may
be required. In case of steep gradients and under influence of temperature change
also thrust blocks may be required for rigidly joined pipes.
It is advisable to avoid sharp bends above 45 degrees. In soft ground as far as

possible two bends should not be put together and be separated by at least one
length of straight pipe.
Anchor or thrust blocks shall be generally as per IS : 5330-1984 and thrust

resistant design pressure shall be equal to the test pressure.
13.4.6 Pipe jointing
The type of jointing will be defined in the detailed working drawing and Schedule
of items i.e. whether they should be (i) socket and spigot with molten lead or lead
wool joint or (ii) flanged joint.
13.4.6.1 Socket & spigot joints
a) Molten lead joints

Unless otherwise specified, socket and spigot joints shall be done with molten
lead.
The spigot shall be cleaned of the coating, carefully entered in the socket of the
adjacent pipe by one or more laps of white hampen spun yarn, sufficient yarn only
being driven into the socket to leave the depth of the lead specified. The proper
depth of each joint shall be tested before running the lead by passing completely
round it a wooden gauge, notched out to the correct depth of lead, the notch being
held close up against the face of the socket. The pipes shall be carefully packed
underneath so that they shall bear properly throughout their whole length.
The lead shall be carefully skinned of all scale when melted in a cast iron pot or
patent melting machine. The joints must be perfectly dug before being run with
lead. The pipes shall again be examined for line and level and the space left in the
socket shall be filled in generally by pouring in melted lead. This may be done
best by using proper loading rings or if these are not available, by wrapping a ring
or hemp rope, covered with clay round the pipe at the end of the sockets leaving a
hole into which lead shall be poured. For large pipes, it is also necessary to leave
one or more air vents around lower half of the joints. The lead shall be rendered
thoroughly fluid and each joint shall be filled at one pouring. If the pipe is too
large for the joint to be filled from one ladle, two or more ladles shall be used. It
is to be noted that the lead should be heated to such a temperature as will ensure
that it flows completely around the joint. Overheating of lead shall be avoided.
After a section of convenient length has been laid, lead caulking shall be
commenced. The lead shall be freed from the loading pipe outside the socket of
the other pipe with a flat chisel, and then caulked around 3 separate times, with
proper caulking tools of increasing thickness and a hammer 2 to 3 kg in weight in
such a manner as to make the joints sound and water tight. After being well and
evenly set, the joint is to be left flush neat and even with the socket. The
approximate weight of lead and spun yarn for different size of cast iron pipe
socket and spigot joints, as per IS : 3114-1985 are given in the Table-I.
TABLE – I
QUANTITY OF LEAD AND SPUN YARN

FOR DIFFERENT SIZES OF PIPES
Nominal size Lead / Joint kg

of pipe mm
80 1.8
100 2.2
125 2.6
150 3.4
200 5.0
250 6.1
300 7.2
350 8.4

400 9.5
450 14.0
500 15.0
600 19.0
700 22.0
750 25.0
800 31.5
900 35.0
1000 41.0
1100 46.0
1200 50.0
1500 66.5
Note : The quantities of lead given are provisional and a variation of 20% is
permissible either way.
b) Lead wool joint
In the event of the Engineer specifying or permitting the use of lead wool the joint
shall be made as follows :
Hempen spun yarn shall be driven into the socket and thoroughly caulked with
suitable caulking tools. Lead wool shall then be introduced and this caulking shall
be repeated with each turn of lead wool under which the socket is full within 3
mm and the wool of the lead wool is compressed into dense mass. The joint shall
then be finally pressed with finishing tool. The table giving the quantity of lead
wool and yarn to be used in different sizes of pipes is given in the Table-2
TABLE – 2
Nominal Internal dia in Lead wool weight in kgyarn weight in kg

mm
80 1.30 0.17
100 1.70 0.23
150 2.41 0.34
175 2.89 0.37
200 3.37 0.57
225 3.63 0.64
250 4.11 0.74
300 4.82 0.82
350 6.04 1.17
375 6.52 1.25
400 7.00 1.33
450 9.64 1.84
500 10.86 1.99
600 12.79 2.83
750 15.68 3.52
825 17.12 3.88
900 18.80 4.25
1200 28.44 6.01

Note : Higher tolerance may be permitted under special circumstances depending upon
site condition for quality of lead wool and spun yarn.
13.4.6.2 Flanged joints
Flanged joints should be made by painting the facing of the flanged with graphite
or red lead freely. Packing should be of rubber insertion sheet or compressed fibre
board and of approved thickness. The packing should be of full diameter of the
flange with proper pipe hole and bolt holes cut out and even at both the inner and
outer edges. All the bolts shall be tightened up evenly on all sides keeping the
longitudinal axes of adjoining pipe in exactly the same straight line.
The interior of the pipe must be checked carefully so as to be free from all dust
and other foreign matters as the work proceeds. For this purpose a disc plate or
brush sufficiently long to pass two or more joints from the end of the pipe last laid
shall be continuously drawn forward as the pipes are laid. The ends of the pipes
must be securely protected preferably with wooden plugs during the process of the
work. The pipes laid must not be made receptacles either for tools, cloth or any
other material during progress of the work.
13.4.7 Inspection & testing
a) If required all materials shall be inspected by the Engineer before dispatch

to site. All the tests shall be carried out in the manufacturer's works and
necessary test certificates shall be furnished as proof of such testing. The
Contractor shall intimate the Engineer at least two weeks in advance for
any such inspection / testing. All facilities for inspection / testing
including necessary test certificates shall be provided by the Contractor at
his own cost.
b) After completion of erection all pipelines shall be inspected by the

representative of the Contractor and the Engineer. Any discrepancy, defect
pointed out during this inspection shall be made good by the Contractor to
the entire satisfaction of the Engineer without additional cost.
c) All pipes with valve and fittings shall be tested to 1.5 times maximum
working pressure. The pressure should remain constant for a period of 8
hours. All arrangements for testing shall be done by the Contractor. Any
defect found during testing shall be made good by the Contractor to the
entire satisfaction of Engineer and the test shall be repeated till acceptable
results are achieved. Any special tools, instrument or equipment required
for these tests shall be provided by the Contractor for tests only.
d) All oils, lubricants and other consumables required during tests and trials
of different equipment shall be supplied and arranged by the Contractor at
his own cost.
13.4.8 Painting

i) All equipment, valves and other exposed steel parts shall be given a coat
of red oxide, zinc chromate or red lead and two coats of final approved
quality paint according to the colour scheme of the Purchaser.
ii) All the exposed pipes and fittings shall be painted with two coats of paints
of approved quality.
13.4.9 Commissioning
After pressure testing the main, it should be flushed with water of sufficient
velocity to remove all dirt and foreign materials.
The system shall be commissioned after all necessary tests have been conducted
successfully. All lubricants, oils, and other consumables required for com-
missioning of the system shall be supplied by the Contractor at no extra cost.
Commissioning of the equipment to be supplied, if any, by the Owner, shall be
carried out by the Contractor under guidance of the representatives of the supplier
of these equipment and Engineer. Any adjustment and/or changes/ rectifications
that may be found necessary during commissioning of these equipment shall be
carried out by the Contractor at his cost.
13.5. Stoneware Glazed Pipelines (S.W.G)
13.5.1 Back filling
Trenches shall not be back filled until the pipe joints have been tested, alignment
and gradient passed by the Engineer, but back filling shall be done at least for a
depth equal to the diameter of the pipe or 300 mm whichever is greater over the
pipes leaving 450 mm on either side of the joints uncovered with earth till the
testing is completed. These joints should however be kept covered with mats,
gunny bags, straws etc., to avoid damage to joints by temperature effects.
While back filling care should be taken to ensure that no damage is done to the
pipelines. The first 300 mm of filling material immediately over and around the
pipe should be of soft material free from clods and stones etc. The remainder of
the filling materials shall be watered and rammed in layers not exceeding 250 mm
at a time.
Paving and metalling shall be reinstated in as good order as before laying of the
pipelines.
Unless otherwise required by the Engineer, there shall be a minimum cover of 700
mm over the pipes and at road crossing etc., it shall not be less than 900 mm.
13.5.2 Laying of pipes
The laying of the pipelines shall commence only after the levels of the bottom of
the trench at various points have been checked by the Engineer. Cracked pipes
whether at the socket or in the body shall be rejected. All SW pipes shall be fitted
together on the surface of the ground to ensure a proper fit before they are

lowered. The spigots and sockets shall be properly cleaned and brushed, if
necessary & then lowered by hand to the bottom of the trench.
The pipes shall be carefully laid to the alignment, levels and gradients shown on
the plans and sections, and great care shall be taken to prevent, sand, earth or other
matter from entering the pipes during laying. As it is not permitted to rectify
errors of grade by packing up underneath with earth, care should be taken in
excavating and slight scraping, if necessary, done to bring to grade. The pipes
between manholes shall be laid truly in straight lines without vertical or horizontal
undulations.
Bedding, haunching or encasing of the pipes during laying shall be in accordance

with IS : 4127-1983 and shall be done with cement concrete in proportion (1:4:8)
to prevent ground water from entering the pipelines.
All inverts shall be laid from site rail fixed at the true levels, with proper boning
rod. The sight rails and boning rods shall be provided, fixed and maintained by
the Contractor at his own expense.
The pipes shall be laid, sockets facing up the gradient, beginning at the lower end,
and with the sockets, resting in the socket rest holes cut in the trench bottom.
Each pipe shall be laid singly and no pipe shall be laid until the trench has been
excavated to its required depth to a distance of twenty yards in front of the pipes to
be laid.
No pipes of any description shall be covered until they have been passed by the
Engineer.
13.5.3 Jointing of pipes
(a) Cement joint
The stoneware pipes shall be cement jointed normally. In case, if specified so,
bituminous joints shall be used. In each joint, spun yarn soaked in neat cement
slurry or gasket of tarred yarn shall be passed round the joint and inserted in it by
means of suitable jointing tools. More skeins of spun yarn or gasket shall then be
added and well rammed home. The yarn shall be moistened to avoid absorbing
moisture from cement mortar.
The yarn should be so placed as to centre the spigot of one pipe within the socket
of the other and shall prevent the jointing mortar penetrating inside the pipe where
it might set and interfere with the flow of sewage.
Yarn or gasket (cemented or tarred) so rammed shall not occupy more than one-
fourth of the depth of socket.
The cement shall be thoroughly mixed with medium sand in the proportion of 1:1
(1 cement : 1 sand) and then just enough water shall be added to make the mix
plastic. On no account, the mortar shall be made soft or sloppy. The mix shall
then be carefully inserted by hand into the joint.

Special care shall be taken for inserting the mortar into the portion of the joint
underneath the pipe. When the cement mortar has been inserted, it shall be
punched or caulked into the joint with wooden caulking tools, and more cement
mortar shall be added until the space of the joint has been filled completely with
tightly caulked cement. No fillet of cement shall be added.
No mortar which is older than 30 minutes shall be permitted for jointing. The
cement mortar joints shall be cured at least for seven days before testing.
The inside of each pipe shall be carefully wiped out with a mop or scrapper
sufficiently long to pass two joints from the end of the pipe and any projecting
cement shall be removed.
All pipes entering the manholes should be set in cement mortar 1:3 and a
completely watertight junction effected.
(b) Bituminous joints
If specified so this joint will be used. Asphalt and sand in the ratio of 1:7 shall be
boiled together and filled into the socket in a molten state with the aid of special
moulds.
13.5.4 Testing of pipes
Testing of pipes shall be done wholly at contractor's expense inclusive of

apparatus, provision of water etc., and/or as per IS : 4127-1983.
After cement has had time to set, the pipes shall be tested in lengths between
manholes in the following 'manner'. In the lowest manhole a plug shall be inserted
in the pipe. The disc in the pipe and at the upper manhole shall be fitted with a
filling pipe with a right angle bend and an air cock. The length of pipe shall then
be filled with water by means of the pipe connection on the upper disc. The air
cock in the upper disc shall be kept open, while the pipeline is being filled to
permit the escape of air.
When the pipes have been filled with water and air excluded, the air cock shall be
shut and water shall be poured into a conical "Filler" attached to the testing and
filling pipe of the disc in the upper manhole until water remains in the filler. The
testing or filling pipe shall then be raised and fastened so that the height of the
pipe is six feet, which will be the usual test pressure for stone ware pipe joints.
The test will be for an hour or such longer period as may be set by the Engineer.
If the water level does not fall more than 25 mm in the length of 90 metre, the test
may be considered satisfactory.
If it is found that certain pipe joints are leaking, the water shall be run off and
joints recaulked with cement mortar and the test repeated till it is proved by the
Contractor that the joints are leak-proof.
13.5.5 Concrete bedding, haunching & encasing

Unless otherwise specified in the Schedule of Quantities, all SW pipes shall be

laid in accordance with IS: 4127-1983 As per site condition haunching or/and
encasing of pipes with cement concrete may be required as per clause 4.2 & 4.3 of
IS 4127-1983. The concreting shall be done with 1:4:8 cement sand concrete.
Where sewers have less than 1.2 m cover at places of heavy traffic, these shall be
surrounded with mass concrete if directed by the Engineer.
13.5.6 Handling of pipes
While unloading, pipes shall not be dropped from the trucks/carts on the ground.
Timber skids and steadying rope should be used while unloading or lowering in
trenches. To avoid damage specially to spigot end, pipes should not be dragged
on the hard surface.
13.6 Manholes
All manholes shall be of the size and type as given in the Schedule and shall be
provided as per drawing or as directed by the Engineer. All the manholes shall be
circular or other shape as shown in drawing. The bed shall be in cement concrete
of Mark-10B (or 1:3:6 mix) (Size of coarse aggregate 40 mm and down) of 100
mm thickness or as shown in the drawing and shall be projected out 75 mm from
the outside face of the wall all round. or as shown in the drawing. The working
part including channeling, benching etc., made of P.C.C. shall be of grade-15C
(or 1:2:4 mix). All manholes shall be plastered inside with 1:3 cement plaster 20
mm thick and finished with a floating coat of neat cement unless otherwise
specified.
Concrete used for precast RCC cover slabs shall be of grade 20C (or 1:1.5:3
mix)and shall be constructed as per drawing.
The top level of manholes shall be generally 100 mm above the surrounding
ground levels or as directed by the Engineer. Channeling inside the manhole shall
be done in smooth bends.
The end of pipe shall be neatly built in and finished in cement mortar 1:3.
Circular medium duty Cast iron water sealed manhole cover and frames, 560 mm
dia (clear opening) and nominal weight 128 kg shall be provided for each manhole
and shall be in accordance with IS:1726-1991 Manhole covers with double seals
(Light duty) with wt. as specified in schedule of item shall be provided within
compound near the buildings if specified so. If specified heavy duty cover and
frames, either circular or double triangular type, shall be provided. Step irons shall
be provided with two coats of bituminous paint and shall be as per drawing.
In cases where branch pipe sewers enter the manhole or main pipe sewer at a level
more than 1m, from the main sewer, a drop connection shall be provided. The
extra pipe length required for this connection will be paid under item for pipelines.
No other extra payment will be allowed.

All exposed surfaces of cast iron frame and cover shall be painted with two coats
of bituminous painting
13.7 Marker plates
Marker plate indicating the particular service installed shall be provided along the
routes of pipes laid below ground. These shall be of mild steel, with the type of
service and direction of flow, painted on it. The markers shall be set firmly in a
concrete base and installed at all corners and turning points. Over straight runs
markers shall be spaced at 100 m intervals generally.
14.0 Road work
14.1 General
Road works in general shall be constructed according to the requirements to the

various specifications and codes of practices of the Indian Roads Congress.
Works such as earthwork, masonry, concreting and the like, wherever they occur
in association with construction of roads, shall be governed by the respective
specifications of these series.
14.2 Trenching and Preparation of Subgrade
The surface of the formation of width equal to that of soling coat shall first be cut
to a depth below the proposed finished level equal to the combined depth of soling
and wearing coat, (due allowance being made for consolidation), and dressed
parallel to the finished profile. Any roots of bushes, trees etc., shall be taken out
to the full depth and the cavities thus formed shall be filled up and rammed by the
contractor at his cost.
In slushy soil or in areas where water logging is frequent, adequate arrangement

shall be made for drainage of the area so that the sub-soil water level is kept as
low as possible.
The sub-grade shall then be consolidated with a power road roller of 8-10 tonne
capacity by rolling with minimum of 5 numbers of passes till it is densely
consolidated to the satisfaction of the Engineer.
Surplus earth shall be disposed of as directed by the Engineer and the areas where
it is disposed of shall be neatly dressed.
All undulations of the sub-grade surface that might develop due to rolling shall be
made good with earth and sub-grade re-rolled.
14.3 Ash / Moorum Carpet
Wherever the ground is soft and slushy, ash carpet consisting of common boiler
ash shall be laid to 5 cm thickness over the subgrade and then rolled. In firm
ground no ash carpet is necessary and boulder soiling shall be laid directly over

the sub-grade. If decided by the Engineer, a bed of moorum of specified thickness

shall be provided for to form a sub-grade.
14.4.1 Boulder Soling
The width of the soling coat shall be 30cm (15cm on either side) more than that of
the wearing coat. Its depth shall be 15cm in cutting and 23cm in filling and made
up soil, unless otherwise specified in the schedule of quantities or shown in the
drawing.
The edges of the soling shall be marked out by strings and stakes. Soling stone
shall be hand packed and set on edge with greatest length across the road. This
shall be laid closely in position on the sub-grade, firmly set with their broadest
side downwards. The joints shall be staggered. All interstices between the stones
shall be wedged in with locking smaller stones well driven into gaps to ensure
tight packing and complete filling of interstices. Such filling shall be carried out
simultaneously with the placing in position of soling stones and shall not lag
behind.
After packing, surface shall be checked with template of approved shape and high
and low spots corrected by removing soling and re-packing. The top surface of the
soling coat shall be perfectly true to camber and grade.
The soling shall then be thoroughly consolidated with power roller of 8-12 tonne
weight depending upon the type of soling stones, starting at "edges" and working
towards the centre. In case of super-elevated curve the rolling shall commence
from the inside edge of the curve to the outside edge. The roller shall run over the
same surface of soling at least 10 times or more till the soling coat is well
consolidated to the satisfaction of the Engineer. The surface shall be checked by
templates and any disturbance in grade or camber corrected after every rolling and
finally consolidated. After that, at least 50mm thick moorum shall be laid on top
of soling coat and rolled with water to proper compaction so that the top surface
seems smooth. The rate for soling coat shall be inclusive of the cost of the
moorum as blinding materials for which no separate payment shall be made.
14.4.2 Laterite soling
In case of laterite soling the thickness of soling shall be as follows :
(i) For road width of 7m and above the sub-base shall consist of two layers of
laterite stones 150mm maximum size. The sub-base shall be rolled to a
thickness of 230mm after compaction.
(ii) For road width of 4m to 7m,the sub-base shall consist of one layer of
laterite stone of 150mm maximum size consolidated to 115mm thick.
(iii) A layer of moorum,33.3 % in volume of laterite, shall be spread over the

laterite to a uniform thickness and rolled with 8 tonne roller with constant
watering until the mixture penetrates into the voids of laterite layer. Care
shall be taken to maintain the camber and slopes.

Other steps for laying, compacting etc. of the laterite soling shall be same as given
under clause 14.4.1 "Boulder soling".
14.5 Kerbs
Concrete or stone kerbs, where shown in drawings, shall be fixed in position after
laying and consolidation of soling. They shall be fixed true to line and level and
secured in position by approved means.
14.6 Water Bound Macadam Surfacing
The construction of water bound macadam shall be carried out according to IRC :
19-1981 "Standard Specification and Code of Practice for Water Bound
Macadam".
14.7 Preparation of Base and Shoulders
The subgrade shall be reshaped to the required grade and camber. Where water
bound macadam is to be laid over existing black top surface, 50 mm x 50 mm
furrows shall be cut in the existing surface at 1 m intervals inclined 45 degree to
the centre line of the carriageway, before laying of coarse aggregates. Necessary
arrangements shall be made for the lateral confinement of aggregates by
constructing shoulders in the form of two parallel mud walls 20 x 15cm which
shall be made along the outer edges of the wearing course.
14.8 Spreading Coarse Aggregate
The coarse aggregates shall be spread uniformly and evenly upon the prepared
base in required quantities from stock piles along the roadside or directly from
vehicles. In no case shall these be dumped in heaps directly on the base. The
aggregates shall be spread to proper profile by using templates placed across the
road about 6m apart. Where possible, mechanical devices shall be used to spread
the aggregates uniformly.
The water bound macadam course shall be constructed in layers of not more than
75 mm thickness. However, the Engineer may permit courses of 100 mm
compacted thickness to be constructed in a single layer. Each layer shall be tested
by depth blocks. No segregation of large or fine particles shall be allowed.
14.9 Rolling
The coarse aggregates spread as described above shall be compacted to full width
by rolling with either three wheel power roller of 6 to 10 tonnes capacity or an
equivalent vibratory roller. The weight of roller shall depend on the type of coarse
aggregate.
The rolling shall begin from edges and after the edges have been compacted,
progress gradually towards the centre, parallel to the centre line of the road,
uniformly lapping each preceding rear wheel track by one half width. On super
elevated portions, rolling shall commence from the lower edge. Where screenings
are to be applied, rolling shall be discontinued when the aggregates are partially
compacted with sufficient voids to permit application of screenings. Where

screenings are not to be applied, as in the case of crushable aggregates compaction

shall be continued until the aggregates are thoroughly keyed, with no creeping of
stones ahead of the roller. Slight sprinkling of water may be done during rolling,
if necessary.
Rolling shall not be done when the subgrade is soft or yielding nor when it causes
a wave like motion in the base course. If irregularities develop during rolling, and
exceed 12 mm when tested with a 3m straight edge, the surface shall be loosened
and aggregates added or removed before rolling again. The surface shall be
checked by template for camber. In no case shall screenings be used to make up
depressions.
14.10 Application of Screenings
After coarse aggregates have been rolled, screenings to fill the interstices shall be
applied gradually over the surface in thin layers. Dry rolling shall be done when
the screenings are being spread, so that the jarring effect of roller causes them to
settle into the voids of the coarse aggregates. Damp and wet screenings shall not
be used and the spreading, rolling and brooming of screenings shall be taken up on
sections which can be completed within one day's operation.
14.11 Sprinkling and Grouting
After application of screenings, the surface shall be copiously sprinkled with

water, swept and rolled. The sprinkling, sweeping and rolling operations shall be
continued and additional screenings applied where necessary until the coarse
aggregates are well blended and firmly set and a grout of screenings and water
forms ahead of the wheels of the roller.
14.12 Application of Binding Material
After the application of screenings, approved binding material, where it is required

to be used, shall be applied at a uniform and slow rate in two or more successive
thin layers to a thickness of 2.5 cm. After each application of binding material,
the surface shall be copiously sprinkled with water and the resulting slurry swept
in with brooms, so as to fill the voids properly. This shall be followed by rolling
with a 6-10 tonne roller, during which, water shall be applied to the wheels to
wash down the binding material that may get stuck to them. The spreading of
binding material, sprinkling of water, sweeping with brooms and rolling shall
continue until the slurry of binding material and water forms a wave ahead of the
wheels of moving roller.
14.13 Setting and Drying
After final compaction the road shall be allowed to cure overnight. Next morning,
hungry spots shall be filled with screenings or binding material, lightly sprinkled
with water and rolled. No traffic shall be allowed till the macadam sets.
14.14 Surface Evenness
The surface evenness of completed water bound macadam course in longitudinal

direction shall be within 12 mm when tested with a 3 m straight edge and in cross
profile within 8 mm when checked with a template.

14.15 Bituminous Pavements
14.15.1 Bitumen premix carpet with seal coat
The consolidated thickness of this type of treatment shall be 2cm/2.5cm/4cm or as

specified.
14.15.1.1 Surface preparation
Water bound macadam surface on which black topping is to be provided shall be

thoroughly cleaned of dust, loose materials, caked mud and other foreign material
with the help of wire brush, chisel, picks etc. Cleaning shall be such as to expose
the stone metal to a depth of about 6mm without dislodging the interlock of the
metal. All dust and other materials thus removed shall be thrown away at a
suitable place as directed by the Engineer.
Any potholes, depressions and undulations found after cleaning shall be made
good with premixed chippings, and well rammed.
14.15.1.2 Tack coat
Just before the application of tack coat, the surface shall be thoroughly cleaned by
brooms and then by fanning with gunny bags.
Bitumen of specified grade heated to a temperature of 177 to 188 degree 'C' shall
be spread on the prepared surface uniformly at the rate of 0.75 kg/sq.m. by means
of sprayers. It shall be applied just ahead of and keeping pace with, laying of
premix carpet.
14.15.1.3 Preparation of mix, laying & consolidation
The stone grit (aggregate) shall be surface dry and contain not more than 2%
moisture before use. It shall be first screened of dust and measured in boxes and
then loaded into the drum mixer according to the capacity of the mixing drum in
the proportion given in the table below. The aggregate shall be heated to facilitate
mixing with the binder in cold weather, where so directed by the Engineer.
The binder heated in boilers, to a temperature of 149 to 177 degrees C or as

specified for the grade used and maintained to that temperature, shall be drawn off
from the boiler into a suitable container or in bucket gauged to show the weight of
bitumen in it. This shall then be poured over the aggregate in the mixer at the
correct rate of 64 Kg/cum of aggregate or as specified and mixing started and
continued till aggregate is uniformly coated with bitumen.
Immediately after applying the tack coat, the hot mix shall be discharged from the
mixer, carried to the road surface and spread to a thickness sufficient to achieve
after consolidation the specified thickness. Rakes or drag spreaders shall be used
for spreading the mixture.
When the premix has been laid for a length of 15-20 metres it shall be rolled.
Rolling shall commence from edges and proceed towards the centre. The roller
wheels shall be moistened continuously so as to prevent metal chips sticking to it.

Any high spot or depression which become apparent shall be corrected by addition
or removal of premix materials.
Further the prepared finished surface shall be protected from the traffic for 24 hrs
or such period as may be specified by the Engineer.
14.15.1.4 Materials
Quantity of materials required per 100 sqm of road surface shall be as given in the
table below, unless otherwise specified.
Quantity of materials required per 100 sqm of road surface shall be as given in the
table below, unless otherwise specified.
Consolidated thickness Stone chips Sand Binder

of premix carpet (cum) (cum) Tackat Carpet Seal coat
(kg) (kg/cum) (kg/cum)
Priming tack coat
on a water bound
macadam surface
on an existing black top

surface
Carpet
2 cm 2.4 (10 mm
nominal size)
2.5 cm 3.0 (10 mm

nominal size)
4.0 cm 4.8 (12 mm

nominal size)
Seal Coat
Dry area (Premixed sand
seal coat)
Wet area (Liquid seal coat

with chips
14.15.2 Seal coat

In dry areas where rainfall is under 150cm per year a premix sand seal coat shall
be applied immediately after laying the carpet. The binder shall be heated in
boilers of suitable design, to the temperature appropriate to the grade of bitumen.
The aggregates shall be dry and suitably heated to a temperature directed by
Engineer before the same are placed in the mixer of suitable design. Mixing of
binder with aggregates to the specified proportions shall be continued till the latter
are thoroughly coated with binder. The mix shall be immediately transported from
the mixing plant to the point of use and spread uniformly on the bituminous
surface to be sealed. As soon as sufficient length has been covered with premix
materials, the surface shall be rolled with 6 to 8 tonne power roller. Rolling shall
be continued till the premix material completely seals the voids in the bituminous
course and a smooth uniform surface is obtained.
In wet areas where rainfall is above 150cm per year a liquid seal coat with
chippings (not sand) shall be applied after laying the carpet. The binder shall be
heated in boilers of suitable design, to the temperature appropriate to the grade of
bitumen and spread on the surface preferably using mechanical sprayers.
Immediately following the application of the binder, stone chippings in a perfectly
dry condition shall be uniformly spread on the surface. Immediately after the
application of the cover material, the entire surface shall be rolled with 8-10 tonne
road roller.
14.15.3 Surface dressing
The surface shall be prepared in the same way as that for premix carpet work as
per 14.15.1.1. Depression or pot holes, if any, shall be repaired as indicated.
After the surface has been prepared and is in perfectly dry condition, bitumen
heated in the same manner as for premix carpet, shall be sprayed over the surface
preferably using mechanical sprayers. It shall be ensured that there is even and
uniform distribution of bitumen on the surface. Spraying shall be carried out
parallel to the centre line of the road.
Immediately following the application of bitumen, stone chippings in a perfectly

dry condition, shall be uniformly and evenly spread as specified in the item, over
the entire sprayed surface. Spreading may be done preferably by means of
mechanical gritter. Finally the entire surface shall be broomed to ensure perfect
uniform spreading.
The final surface shall be checked by means of camber board etc. The spread
surface shall be rolled with 6 to 8 tonne roller till there is sufficient boundage of
chippings with bitumen. The finished surface shall be thrown open to traffic on the
following day.
14.15.4 Premixed Bitumen Concrete
14.15.4.1 General
In this type of road carpet a mixture of sand and stone aggregate is used as
aggregate producing a dense mixture. Seal coat is not necessary as the sand used

in the mix works up to the surface and forms a seal by itself. The consolidated
thickness of this type of treatment shall vary from 4cm to 7.5cm as specified.
14.15.4.2 Surface Preparation
Same as in para 14.15.1.1 above.
14.15.4.3 Tack Coat

Same as in para 14.15.1.2 above.
14.15.4.4 Preparation of Mix, Laying & Consolidation
Para 14.15.1.3 shall generally apply except that the mixing shall be done in two
stages. The stone aggregate of the the correct specified size and in the proportion
shown in the table above shall be fed into the mixer to which 2/3rd of the total
specified quantity of bitumen heated to the appropriate temperature shall be added.
When the stone metal is well coated, the sand in the specified proportion and the
balance 1/3rd quantity of total bitumen shall be fed into the mixer. Mixing shall be
continued until a homogeneous mix is produced and all particles are uniformly
coated with bitumen.
The premix shall be emptied on to wheel barrows or stretchers and carried to the
site of work. It shall then be spread uniformly on the road surface with rakes or
drag spreaders immediately after applying the tack coat to a thickness sufficient to
achieve after consolidation the specified thickness. When the premix has been laid
for a length of 15-20m it shall be rolled. Rolling shall commence from edges and
proceed towards the centre.
The roller wheels shall be moistened continuously so as to prevent metal chips

sticking to it. After preliminary rolling, all honeycombs, any high spot or
depression which become apparent shall be corrected by addition or removal of
premix materials. Camber and grade shall be checked at every stage to ensure
correctness and any defect found shall be rectified.
14.15.4.5 Materials
Quantity of materials required per 100 sq.m of road surface shall be as given in the
table below unless otherwise specified.
The nominal size of Coarse Aggregate herein shall mean as defined below:
BINDER
Thickness of consolidated Tack coat Hot Bitumen (cut back)/ Paving Bitumen 80 / 100
bitumen concrete (kg) grade
surfacing
Bitumen concrete

Stone aggregate (kg / cum) Sand (kg / cum)
4 cm, 5 cm, 6 cm & 7.5 cm 75 560 128
Aggregate
Thickness of Stone aggregate Coarse sand

compacted bitumen (cum / 100 sqm) (cum / 100
concrete surfacing Sq.m)
1. 4 cm 3.8 (12mm nominal size) 1.90

2. 5cm 4.8 (20mm nominal size) 2.40
3. 6cm 5.8 (60% 40mm nominal size) 2.90
(40% 25mm nominal size)
4. 7.5 cm 7.3 (60% 50mm nominal size) 3.65
(40% 40mm nominal size)
The nominal size of Coarse Aggregate herein shall mean as defined below:
Designation of IS sieve Designation of IS sieve

Nominal size of coarse through which the through which the
Sl. No.
aggregate aggregate shall wholly aggregate shall be
pass retained
i) 40 mm 50 mm 25 mm
ii) 25 mm 40 mm 20 mm
iii) 20 mm 25 mm 12.5 mm
iv) 12 mm 20 mm 10 mm
v) 10 mm 12.5 mm 6.3 mm
vi) 6 mm 10 mm 2.36 mm
14.15.5 Surface evenness
The finished surface of premix carpet and bituminous concrete shall be tested with
a straight edge 4.5 m long and any irregularity greater than 6mm shall be
corrected.
14.16 Berms
Shoulders and berms shall be prepared as shown on the drawings. Work on

making berms shall not lag more than 100 metres behind the water bound
macadam consolidation. Suitable drains shall be cut on the berms so that the
water bound macadam surface is kept drained till bituminous macadam is laid.
14.17 Kerbs

Kerbs shall be laid and set in place before completing the bituminous or concrete
wearing surface as well as the wearing surface of footpath. Setting shall be done
in mortar where so specified with Schedule of Items. They shall be laid and set in
such a way as to obtain straight lines in the finished work, the top surface
matching with the finished surface of footpath.
Where the road edge forms a curve, the kerbs shall follow such curve. Gaps shall
be left as shown in drawings or as may be required to provide for drainage.
14.18 Bridges and Culverts
Bridges and culverts shall be constructed according to the specifications

of Indian Roads Congress. Relevant chapters of earthwork, concrete,
masonry etc., of these series shall apply.
14.19 Boulder Pitching
Wherever specified, boulder pitching shall be provided at the inlet and

outlet of pipe culverts, or for embankments of bridges. The subgrade shall
first be dressed to level or slight slope as indicated. The transverse slope
of the pitching shall be made strictly in accordance with the drawings or
as directed by the Engineer.
14.20 Scarifying & Dismantling
Where a new carriage-way abuts or includes an existing carriage-way and

the Engineer so directs, the surface of the latter shall be scarified, adjusted
and reshaped to conform with the existing and new camber or crossfall.
Materials from the existing road shall be used or disposed off as directed
by the Engineer.
Where dismantling of the existing road has been specified, the various
layers of the road viz., bituminous macadam, water-bound macadam and
soling shall be scarified separately. Scarifying can be done either by hand
picks, or by means of scarifiers fixed to the roller. When a roller is used
for scarifying, crushing of the metal shall be avoided by moving the metal
clear of roller wheels after the scarifier has passed over it. The loosened
material shall then be combed by means of rakes to bring out most of the
larger stone. If necessary, the larger stones thus collected shall be
screened to separate fine particles if any.
The remaining metal shall then be removed and screened to recover

reusable metal. Different grades of metal shall be stacked separately and
measured.
14.21 Diversions
Where the construction of the road or culvert or bridge is in progress, the

road shall be closed to traffic and a suitable diversion shall be provided for
traffic by the Contractor, as directed by the Engineer.
The road shall be closed by the erection of barriers and suitable sign
boards at both ends which shall be provided with lights at night. Both

during night and during day, one man shall be posted at each barrier to
suitably divert the traffic and to keep the light burning during the night.
15.0 WATERPROOFING TO ROOFS & WATERPROOFING PAINTS
15.1 Scope
This chapter deals with different types of waterproofing on roof.
15.2 Material
The materials shall conform to Part-I.
15.3 General Workmanship
The waterproofing to roofs being specialised works the Contractor shall

get these done by specialised firms/agencies.
15.4 Painting with Hot Bitumen
The surface to be painted shall be thoroughly dried and then cleaned, with
wire brushes and cotton or gunny cloth, of all loose materials and scales.
The surface shall further be cleaned with a piece of cloth lightly soaked in
kerosene oil. Bitumen shall be brought to the site in its original container
and this shall not be removed from site till the painting job is completed.
Before applying the main coatings of hot bitumen paints, one coat of
bituminous primer shall be applied. The number of coats of hot bitumen
shall either two coats or as specified in the Schedule of Items. The
bitumen of approved quality (either of grade 80/100 or 30/40) or as
specified shall be applied to the surface after heating it to the manufac-
turer's specifications. Care shall be taken to see that no blank patches are
left and the quality of bitumen to be spread shall be as specified and shall
be to the satisfaction of the Engineer.
15.5 Painting with Bitumen Emulsion
Before applying, the surface shall be cleaned thoroughly. Generally two

coats of Bitumen Emulsion are provided over a coat of emulsion primer.
Since the painting is with emulsion, the surface need not be made dry.
15.6 Waterproofing of Roof (For this project all the water proofing work
shall be done by using non shrink water proofing materials as per
manufacturers specifications of reputed makes like
CICO,CICA&FOSRAC etc)
15.6.1 With bitumen felt

Prior to laying the insulation, roof gradient shall be checked. If necessary,
the roof shall be re-graded by screed to ensure everywhere a run off
gradient of not less than 1 in 120. The screed shall consist of one part
cement and four parts medium to coarse sand by volume. The screed shall

be cured for 7 days. The surface shall then be cleaned of all foreign
matter by wire brushing and dusting.
Waterproofing unless specified otherwise in drawings shall be the "heavy

treatment type" with primer coat as described in IS : 1346-1991. The
method of laying roofing treatment, surface finishing with pea gravels,
special mode of treatment for drain outlets, projecting pipes, parapet
walls, expansion joints, gutters, timber roofs etc., shall conform to IS :
1346-1991. The number of layers of felts shall be as specified in the
drawing or Schedule of Items. The bonding bituminous material shall be
of grade 30/40 or as specified and the minimum quantity of hot bitumen to
be applied, shall be 1.2 kg/m2. Unless specified otherwise, the
bituminous felts shall be hessian bases of Type-3 Grade-2. Pea gravel
finish may be substituted by a coat of bituminous aluminium paint, where
so specified in the Schedule of Items.
The cement mortar used for filling the chases shall be of mix 1:4 and the
cement concrete for fillets shall be of the same grade as the roof slab.
Where special surface finish with precast concrete or clay tiles is

specified, it shall be in accordance with the relevant chapter of this series.
15.6.2 With bitumen mastic
The work shall be carried out generally in accordance with IS : 4365-1967

"Code of Practice for Application of Bitumen Mastic for Waterproofing of
Roofs" or according to the manufacturer's specifications. The work shall
be carried out by a firm of specialists in the trade.
The type of underlay or primer, thickness of application, surface finish

etc., shall be as shown on drawing or described in the Schedule of Items.
Bitumen melting shall be done in a mechanical mixer by gradually
heating to about 200 degree 'C'. Coarse aggregate where required shall be
added to the hot bitumen and stirred.
Each coat shall be spread evenly and uniformly by means of a float to the
required thickness. Timber gauges shall be used to regulate the thickness.
Particular care shall be taken to tuck the mastic into grooves on vertical
surfaces, at joints, around pipes or other projections and at junction of
adjoining bays.
15.6.3 Waterproofing of RCC roof with Lime concrete and Pressed clay titles.
Lime concrete shall consist of broken brick aggregates and lime.

Proportion of brickbat coba shall be 2.5 parts of brick jelly to one part of
lime. The brick jelly shall be hard, well burnt and of size varying from
12mm to 25mm.
The lime concrete is then laid over roof to slope to give specified
thickness and in slope of 1 in 80 or as shown on the drawing for proper
roof drainage as per roof drainage plan. The lime concrete is then to be

beaten in the manner approved by the Engineer for 48 hours or as directed

with hand beaters.
If the surface during the process of compaction becomes so uneven that

water lodges in pools, the surface shall be pricked up, and fresh concrete
spread and consolidated as necessary to obtain an even surface.
The concrete shall then be cured by sprinkling water and allowed to

harden for a period of not less than six days before laying the roof finish.
Roof shall be finally finished with one coarse of machine pressed clay
titles 20 mm thick laid over a 12mm thick of 1:3 mix cement mortar
mixed with 5% crude oil by weight of cement mixed in mortar. The
pressed clay tiles shall be immersed in water for two hours before being
used. The side joints of the tiles shall be more than 60 mm thick set full in
mortar. Before the work dries up completely, the tile joints shall be raked
out and pointed with cement mortar 1:3 mixed with crude oil which shall
be 5% by mass of cement. The joints shall be well rubbed over with thin
bar trowel and excess of mortar scrapped off until the surface of the
pointing attains a black polish and becomes hard. As the work proceeds, it
shall be kept thoroughly wetted until the mortar has set firm and hard.
Watering shall be continued for three weeks after construction.
Lime concrete and tiles shall be taken up the parapet walls to a height of
150 mm or as shown in the drawing.
The specification of pressed clay titles shall be as given in IS:2690-1975

(Part-I). The specification of crude oil shall be as per IS:2119-1980.
The areas around drain pipes shall be properly finished with provision of
adequate slope.
The contractor shall give guarantee for any/all types of waterproofing for
a period of 7 years against bad of faulty material and construction and
shall rectify the same at his own cost during the guaranteed period.
15.7 Waterproofing for Basement
15.7.1 The specification covers the requirements of waterproofing of basements,

tunnels, ducts, pits, bunkers, etc.
The material used shall be bitumen felt type-3 of grade-2 conforming to IS

: 1322-1982, together with the specified bonding material and primer.
Waterproofing shall be provided on the outside of walls and top of the

floors and shall be carried 150 mm above ground level.
The number of layers of bitumen felt to be used for walls and floor unless
otherwise shown in the drawing shall be :
i) For depths upto five metres below ground : 2 layers.

ii) For depths beyond five metres : 3 layers.
The method of laying the bitumen felts and workmanship shall in general
Waterproofing work shall be taken in hand only when the sub-soil water
level is at its lowest, the site shall be kept dry by adequate arrangements
for pumping out water till the work has been completed. For this purpose
drains shall be formed along the edges of the excavation but beyond the
building line, with suitable collecting sumps. In case of large excavation
areas where it is necessary to dewater under the floor, additional land
drains shall be formed across the excavation, to adequately drain the area.
Adequate arrangements shall be made to prevent the sides of excavation
from slipping while the work is in progress.
The base concrete of mud-mat shall be rendered smooth by a 20 mm thick

sand-cement plaster (6:1). Any sharp corner over which the
waterproofing course is to be laid shall be eased out by means of cement
mortar fillets 7.5 cm in radius.
The surface must be dry before the next operation is carried out. Blown
bitumen conforming to IS : 702-1988 shall be applied hot over the
prepared surface at the rate of 1.5 kg/m2 for the first layer and for every
other subsequent layer(s). The laying of felt over the bitumen so applied
shall always commence on the floor, and shall be carried to the walls only
after treatment of the floor is complete. The minimum overlapping of
joints at sides and ends of felts shall be 10 cm. Joints for subsequent
layers of felt shall be staggered. All joints shall be completely sealed by
blow lamp.
A protective flooring of either flat bricks in cement mortar 1:3 or 6 cm

thick cement concrete type M15B or a coat of cement sand plaster (1:3) 4
cm thick shall be constructed over the waterproofing treatment to prevent
damage to the latter during subsequent construction of the structural floor.
The walls shall be treated in a similar way, the bitumen felts joining at the
base with the projecting felt laid over the mud-mat. The wall surface shall
be made smooth, where necessary with a coat of cement plaster 1:5, the
felts shall be laid as for the floor ensuring that the surface to be treated is
dry and then a protective brick wall, half-brick nominal thickness shall be
built in cement mortar 1:6 over the projecting mud-mat, the space between
the wall and felt being grouted with cement slurry. Sufficient care shall
be taken to ensure a perfect bond between the waterproofing on the floor
and that on the walls.
The treatment on the wall shall be carried 150 mm above the surface of
ground and tucked into a grove 6.5 cm. wide and 7.5 cm deep, the chase
being filled with cement mortar (1:4).
Where waterproofing is done to the roof of an underground structure, such

as a tunnel, it shall be done in a similar way. The structural concrete shall

be rendered smooth, hot bitumen and bitumen felts applied in the same
way as for the floor and walls, and over this shall be laid a protective layer
of cement concrete grade M10C, 7.5 cm thick.
15.7.2 With epoxy based emulsion
Over the mud-mat a 20 mm plaster is to be provided to make the surface

even.
On the plastered surface of the mud-mat, three coats of epoxy based

leakproof emulsion shall be applied with reasonable gap between each
coat in order to permit sufficient drying time.
Precaution should be taken that during the process of rod binding if any
damages happens it should be immediately rectified by making patch
painting on the affected portion only and as such a complete vigilance is
to be kept to rectify the defect.
After the rod binding is over the concreting should be done with high
polymer based, chloride and sulphide free cement waterproofing
additive/admixtures @ 2% by weight of cement all through the floor area
and all through the vertically raised walls of four sides which shall remain
underground upto a depth of 8 metre and above from ground level.
After the concreting and immediately after de-shuttering cleaning of the

concrete surface on the external faces of the walls are to be done and then
three coats of epoxy based leakproof emulsion shall be applied with a
reasonable gap between the each coat before back filling. If the back
filling is with hard material again a protective layer of plaster shall also be
applied on the external faces of walls in order to avoid damages on the
painted surface.
If the back filling is with soft sandy or alluvial soil there is no necessity
for protective layer of plastering as mentioned above.
Epoxy based paint can be applied on the wet surface hence there shall be
no stoppage of the normal progress of the project works.
15.8 Surface Application
Waterproofing done by surface application of bitumen based or epoxy

based material shall conform strictly to the recommendations of the
manufacturer. The work shall be carried out by a firm of specialists in the
trade.
15.9 Guarantee
For the waterproofing on the roof as well as for underground basements

the Contractor shall give guarantee in writing for the period of 7 to 10
years as specified in the Schedule of Item. For such guarantee the
Contractor shall get guarantee from the manufacturer/specialised firms

and forward the same to the Engineer. However, the Contractor shall be
fully responsible for the serviceability of the waterproofing treatment
throughout the guarantee period and any leakage during that guarantee
period shall be stopped by the Contractor at no cost to the Owner and
without disturbing working facility of the Owner.
15.10 Water proofing course with Fibre glass R.P. tissue
15.10.1 Scope
This section covers the furnishing of all labour, equipment and performing
all operations necessary to complete to provide water proofing course of
Fibre glass R.P. tissue all in accordance with the drawing and these
specifications.
15.10.2 Terminology
For the purpose of these specifications the following definitions detailed

hereinafter shall apply.
15.10.3 Preparation of surfaces
Surface to receive waterproofing shall be dry, free from dirt, loose

particles and foreign materials. Projections which might puncture the
membrane shall be removed and voids and crevices shall be filled in prior
to the start of work.
Adequate covering shall be provided during this work to avoid splashing

or staining of the adjacent work and surfaces. Any work or surface
splashed or stained shall be thoroughly cleaned to the satisfaction of the
Engineer. Joints in the tissue felt in the different layers shall be staggered.
15.10.4 In built-up roofing
Application
i) Suitable slope shall be provided in the roof as per manufacturers

specifications. Heat insulation may also be provided if necessary.
ii) Prime the plastered surface primer at the rate of 0.4 Kg/sqm. This should
properly impregnate the surface and should be left till the time it is touch-
dry.
iii) Apply first coat of hot bitumen @ 1.8 Kg/sqm.
iv) Embed first layer of fibre glass RP tissue. Overlaps shall be 100mm
between the layers in either direction.
v) Apply second coat of hot bitumen @ 1.8 Kg/sqm.

vi) Embed second layer of fibre glass RP tissue after the surface of the first
layer has become dry.
vii) Apply third coat of hot bitumen @ 1.8 Kg/sqm.
viii) Embed third layer of fibre glass RP tissue.
ix) Apply fourth coat of hot bitumen @ 1.8 Kg/sqm.
x) Finish with gravel grit @ 0.006 cum per sqm. Guarantee
A written guarantee for the water tightness shall be taken for a minimum
period of 10 years.
15.10.5 Specification
Water proofing medium
i) By impregnation into the fibre glass reinforcement membrane forms a

monolithic mass.
ii) Prevents the penetration of water/moisture.
iii) Acts as a top dressing.
Layer
A single thickness of fibre glass tissue impregnated with bituminous

compound.
Multiple layer
2 or more layers of fibre glass tissue laid consecutively with overlapping

joints and impregnation with bitumen.
Bitumen/primer
A liquid bitumen of low viscosity which penetrates into a prepared surface

upon application.
Half-brick masonry shall be of approved quality 50 class brick work in

cement mortar 1:4 (1cement : 4 sand). Plaster should be in cement mortar
1:4 (1cement : 4 sand). Sand should be fine sand conforming to IS 383
Application
Suitable slope may be provided in lean concrete, if necessary. Over this,

12mm thick plaster with cement mortar 1:4 (1cement : 4 coarse sand)is to
be laid.

Prime the plastered surface with primer at the rate of 0.4 Kg/sqm. This
should properly impregnate the surface & then should be left till the time
it is touch dry.
Water proofing shall be as follows :-
i) Apply first coat of hot bitumen @ 2.4 Kg/sqm.
ii) Embed first layer of fibre glass RP tissue. Overlaps shall be 100mm
between the layers in either direction.
iii) Apply second coat of hot bitumen @ 2.4 Kg/sqm.
iv) Embed second layer of fibre glass RP tissue after the surface of the first
layer has become dry .
v) Apply third coat of hot bitumen @ 2.4 Kg/sqm.
vi) Embed third layer of fibre glass RP tissue after the surface of the second
layer has become touch-dry.
vii) Apply fourth coat of hot bitumen @ 2.4 Kg/sqm.
viii) Embed fourth layer of fibre glass RP tissue after the surface of the third
layer has become touch-dry.
ix) Apply fifth coat of hot bitumen @ 2.4 Kg/sqm.
x) A layer of 12mm thick fine sand is to be laid after completing the above
operations. The layer of sand will not be applied on vertical walls.
The surface should be finished with half-brick masonry in cement mortar

1:4 (1cement : 4 coarse sand).
Guarantee
A written guarantee for the water tightness shall be taken for a minimum
period of 10 years.
General
The work will be carried out by specialists in the trade. Workers shall be
provided with gum boots and hand gloves. There shall be no air pockets.
Corners shall be treated flush without any air pockets or voids.
Measurement
The unit will include supply of materials, transport, preparation of surface,

application of water proofing treatment, plastering, masonry work etc., as
specified herein. The measurement of the item will be in square metres
nearest to the second decimal of the concrete surface which is to be damp-
proofed.

15.11 Water proofing course with P.V.C sheets/ membranes
15.11.1 Jointing
The adjacent lengths of the P.V.C sheets shall be jointed by giving an

overlap of 25mm, one over another by sealing with the approved adhesive.
A minimum width of the sheet, as specified in the item, shall be used
without any joint. Jointing of the sheets, to the extent possible and
practicable, shall be done at the site workshop.
15.11.2 Laying
i) Horizontal areas: The base concrete shall be rendered smooth by cement

sand plaster 1:6 mix of 20mm thick unless otherwise specified. It shall be
ensured that there are no sharped crivices, projections etc which may
puncture and damage the sheet. P.V.C sheets shall then be evenly laid
over the smooth rendered surface while it is green.
After laying of sheets a protective cover shall be laid over it. This cover
may be of 1:6 cement sand mortar bed of thickness 20mm and above, flat
brick/tile soling over cement sand mortar bed, any other suitable layer or
thermal insulation cover as specified in the item. However care is to be
taken that sheets do not get damaged while laying the protective cover.
The horizontal layer of P.V.C sheets shall be carried over to a minimum of
150mm height and tucked in to the connecting vertical walls as in the case
of roof parapets, if there is no provision of continuous laying of the sheets
in the adjacent vertical surface.
ii) Vertical surfaces
On vertical concrete surfaces the P.V.C sheets shall be fixed along with
the form work with the knobs projecting toward concrete. The sheets shall
be clamped on the top of the form work to keep it in position. Concrete is
then poured and knobs are locked in it. After the forms have been stripped
off, all the tie bolt holes, cuts and other damages are sealed with additional
patches of sheets as per manufacturer's specification.
In case good quality of soil, completely free from foreign materials like
stone piece, hard lumps and rubbish etc, is available, it can be used
directly as a back fill. Otherwise a half brick wall or any other measure as
specified shall be provided as a protection barrier over the projecting base
of the concrete/mud mat. The top edge of the sheet shall be tucked into a
chase to be subsequently sealed with cement sand mortar of 1:4 mix.
In case of sheets being laid both on horizontal and adjacent vertical

surfaces, the horizontal sheets shall be carried on the vertical portion as
one monolithic layer.
15.11.3 Agency

The execution work including jointing, laying and testing etc. shall be
done by a specialised agency duly approved by the Engineer.
15.11.4 Testing
After laying is complete, the sheets shall be tested by an Electronic Pin

hole detector for pin holes, cuts and other damages etc. All such portions
shall be patched suitably with additional sheets as directed and again test
checked.
15.11.5 Expansion joints
All Expansion Joints etc of dimensions as specified, shall be filled up by

Polymer Sealant of pourable grade as per manufacturer's specification on
the P.V.C sheets locked in the joint.
15.11.6 Guarantee
The contractor shall guarantee the water tightness and leak proofing of the
structure for a period of ten years after certified completion and handing
over of the jobs by furnishing a free maintenance guarantee as per
prescribed format and as specified.
Waterproofing with Non-Shrink Polymeric Waterproof Grouting

Compound
15.12.1 Work Included
The Contractor shall furnish materials, labour, plant, equipment and tools
to complete the work as specified and/or as shown in drawings.
15.12.2 Materials
Cement
Ordinary portland cement shall conform to IS : 269-1989 and portland

blast furnace cement shall conform to IS : 455-1989.
Aggregates
All aggregates shall conform to IS : 383-1970 Fine aggregates shall be

approved river or pit sand.
Cement waterproofing compound
All cement waterproofing compound shall conform to IS : 2645-1975 and

shall be of approved quality.
Solvent less resin

High build polymeric surfacing which forms a thick resilient and flexible
membrane on concrete with high resistance to oil and water.
Nozzle
15 mm dia threaded G.I. pipes of suitable length.
Super plasticiser
High range water reducing admixture and integral cement waterproofer

for concrete. Super plasticiser shall conform to ASTM C-194 Type F, IS:
9103-1979 & IS:2645-1975.
15.12.3 Waterproofing of underground structures
Waterproofing shall be carried out as per the approved manufacturer's

specification and as stated below:
15.12.3.1 Raft
The sub-base (PCC) of the underground structure shall be cleaned of all

dirts and kept dry by continuous pumping of water. 20 mm thick plaster
with cement-sand mortar (1:3) mixed with approved cement
waterproofing compound as per manufacturer's specification shall be laid
on top of the sub-base. The plaster shall be finished smooth with a steel
trowel.
The plastered surface shall then be painted with two (2) coats of approved
solvent less resin to form a thick resilient and flexible resinous membrane
over the plastered surface.
Threaded nozzles of 15 mm dia and of suitable length shall be placed and

fixed in a grid pattern of maximum 1.5 m centre to centre over the whole
raft, prior to casting of RCC raft. similar nozzles will also be placed along
the construction joint, if any, at regular intervals not exceeding 1.5 m c/c.
Adequate precaution shall be taken to keep the nozzles plugged at both
ends to prevent them from getting clogged by concrete. Similar nozzles
shall also be post fixed at critical points, if required. Approved super
plasticiser-cum-cement waterproofer shall be added to the concrete which
shall be at least M20 grade as defined by IS : 456-1978 and the water
cement ratio of the concrete shall not exceed 0.45. Adequate precaution
shall be taken to keep the nozzles vertical while concreting.
Approved non-shrink polymeric waterproof grouting compound mixed

with cement slurry shall be injected through the nozzles under pressure by
pump as per the instructions of the manufacturer. When the injection
operation is over the nozzles shall be sealed with a sealing compound as
per manufacturer's specification and instruction.
15.12.3.2 Vertical wall

15 mm dia threaded nozzle of suitable lengths shall be placed and fixed in

a grid pattern of maximum 1.5 m centre to centre over the entire surface
prior to concreting of the vertical wall. Similar nozzle are to be also fixed
at construction joints, if any, y, at regular intervals not exceeding 1.5 m
c/c. Adequate precaution shall be taken to keep the nozzles plugged at
both the ends to avoid clogging of the nozzles by concrete. Similar
nozzles shall also be post fixed at critical points, if required.
The concrete for the vertical wall shall be at least M20 grade as defined by
IS:456-1978 having a maximum water cement ratio of 0.45. Approved
super plasticiser-cum-cement waterproofer shall be added to the concrete
as per the manufacturer's specification. Adequate precaution shall be taken
to keep the nozzles horizontal during concreting. The exterior surface of
the concrete shall be plastered with 12 mm thick cement sand mortar (1:3)
mixed with approved cement waterproofing compound conforming to
manufacturer's specification. The plastered surface shall then be finished
smooth with a neat coat of cement slurry and painted with two coats of
approved solventless resin to form a thick resilient and flexible resinous
membrane over the plastered surface. Approved non-shrink polymeric
waterproof grouting compound mixed with cement slurry shall be injected
through the nozzles under pressure by pump as per the manufacturer's
specification and shall be sealed with a sealing compound as per
manufacturer's specification and instruction.
16.0 MISCELLANEOUS
16.1 False ceiling
16.1.1 Scope
This chapter deals with the specification for various types of false ceiling
as listed below :
a) Wooden ceiling (solid wood) and decorative ply.
b) Ceiling with insulating Building Board/Particle Boards etc.,
c) A.C. Sheet and ply wood ceiling.
d) Plaster of Paris ( Gypsum Anhydrous ) ceiling over wooden frame.
e) Plaster of paris ( Gypsum Anhydrous ) Tiles ceiling.
f) Wooden cover, fillets, beading for ceiling.
16.1.2 General
16.1.2.1 Materials
All materials shall be in accordance with the general specifications of

materials, Part-I, Schedule of items and as shown in drawings.

Special finishing materials as specified in schedule of item shall be

procured from the specified source and got fixed by employing skilled
worker in the trade under direct supervision of the manufacturer.
16.1.3 Openings for installation of light fittings
Openings in the ceiling for installation of A/C grills, light fittings shall be
provided as per drawings.
16.1.4 Recess for pelmet
Recess for the installation of pelmets shall be provided where shown in

drawings along the windows/ doors.
16.1.5 Grills
Grills made of wooden, M.S., Aluminium, PVC or any other material as

necessary shall be provided as indicated in the drawing.
16.1.6 Frame work
The type of frame to receive the ceiling material may be of wood,

aluminium or M.S. as specified in the schedule of item and as mentioned
in the drawing.
16.1.7 Wooden framing for false ceiling
Unless otherwise specified in schedule of items the wooden frame work

shall be of following description :
The frame work for false ceiling shall be of approved quality teak wood
scantlings, the runners shall be 75 x 50 mm size and shall be spaced at
1200 mm c/c and the battens shall be 50 x 50 mm size spaced at 600 mm
c/c (approx) forming a grid of 600 x 600 mm or any other grid suitable for
fixing the false ceiling material and its size. The runner and battens shall
be joined by halving joint using counter sunk 6 mm bolt with washer of
required length with soffit of runner and batten in perfect level. The
heading joints between runners shall be made with lap joints using 2 nos.
6 mm dia counter sunk bolts with washer. Heading lap joints between
battens shall be made with suitable size screws. The wall ends of the
runner shall be embedded in the wall (50 mm deep) and shall be grouted
with 1:2:4 cement concrete. The soffit of framework shall be made
perfectly horizontal. The teak wood frames shall be treated with 2 coats
of wood preservations treatment before fixing the tiles/boards as the case
may be.
The main runners of frames shall be suspended by M.S. flat 40 x 3 mm

/12mm dia M.S. round/T.S. hangers placed at 1200 mm c/c (approx), the
top end of the hangers shall be hocked to R.C.C. reinforcement of slab or
fixed to M.S. flat cleats installed in slab for the purpose or hooked to

purlins of the trusses. The hangers may be twisted or ends of M.S.

round/T.S. hanger flattened to allow for fixing the same with T.W. frame
or M.S. cleats with bolts of suitable size.
For teak wood framings of shaped ceilings the spacings of frames and
hangers levels of false ceiling etc., shall be required to obtain the
shapes/drops and profile of the ceiling and to the requirement of ceiling
material. The frames shall be locally adjusted to create openings of
required sizes for installation of light fittings, grills of air conditioning
system.
16.1.8 Metal framing
16.1.8.1 Galvanised pressed steel framing system
Galvanised pressed steel framing system for false ceiling shall be

procured from reputed manufacturer and installed by specialist agencies
under technical guidance of the manufacturer and strictly as per their
specifications. Unless specified otherwise these shall consist of G.I.
rectangular pipes at 900 mm c/c suspended by M.S. hanger fixed to
R.C.C. slab with M.S. cleats and cross channels fixed to rectangular pipes
at 450 mm c/c as per "Galvolock" system of M/s Eastern Interior Pvt
Limited or equivalent. Ceiling materials shall be fixed to cross channels as
per specifications of the manufacturer.
Framing shall be adjusted to provide openings for the light fittings and air-
conditioning grills but these shall be supported independently and not on
the framing.
16.1.8.2 Aluminium grid ceiling framing system
Framing for Aluminium grid false ceiling system shall be of reputed

manufacturer Bestlok, Eezilock or equivalent. It shall consist of
aluminium main tee and cross tee's suspended by adjustable hangers fixed
to R.C.C. floor with cleats. The grid may be 600 x 600 mm, 1200 x 600
mm or as per drawings. Ceiling materials, shall be fixed to frames strictly
as per manufacturers specification.
16.1.9 Fixing of Ceiling
16.1.9.1 Wooden ceiling with planks
These shall be of class of wood and thickness as specified in Schedule of

items. Unless specified otherwise the width of the ceiling board shall be
100 mm to 150 mm and shall be planed true on the exposed surface. The
maximum length of the finished board shall be 1800 mm. The
boards/strips shall be joined with tongue and grove joints and heading
joints in adjacent board of the same strip shall be square butt type neatly
finished. These joints shall be staggered in alternate strip or line. The
boards shall be fixed to T.W. battens by headless brass pins. Moulding
beads at junctions with walls and other locations as per drawings shall be
provided. Necessary opening for installation of light fittings and A/C grill

shall be provided and junctions if required shall be finished with moulded

beads.
The false ceiling shall finally be checked for line and level, sand papered
and polished with colourless polish to achieve matt satin natural finish.
16.1.9.2 Decorative ply ceiling
These shall be with decorative selected group matched ply of Teak Ply,
white cedar ply or any other approved class of veneer ply in strips, square
or rectangular panel matching the ply of wall panelling, if any, in the same
room and of thickness as per schedule of item and drawings. The strip ply,
square/rectangular panels shall be fixed to T.W. framework with panel
pins. Moulded beads of same wood as that of ply of matching shade shall
be provided at junctions with walls and as specified in drawings.
Where specific pattern of grains and shade is required the ply cut into
shapes as per design may be pasted on a backing ply with adhesive and
such made panels shall be fixed to framing.
The ceiling shall be checked for line, and levels and exposed surfaces
shall be sand papered and finally polished with colourless polish to
achieve matt satin natural finish.
16.1.9.3 Ceiling with insulation board/particle boards
Insulation boards shall be of approved manufacturer, shade, design and

thickness as specified in schedule of items and drawings. These may be
plain, textured, perforated with natural finish or with white finished
surface.
The boards shall be cut to suit the panel sizes of ceiling with special tools
and by skilled workmen strictly as per manufacturers specifications. The
board shall be fixed to T.W. frames with brass screws or as per
manufacturers recommendation and in case of metal frames as per
recommendations of the manufacturer of the ceiling system. The joints
where exposed shall be of uniform thickness (3 mm to 6 mm) and pattern
as shown in drawings.
The ceiling shall be checked for line and level and exposed surfaces
prepared appropriately to receive the paint as specified in schedule of item
and drawing.
16.2. Wooden partitions
16.2.1 Scope
All materials for the wooden partitions shall be of respective class as

specified in the part (I) and as mentioned in schedule of items.
16.2.1.2 Frame work

Unless otherwise specified in the schedule of items, framing for partitions

shall be made of approved quality teak wood scantlings of sizes as
mentioned in schedule of items and drawing. The spacing of frames shall
not exceed 1200 mm c/c in both direction. The joints of the frame shall be
made as per standard joinery practice using standard adhesive as described
in wood work chapter. The faces of the frames to receive ply/wooden
board shall be true to line, level and plumb. The frames shall be firmly
secured to walls, ceilings, floors by making chases and grouting the
frames in 1:2:4 cement concrete or fixing the frames with metal
clamps/flats screwed to above elements. The frame shall be treated with 2
coats of wood preservative. Where the panelling material is of decorative
ply of 3.5 mm to 4 mm thickness, commercial ply of 6 mm thickness shall
be fixed to the frame work for backing purpose. Where sunk (coffered)
panels are to be made, combination of single and double layers ply shall
be used for backing to achieve level difference for sunk panels.
16.2.3 Boarding/facing for partition
a) Wooden plank/board
These shall be of class of wood and thickness as specified in the schedule

of item and drawings. These shall be fixed to backing wooden frame
work with counter sunk brass screws in pattern and designs, with groves,
joints, beads, fillets, cover moulds as shown in drawings. The exposed
surfaces shall be sand papered and polished as specified.
b) Decorative ply wood facing
These shall be with decorative teak wood/rose ply/white cedar 3.5 to 4

mm thickness of selected pieces with matching colour, texture and grains
and shall be fixed to the backing ply with panel pins in pattern, design,
with uniform width of joints, beads, fillets, cover mould as shown in
drawings. The exposed surfaces shall be lightly sand papered finished
with colourless polish to achieve matt satin finish.
c) Jolly pan (laminated) board
Where specified Jolly pan boards shall be fixed to teak wood frame work
strictly as per manufacturer's specification. The boards after fixing shall
be cleaned of all adhesives etc.
d) Formica facing
Formica facing shall be fixed to the backing ply with standard adhesive as
described for panelling works.
16.3 Expansion and Isolation Joints
16.3.1 General

Expansion and isolation joints in concrete structures shall be provided at

specific places as per details indicated on the drawings. The materials and
types of joints shall be as specified hereinafter. In case of liquid retaining
structures, additional precautions shall be taken to prevent leakage of
liquids as may be specified on the drawings or as directed by the Engi-
neer. All materials are to be procured from reliable manufacturers and
must have the approval of the Engineer. Where it is the responsibility of
the Contractor to supply the material, the Engineer may demand test
certificates for the materials and/or instruct the Contractor to get them
tested in an approved-laboratory free of cost to the Owner. Joints shall be
formed true to line, level, shape, dimension and quality as per drawings
and specifications. Prior approval, for the method of forming the joints,
should be obtained from the Engineer before starting the work.
16.3.2 Bitumen impregnated board
Bitumen impregnated fibre board of approved manufacturer as per IS:

1838 (Part 1)-1983 may be used as fillers for expansion joints. It must be
durable and waterproof. It shall be compressible and possess a high
degree of rebound. The dimensions of the board should be equal to that of
the joint being formed. At the exposed end, the joint shall be sealed with
approved sealing compound to a depth of at least 25 mm after application
of an approved primer. The sealing compound and the primer shall be
applied as specified by the manufacturer.
16.3.3 Joint sealing strips
16.3.3.1 General
Joint sealing strips may be provided at the construction, expansion and

isolation joints as a continuous diaphragm to contain the filler material
and/or to exclude passage of water. The sealing strips will be either
metallic like G.I., Aluminium or Copper, or Non-metallic like rubber or
P.V.C.
Sealing strips will not have any longitudinal joint and will be procured
and installed in largest practicable lengths having a minimum number of
transverse joints. The jointing procedure shall be as per the
manufacturer's recommendations, revised if necessary, by the Engineer. If
desired by the Engineer, joints in rubber seals may have to be vulcanised.
16.3.3.2 Metal sealing strips
Metal sealing strips shall be either G.I.or Aluminium or Copper and

formed straight, U-shaped, Z-shaped or any other shape and of thickness
as indicated in the drawing and schedule of items and/or as instructed by
the Engineer.
The transverse joints will be gas welded using brass rods and approved
flux. In case it is found that the joints cannot be made leak proof, longer
lap lengths and different method of brazing which will render it leak

proof, will be adopted by the Contractor without any additional cost to the
Owner. The edges shall be neatly crimped and bent to ensure proper bond
with the concrete.
a) G.I. Strips
G.I. strips shall be minimum 1.5 mm thick and 150 mm in width unless
specified otherwise. The Strips shall be strong, durable, without any rust
or crease. At the joints, the overlapping should be for a minimum length
of 50mm
b) Aluminium strips
Aluminium strips shall be minimum 18 SWG thick and 300 mm wide

unless specified otherwise and shall conform to IS : 737-1986. A
minimum lap of 50 mm length is required at the joints.
c) Copper strips
The copper strips shall be minimum 18 SWG in thickness and 300 mm

width.
It should be cleaned thoroughly before use so as to expose fresh surface,

without any reduction in gauge. A minimum lap of 50 mm in length is
required at the joints.
16.3.3.3 Non-metallic sealing strips
These will be normally in Rubber or PVC Rubber or PVC joint seals can
be of shape having any combination of the following features :
a) Plain
b) Central bulb
c) Dumb-bell or flattened ends
d) Ribbed and corrugated wings
e) V-shaped
Transverse joints will be allowed only under unavoidable circumstances

and with the specific approval of the Engineer. The actual size and shape
shall be as shown in drawings/Schedule of Items and or as directed by the
Engineer.
The method of forming these joints, laps etc., shall be as specified by the
Manufacturer and/or as approved by the Engineer taking particular care to
match the central bulbs and the edges accurately.
a) Rubber sealing strips
The minimum thickness of rubber sealing strips shall be 3 mm and the

minimum width 100 mm. The material will be natural rubber and be
resistant to corrosion, abrasion and attacks from the acids, alkalies and

chemicals normally encountered in service. The physical properties will

be generally as follows :
Specific Gravity : 1.1 to 1.15
Shore Hardness : 65A to 75A
Tensile Strength : 25 - 30 N/mm2
Maximum Safe Continuous

Temperature : 75 Degree 'C'
Ultimate Elongation : Not less than 350%
b) P.V.C. sealing strips
The minimum thickness of P.V.C sealing strips will be 3 mm and the

minimum width 100 mm. The material should be of good quality Polyvi-
nyl Chloride highly resistant to tearing, abrasion and corrosion as well as
to chemicals likely to come in contact with during use. The physical
properties will generally be as follows :
Specific Gravity : 1.3 to 1.35
Shore Hardness : 60A to 80A
Tensile Strength : 10 - 15 N/mm2
Maximum Safe Continuous Temperature : 70 Degree 'C'
Ultimate Elongation : Not less than 275%
16.3.4 Bitumen compound
When directed, the gap in expansion joints shall be thoroughly cleaned

and bitumen compound laid as per manufacturer's specifications. The
compound to be used shall be of approved manufacture and shall conform
to the requirements of IS: 1834-1984.
16.4 Barbed Wire Fencing
16.4.1 Materials
16.4.1.1 Galvanised barbed wire
Barbed wire shall be properly galvanised and shall be obtained from the
approved manufacturer as specified in detail in Part-1.
16.4.1.2 Other materials

The specifications of materials, for angle iron posts, concrete works,

plasters, if any, and for other works, shall conform to the requirements as
specified in Part-I.
16.4.2 Workmanship
The work shall comprise of the following :
a) Excavation in ground of required dimensions with all sides vertical in any

type of soil including soft rock and removing the soil and dressing it
neatly.
b) Filling the holes in full with cement concrete 1:3:6 mix, well packed, after
erecting the posts in correct line, level and plumb. In case of any post
coming at local depression, the hole may not be of full depth but the depth
of concrete will always be made 60 cm raising it above ground level with
necessary shuttering.
c) Where the angle iron posts are specified in the item these shall be 50 mm
x 75 mm x 6 mm unless mentioned otherwise. 10 mm dia holes with saw
cuts for inserting the wires shall be made as per the spacings of barbed
wire shown in drawing or as directed by the Engineer. The foot of the
post shall be provided with base plate for anchorage. The spacing shall
be 2.5 m or as per drawing. After inserting the wire into holes the socket
is to be pressed back.
d) Straining bolts are to be provided 15 m apart from each row of wire for
maintaining proper tension in the wire and without any sag or looseness.
e) Posts are to be painted as directed by the Engineer.
16.5 Chain link fencing
16.5.1 Scope
The work under this specification covers the supply and fixing of
galvanized steel chain link fencing with galvanized steel posts chain link
fabric.
16.5.2 Material
Galvanized steel chain link fabric and galvanized steel pipe posts shall be
obtained from the approved manufacturer as specified in detail in Part - I .
Workmanship
The GI pipe posts shall be embedded in plain cement concrete not leaner
than 1:4:8 foundations. The height of posts above top of foundations and
spacing of post shall not be more than 3 m. The chain link fabric shall be
fixed to the fencing posts with the help of stretcher galvanised bars ( 25 x
6 flats ) which will be bolted to the lugs welded to the posts. The stretcher
bars shall be provided in the lapping of fabric also.

SPECIFICATIONFORFLYASH-CEMENTBRICKS
(ANNEXURE 1)
1.1 Scope
This section covers the setting up of a manufacturing plant for fly ash –
cement bricks as per the directions of the Owner. This section also
includes transportation of raw materials storage and proportioning of raw
materials, handling and mixing of raw materials, manufacturing of bricks,
curing, handling and laying of bricks and conducting quality control tests.
1.2 Unless specifically mentioned otherwise, all applicable codes and

standards published by the Bureau of Indian Standards shall govern
design, workmanship, quality and properties of materials, method of field
and laboratory testing, method of measurement for different items of work
etc.
1.3 Materials
1.3.1 Cement : 33 grade ordinary Portland cement conforming to IS:269 or

Higher Grade above 33 Grade.
1.3.2 Sand : Sand shall be free from deleterious materials like clay and silt in
sand and shall be less than 5%. Sand shall conform to IS: 383.
1.3.3 Fly Ash : Fly ash used for manufacturing flay ash cement bricks shall
conform to Grade-I or Grade-2 of IS:3812. Fly ash will be available near
the Electro static precipitators / fly ash storage silos/at a place indicated by
Purchaser inside plant area
1.4 Collection of fly ash

The contractor has to make his own arrangements for collecting the fly
ash from the fly ash storage silos or other designated area inside the
captive power plant through covered trucks and transporting them to work
site. Fly ash will be transferred in the covered trucks by flexible chute.
No extra charges will be paid for collecting the fly ash from silos inside
the captive power plant and transporting them casting yard. Fly ash is
supplied free of cost at the discharge point of silos.
1.5 Fist Aid Treatment
Necessary first aid treatment shall be made available at site by the

contractor.
1.6 Storage of Raw Materials
1.6.1 Cement
1.6.1.1 The cement used shall be as specified in Clause No. 1.3.1.The contractor
shall carry out the required tests at his own cost in an approved testing

laboratory and submit the test report for the approval of the Engineer
before using the cement in the works.
1.6.1.2 Cement shall be stored on raised platforms inside stores covered on all
sides and roof with provision for ample ventilation. More than ten (10)
bags of cement shall not be stacked one above the other in the stack.
Sufficient space shall be left around the stacks for approach. Stacking
shall be so arranged that bags from the oldest consignment can be
conveniently removed first for use following the principle of first in first
out (FIFO) basis. For the proper label tag indicating date of supply shall
be displayed over the stack of stored cement received that a consignment
(Batch) cement which has hardened, clodded or deteriorated due to over
stacking or long storage shall not be used in the works and shall be
removed from the site immediately with instruction to Employer and
Engineer-in-charge.
1.6.1.3 For ensuring better qualify of fly ash bricks the contractors shall offer to
Employer / Engineer-in-charge for checking the lot No. / Grade of cement
etc. before unloading the same in their store. The contractor shall also
furnish the daily consumption of cement, fly ash bricks manufactured and
balance cement available in their store on day-to-day basis. The contractor
shall offer for checking the storage of cement as and when required by
Employer / Engineer-in-charge.
1.6.2 Sand (Fine aggregate)
Sand shall conform to IS: 383 and shall be river or pit sand. Sand shall be
spread at site on clean and hard base or in compartments. Samples of sand
to be used shall be submitted to the Engineer-in-charge for approval
before commencement of work. The contractor shall ensure that over the
entire period of construction all consignments of sand brought to the site
conforms to the quality and grading as approved by the Engineer-in-
charge before the commencement of work. Whenever directed by the
Engineer-in-charge the contractor shall perform tests at his own cost to
satisfy that the grading and quality approved for sand is being maintained.
Sampling of aggregate shall conform to IS:2430 and tests shall conform to
IS: 2386. The percentage to flaky and elongated pieces should not exceed
15%.
1.6.3 Fly Ash
Fly ash being a very fine material gets air borne easily and causes dust
nuisance. It may also lead to environmental pollution. The fly ash may
require on site temporary stock piling if the rate at which the ash is
transported to the fly ash brick manufacturing site is more than the
demand for an efficient rate of placement. Such cases should be avoided
to the extent possible and in case stock piling at site is inevitable, adequate
precautions should be taken to prevent dusting. Otherwise the surface of
the fly ash stock pile may be covered with tarpaulins or a thin layer of soil
not subject to dusting.

1.7 Proportion
1.7.1 The proportion of raw materials for the fly ash cement bricks is described
based on trial mixes carried over at site earlier based on the test
certificates.
1.7.2 The proportion of Fly ash, sand and cement shall be as given below:
Cement: : 8 – 10 %
Sand (fine aggregate) : 35 – 40 %
Fly ash : 50 – 60 %
1.7.3 The fly ash bricks manufactured shall meet the testing and acceptance
criteria specified in Clause 1.13.
1.8 Moulds
The moulds shall be made of metal and true to shape and dimensions of
the finished product as indicated in the drawings. The moulds shall be
close jointed and perfectly smooth with joints caulked to prevent leakage
of fly ash mixture slurry. The moulds shall be of rigid construction to
prevent distortion and bulging of sides and base. The moulds shall be
designed with suitable fastenings to allow them to be struck without injury
to the casting. The mould must be made to carry a frog of appropriate size
with “NMDC” marked on it.
1.9 Mixing
The raw materials shall be weigh batched and uniformly and properly
blended in pan mixer for about 3 to 5 minutes with required quantity of
water. If the mixture contains lumps, the mixing time shall be increased.
1.10 Manufacturing
Fly ash, sand and cement shall be mixed in proportion as per Cl. No. 1.7
Cement, Sand and Fly ash are added into the pan mixture with optimum
water to form a homogeneous mixture uniform in color and then
transferred to the moulding machine. In the moulding machine, the
mixture is hydraulically pressed or compacted through vibratory press and
removed carefully from moulds. After the removal of bricks from the
mould, they are air dried for 3 days.
1.11 Marking
All pre-cast bricks shall be marked in a manner approved by the Engineer-

in-charge in a conspicuous place with date of manufacture and marking
number. The upper part of the bricks shall be marked distinctly to ensure
proper handling.
1.12 Curing

The contractor shall keep all the bricks wet for not less than 28 days.
1.13 Testing & Acceptance criteria
1.13.1 Sampling and criteria for conformity
Sampling and criteria for conformity of the bricks shall be as given in IS:
5454.
1.13.2 Compressive strength
Minimum compressive strength of fly ash bricks shall be as specified in

IS:12894 when tested as per IS:3495 (Part-1) of class 10, as specified in
sub clause No. 6.1 page 02.
1.13.3 Drying shrinkage
The average drying shrinkage of three units shall not exceed 0.15% when
tested by the method described in IS:4139.
1.13.4 Efflorescence
The bricks shall be tested as per IS:3495 (Part-3) and shall have the rating
of efflorescence not more than moderate.
1.13.5 Water absorption
The bricks, when tested in accordance with the procedure laid down in
IS:3495 (Part-2) after immersion in cold water for 24 hours, shall have
average water absorption not more than 20% by mass.
1.14 Laboratory
The rate of raw materials and quality of bricks shall be tested in the
presence of Engineer-in-charge in the approved laboratory with above
testing facilities.
1.15 Transportation of fly ash bricks
The contractor has to make his own arrangement for transporting the
cured bricks at no extra cost from casting yard to working place.

PART – III NORMS OF CEMENT CONSUMPTION
CONTENTS
1. MASONRY WORK
2. PLAIN/REINFORCED CONCRETE WORK
3. FINISHING WORK
4. FLOORING WORK
5. MISCELLANEOUS ITEMS
6. WATER SUPPLY/DRAINAGE & SANITARY WORKSS

GENERAL
For calculating the requirements of cement in various items of work the following
standards will be adopted. Over the above theoretical quantity of cement, additional
allowance upto plus or minus 3% shall also be allowed as certified by the engineer.
For items not covered in this standard, CPWD standards shall be followed or
calculated as per uses/requirement in absence of standard norms. Cement required
for enabling work and cement required for testing purposes will be taken into
account for consumption purpose. However, in no case such quantity should exceed
5% of the total cement used in the work or as certified by the engineer based on
actual observation whichever is less.
MASONRY WORK
Sl.No. Description of Item Cement Requirement
1. Random rubble masonry with CM 1:4 1.255 quintals per cum

2. Random rubble masonry with CM 1:6 0.825 quintal per cum
3. Coursed rubble masonry in CM 1:6 0.75 quintal per cum
4. Brick work in CM 1:4 0.950 quintal per cum of BW
5. Brick work in CM 1:6 0.625 quintal per cum of BW
6. Half brick work in CM 1:3 1.43 quintals per 10 sqm of area
7. Half brick work in CM 1:4 1.06 quintals per 10 sqm of area
8. 75mm thick brick in CM 1:4 0.65 quintal per 10 sqm of area
9. 75mm thick brick in CM 1:3 0.81 quintal per 10 sqm of area
10. Projected brick bands,
Drip course etc. in CM 1:6
finished with 12mm thick
cement plaster 0.165 quintal per 10 RM
11. Half brick thick,

Honey combed brick work in CM 1:4 0.064 quintals per sqm
PLAIN/REINFORCED CONCRETE
1. RCC/PCC of nominal mix 1:5:10 complete

(excluding finishing with CP) 1.30 quintals per cum of concrete

(excluding finishing with CP ) 1.70 quintals per cum of concrete

(excluding finishing with CP ) 2.23 quintals per cum of concrete
(excluding finishing with CP) 3.18 quintals per cum of concrete
5. RCC/PCC of nominal mix 1:1.5:3 complete

(excluding finishing with CP 4.00 quintals per cum of concrete


(excluding finishing with CP 6.10 quintals per cum of concrete
Controlled Concrete - Plain and Reinforced
7. Concrete grade (i) M -5A

(ii) M -5B
(iii) M -7.5A
(iv) M -7.5B
8. Concrete grade (i) M -10A

(ii) M -10B
(iii) M -10C To be mutually agreed
based on mix design to be
9. Concrete grade (i) M -15B prepared by contractor &
(ii) M -15C approved by the Engineer plus
(iii) M -15D wastage and all incidentals as
decided.
10. Concrete grade (i) M -20B
(ii) M -20C
(iii) M -20D
11.. Concrete grade (i) M -25B

(ii) M -25C
(iii) M -25D
12. Concrete grade (i) M -30C

(ii) M -30D
13. Applying cement slurry on

RCC slab for receiving
cement concrete flooring.
2.75 kg/sqm
FINISHING
1. 6mm thick C.P. 1:4 0.280 quintal per 10 sqm area

12. 12mm thick bearing plaster in 0.590 quintal per 10 sqm area
CM 1:4 with neat cement finish
13. Neat cement punning 0.200 quintal per 10 sqm area

14. Flush or ruled or cut or weather 0.155 quintal per 10 sqm area
pointing on brick work with CM 1:3
15 Flush or ruled or cut out or 0.200 quintal per 10 sqm area

weather pointing on brick work
with CM 1:2
16. Raised and cut pointing on brick 0.235 quintal per 10 sqm area
work with cement mortar 1:3
17. Flush or ruled pointing on brick 0.075 quintal per 10 sqm area
flooring with cement mortar 1:4
18. Flush or ruled pointing on brick flooring with 0.050 quintal per 10 sqm area
cement mortar 1:6
FLOORING
1. Brick on edge flooring in
cement mortar 1:4 1.100 quintal per 10 sqm area
2. Brick on edge flooring in
cement mortar 1:6 0.800 quintal per 10 sqm area
3. 25mm thick (IPS) cement concrete flooring

1:2:4 (1 cement : 2 sand : 4 graded stone chips
12mm nominal size) finished with a floating
coat of neat cement.
1.020 quintal per 10 sqm area
4. 40mm thick (IPS) cement concrete flooring
1:2:4 with 20mm and down stone chips
finished with a floating coat of neat cement.
5. 25mm thick (IPS) flooring with base coat
19mm thick 1:2:4 using stone chips 10mm
nominal size and 6mm topping coat 1:1 (1
cement : 1 stone chips 3mm size ) with a
6. 40mm thick (IPS) flooring with base coat
30mm thick 1:2:4 using stone chips 10mm
nominal size and10mm topping coat 1:1 (1
cement : 1 stone chips 3 to 6mm size) with a
7. 25mm thick cast-in-situ grey terrazzo flooring,
under layer 19mm thick cement concrete 1:2:4
with 10mm nominal size chips and 6mm thick
topping laid in cement marble powder mix 3:1
(3 cement : 1 marble powder) by weight in
proportion of 4:7 (4 cement marble powder
mix : 7 marble chips) by volume.

8. 40mm thick cast-in-situ grey terrazzo flooring,

with 10mm nominal size chips and10mm thick
topping laid in cement marble powder mix 3:1
(3 cement : 1 marble powder) by weight in
proportion of 4:7 (4 cement marble
powder mix : 7 marble chips) by volume.

9. 40mm thick cast-in-situ terrazzo flooring,
with 10mm nominal size chips and top layer
9mm thick with marble chips of size 4 to 7mm
nominal size laid in cement marble powder
mix 3:1 (3 cement : 1 marble powder) by
weight in proportion of 4:7 (4 cement marble
powder mix : 7 marble chips) by volume.
a) Dark or light shade pigment with grey cement
b) Light shade pigment or without any (grey 1.010 quintal per 10 sqm area
cement) pigment with white (grey cement)
cement 0.580 quintal per 10 sqm area
(white cement)
c) Medium shade pigment with 50% grey cement 1.295 quintal per 10 sqm area
and 50% white cement (grey cement)
(white cement)
10. 40mm thick cast-in-situ terrazzo flooring,
with 10mm nominal size chips and top layer
12mm thick with marble chips of size 7 to
12mm nominal size laid in cement marble
powder mix 3:1 (3 cement : 1 marble powder)
by weight in proportion of 2:3 (2 cement
marble powder mix : 3 marble chips) by
volume.
a) Dark or light shade pigment with grey cement

b) Light shade pigment or without any (grey 0.895 quintal per 10 sqm area
cement) pigment with white cement (grey cement)
(white cement)
(white cement)
d) White cement without any pigment 0.895 quintal per (grey 10 sqm area

cement)
(white cement)
11. Terrazzo cast-in-situ skirting and dado, top
layer 6mm thick marble chips laid in cement
marble powder mix 3:1 (3 cement : 1 marble
powder) by weight in proportion of 4:7 (4
cement marble : 7 marble chips) by volume.
(A) 18mm thick with under layer 12mm thick

cement plaster 1:3
a) Dark or light shade pigment with grey cement 1.490 quintal per 10 sqm area
b) Light shade pigment or without any pigment 1.090 quintal per 10 sqm area
with white cement. (grey cement)
(white cement)
(white cement)
(B) 21mm thick, with under layer 15mm thick

cement plaster 1:3
a) Dark or light shade pigment with grey cement 1.640 quintal per 10 sqm area
b) Light shade pigment or without any pigment 1.230 quintal per 10 sqm area
with white cement. (grey cement)
(white cement)
(white cement)
12. Precast terrazzo tiles 20mm thick with marble
chips of sizes upto 6mm laid in 25mm thick
bed of lime mortar, jointed with neat cement
slurry mixed with pigment
a) Dark shades using grey cement 0.88 quintal per 10 sqm area
b) Light shade using white cement. 0.44 quintal per 10 sqm area
(grey cement)
(white cement)
c) Medium shade using 50% grey cement and 0.66 quintal per 10 sqm area

50% white cement (grey cement)

(white cement)
13. Precast terrazzo tiles 20mm thick with marble
chips of sizes upto 6mm in skirting or on walls,
laid on 12mm thick cement plaster 1:3 jointed
with neat cement slurry
a) Dark shades using grey cement 1.395 quintal per 10 sqm area
b) Light shade using white cement. 1.175 quintal per 10 sqm area
(grey cement)
(white cement)
c) Medium shade using 50% grey cement and 1.285 quintal per 10 sqm area
50% white cement (grey cement)
(white cement)
14. White glazed tiles 5, 6 or 7 mm thick in 0.942 quintal per 10 sqm area
flooring, skirting and dado on 12 mm thick (grey cement)
cement plaster 1 : 3 in base and joined with 0.25 quintal per 10 sqm area
white cement, slurry etc. (white cement)
15. Marble stone slab flooring over 20mm thick

base of lime mortar 1:1:1 (1 lime : 1 surkhi : 1
sand) and jointed with white cement slurry etc.
a) 20 mm thick / 30 mm thick / 40 mm thick 0.075 quintal per 10 sqm area

(white cement)
16. Marble stone slab flooring over 20mm thick

base of cement mortar 1:4 & jointed with
white cement slurry etc.
a) 20 mm thick 1.275 quintal per 10 sqm area

(grey cement)
(white cement)
b) 30 mm thick 1.290 quintal per 10 sqm area

(grey cement)
(white cement)
c) 40 mm thick 1.310 quintal per 10 sqm area

(grey cement)
(white cement)

17. Marble tiles 18 to 24 mm thick in risers of 1.16 quintal per 10 sqm area
steps, skirting, dado, walls and pillars laid on (grey cement)
12mm thick cement mortar 1:3 (1 cement : 3 0.075 quintal per 10 sqm area
sand ) and jointed with white cement slurry (white cement)
18. Extra for each additional thickness of 5 mm

granolithic layer of 1:2:4 for flooring
0.016 quintal per 10 sqm of area
19 12mm thick cement plaster skirting, dado risers
of steps and edges of ground sink with CM 1:3
20 15mm thick cement plaster skirting, dado risers
of steps and edges of ground sink with CM 1:3
21. 19mm thick cement plaster skirting and dado
with 12mm thick backing with CM 1:3 and
7mm topping 1:1 (1 cement : 1 stone chips
3mm size) finished with a floating coat of neat
cement. 1.35 quintal per 10 sqm of area
22. 25mm thick cement plaster skirting and dado

with 18mm thick backing with CM 1:3 and
7mm topping 1:1 (1 cement : 1 stone chips
3mm size) finished with a floating coat of neat
cement. 1.85 quintal per 10 sqm of area
MISCELLANEOUS
1. Marble work for wall lining (Veneer work) 1.8 0.715 quintal per 10 sqm of area
to 2.4 cm thick in CM 1:3 including pointing (grey cement)
with white cement mortar 1:2 (1 white 0.170 quintal per 10 sqm of area
cement : 2 marble dust) (white cement)
2. Marble work for wall lining (Veneer work) 4 1.020 quintal per 10 sqm of area
cm thick in CM 1:3 including pointing with (grey cement)
white cement mortar 1:2 (1 white cement : 2 0.170 quintal per 10 sqm of area
marble dust) (white cement)
3. Grading roof for water proofing treatment with

:-
a) CC 1:2:4 (1 cement : 2 coarse sand : 4 stone 3.2 quintal per cum of Concrete
aggregate 20mm nominal size)
b) CM 1:3 5.1 quintal per cum of mortar
c) CM 1:4 3.8 quintal per cum of mortar

4. Providing and fixing MS fan clamps of

standard shape and size in existing RCC slab
including cutting chase and making good.
0.016 quintal each
5. Making plinth protection 50mm thick of CC

1:3:6 (1 cement : 3 sand : 6 graded stone
aggregate 20mm nominal size) over 75mm bed
of dry brick ballast 40mm nominal size well
rammed and consolidated and grouted with
fine sand including finishing the top smooth.
6. Grouting with
a) CM 1:2 7.18 quintal per cum
b) CM 1:3 5.40 quintal per cum
7. DPC 25mm thick (1:2:4) 0.81 quintal per 10 sqm of area
8. Making plinth protection with bricks on edge

in CM 1:6 over 7.5cm bed of dry brick
aggregate 40mm nominal size rammed,
consolidated and grouted with fine sand and
top of bricks pointed with CM 1:2.
9. Providing and fixing 25mm dia GI pipe outlet

in CM 1:3 including cutting and making good
the walls. 0.05 quintal per 10 RM
10. Providing and fixing 40mm dia GI pipe outlet

in CM 1:3 including cutting and making good
the walls. 0.075 quintal per 10 RM
11. Providing chases 75mm wide 50mm deep in
walls for conduit pipe and filling the same with
CC 1:3:6 0.075 quintal per 10 RM
12. Fixing steel windows with 1:2:4 concrete
blocks 0.40 quintal per 10 sqm of area
13. Cement-sand mortar :
a) 1:1(1cement :1sand) 10.2 quintals per cum
b) 1:2(1cement : 2sand) 6.8 quintals per cum

c) 1:3(1cement : 3sand) 5.1 quintals per cum
d) 1:4(1cement : 4sand) 3.8 quintals per cum
e) 1:5(1cement : 5sand) 3.1 quintals per cum
f) 1:6(1cement : 6sand) 2.5 quintals per cum
DRAINAGE/SANITARY & WATER SUPPLY INSTALLATIONS
1. 100mm dia AC rain water pipe

I/c fittings with CM 1:2 0.725 quintal per 100 RM of pipe
2. 150mm dia AC rain water pipe

I/c fittings with CM 1:2 0.82 quintal per 100 RM of pipe
3. Fixing IWC pan with traps, pair of footrests,

and flushing cistern complete
0.125 quintal each
4. Fixing EWC pan with trap and flushing

cistern complete 0.01 quintal each
5. Fixing wash basin and kitchen sink 0.025 quintal l each
6. Fixing urinal cistern including pipes 0.025 quintal each
7. Fixing & finishing floor trap 0.015 quintal each
8. Fixing HCI pipes and specials, 100mm dia

and 75mm dia including making good the
walls 0.135 quintal per 10 RM of pipe
9. Fixing GI pipes of all dia with clamps (for

inside work only) 0.015 quintal per 10 RM of pipe
10. Jointing glazed stoneware pipe with CM 1:1
a) 100 mm dia 2.17 quintals per 10 RM of pipe
b) 150 mm dia 3.23 quintals per 10 RM of pipe
11. Laying cement concrete 1:5:10 all round SW

pipe including bed concrete as per standard
design
a) 100mm dia SW pipe 19.24 quintals per 100 RM of pipe
b) 150mm dia SW pipe 23.53 quintals per 100 RM of pipe

12. Gully chamber as per specification. 0.385 quintal each
13. Stopcock chamber as per specification

0.185 quintal each
14. Inspection chambers as per specification
a) 600x600x600mm deep 1.43 quintals each
b) 750x600x600mm deep 1.435 quintals each
c) 900x900x600mm deep 1.885 quintals each
15. Extra depth of inspection chambers as per

specification
a) 600x600mm 0.805 quintal per RM of depth
b) 750x600mm 1.295 quintal per RM of depth
c) 900x900mm 1.460 quintal per RM of depth
d) 1200x900mm 1.835 quintal per RM of depth

PART – IV DIMENSIONAL TOLERANCE
GENERAL
The materials used in construction shall, besides conforming to the specifications and
standards mentioned, be the best of the existing kinds obtainable. Where a particular
'Brand' or 'Make' of material is specified such 'Brand' or 'Make' of material alone shall be
used.
A high standard of workmanship and accuracy shall be achieved in all sections and parts
of the work. The workmanship shall be in accordance with the latest and the best civil
engineering practice.
The Contractor shall ensure that all sections of the work are carried out with utmost care to
achieve the dimensions shown in drawings or specifications. Where special and close
tolerances are required in any particular section of work, these will be shown in the
drawing and such tolerances shall be met. In the absence of such specific mention in
drawings the following dimensional deviations may be tolerated, provided they do not
impair the appearance or render the particular section of work unacceptable to the purpose
for which it is intended. Tolerance for materials and workmanship not covered in this part
as mentioned hereinafter will be in accordance with the relevant IS code.
Description Permissible tolerance
Building bricks, in length width and height : As per IS 1077 - 1992
Laterite stone, in length, width & height : Plus or minus 5 mm
Natural building stone
a) For stones required in ashlar masonry : Length

& Breadth : Plus or minus 5mm
Height : Plus or minus 3mm
b) For stones required other than in ashlar masonry

:
Length & Breadth : Plus 5mm, minus 10mm
Height : Plus 5mm, minus 5mm
Concrete and reinforced concrete pipes : Length

: Plus or minus 1% of standard
length
Internal diameter, upto 300 mm : Plus 3 mm Minus 1.5 mm

Description Permissible tolerance
Cast iron spigot & socket pipes and fittings
Length of fittings : Plus or minus 10mm
Length of pipe : Plus or minus 20mm
Thickness : minus 1 mm
Internal dia of socket : Plus or minus 3 mm
Depth of socket : Plus or minus 10mm
External dia, upto 75 mm : Plus or minus 3mm
100 mm : Plus or minus 3.5mm
150 mm : Plus or minus 4mm
Stoneware pipes, in length
upto 75 cm : Plus or minus 10mm
Upto 90 cm : Plus or minus 15mm
In thickness of barrel and socket not exceeding 450mm

: Plus or minus 2mm
In thickness of barrel and socket between 500 to 600mm

: Plus or minus 3mm
Glazed tiles, length of all 4 sides : Plus or minus 0.8mm
Individual dimensions and thickness : Plus or minus 0.5 mm
Metal doors, windows and ventilators - In overall

dimension : Plus or minus 1.5 mm
Wooden doors, windows, ventilators Overall dimension

of door, window, ventilators : Plus or minus 3 mm
All components of shutter except glazing bar Width

: Plus or minus 3 mm
Thickness : Plus or minus 1 mm
Glazing bar, width & thickness : Plus or minus 1 mm

Mild steel tubes, tubulars and other wrought steel fittings
a) Thickness
i) butt welded light tubes : Plus not limited minus 8%
medium and heavy tubes : plus not limited minus 10%
ii) seamless tubes : plus not limited minus 12.5%

b) Weight
i) single tube (irrespective of the quantity) : + 10% , - 8%
ii) for quantity of less than 150m of one size

: + 10% , - 8%
iii) for quantity of 150m and over of one size : + 4% , - 4%
Earth work
Finished level of site levelling in hard rock : Plus or minus 50mm
Finished level of site levelling except for hard rock

Level of pits, trenches foundations : Plus or minus 50mm
Concrete & Reinforced concrete
Footings, plan dimension : Plus 50 mm Minus 12 mm
Eccentricity : 0.02 times the dimension of footing

in the direction limited to 50 mm
Thickness : Plus or minus 0.05 times the

specified thickness
Foundations
Deviation of planes and lines of their intersection from

vertical or inclination along full height
Deviation of horizontal plane from horizontal line
for 1 m of the plane in any direction : Plus or minus 5mm
for the whole plane : Plus or minus 20mm
Sizes of cross section : Plus or minus 8mm
Surfaces of inserts to support loads : Plus or minus 5mm

Length of elements : Plus or minus 20 mm
Equipment foundations :
Top level of bolt : Plus 20mm
Top level of foundation before grouting : Minus 20mm
Axes of anchor bolts in plan : Plus or minus 5mm
Axis of foundation in either direction : Plus or minus 10mm
Deviation in vertical line along height : Plus or minus 10mm
Sizes of pits in plan : Plus or minus 20 mm
Sizes of steps in plan : minus 20mm
Levels of steps, benches and pits : minus 20mm
Axes of inserts in plan : Plus or minus 10 mm
Basic dimensions in plan : Plus or minus 10mm
Deviation of horizontal plan from horizontal line
for 1 m of plane in any direction : Plus or minus 5mm
for the whole plane : Plus or minus 20mm
Local deviations of top surface when checked with a 2

m long straight edge : Plus or minus 8mm
Buildings :
Surfaces when checked with a 2 m long straight edge

: Plus or minus 8mm
Sizes of cross section : Plus 8mm Minus 0 mm
Length of elements : Plus or minus 20mm
Deviation from horizontal plane, for whole building

: Plus or minus 10mm
Plumb in verticality : 1 in 1000 of height
for columns supporting floor beams : Plus or minus 10mm
for framed columns linked with crane girders and beams

: Plus or minus 10mm
Reinforced concrete walls : Length : Plus or minus 20mm
Flatness of surface when checked with a 2 m long

straight edge : Plus or minus 8mm
Level of top surface to support assembled elements

: Plus or minus 5mm
Deviation in planes and lines of intersection from

vertical : Plus or minus 15mm
Size of cross section : Plus or minus 8mm
Placing of reinforcement :
Length of bar upto 75 cm long (Other than straight bars)

: Plus 3 mm Minus 5 mm
75 - 150 cm long : Plus 5 mm Minus 10 mm
150 - 250 cm long : Plus 6 mm Minus 15 mm
250 cm long and above : Plus 7 mm Minus 25 mm
Straight bars, all lengths : Plus or minus 25 mm
Spacing of bars : Plus or minus 5 mm
Anchor bolts :
Shift in location in plan : Plus or minus 5 mm
Same, when bolts are located outside of structural

columns : Plus or minus 10mm
Top level : Plus 20 mm
Threaded length : Plus 30 mm
Masonry For Walls For Pillars
Width : Plus or minus 10 Plus or minus 10 mm

mm
Shift in axes : Plus or minus 10 --- ---

mm

Deviation in row from horizontal line

for every 10m length
: Plus or minus 15 --- ---
mm
Flatness of surface when checked

with a 2 m long straight edge
: Plus or minus 10 Plus or minus 5 mm
mm
Deviation in lines separating storeys

Deviation of surface from vertical and
and at angles and corners
: Plus or minus 15 Plus or minus 15 mm
mm
for 1 storey : Plus or minus 10 Plus or minus 10 mm

mm
for whole building : Plus or minus 30 Plus or minus 30 mm

mm
Dimensions of openings for doors,

windows etc : Plus 15 mm
Minus 0 mm
Flooring, skirting, dado and plastering :
Insitu concrete floor : 4 mm
Concrete tile and mosaic, in any 3 m

length : 3 mm
in large open area : 15 mm
wall tiling - surface should not vary

from general plane by more than 1 in
200. Marble and such superior work,
in any 2 m length
: 1.5 mm
in any row : 3 mm
Plastered surfaces, flatness when

checked with a 2 m long straight edge
: 3 mm
Vertical surfaces, upto 1 storey : 5 mm
Over full heights : 10 mm

Metallic Inserts on assembled

components length and width : Plus or minus 3 mm
Road work
The levels of the sub-grade and different pavement courses should not vary from those
calculated with reference to the longitudinal and cross-sections of the road as shown on the
drawing beyond the tolerance given below :-
Sub-grade : plus or minus 25mm

Sub-base : plus or minus 20mm
Base : plus or minus 15mm
Wearing course : plus or minus 6mm

PART – V METHOD OF MEASUREMENT
GENERAL
2.0 EARTHWORK
3.0 ANTI - TERMITE TREATMENT
5.0 MASONRY
6.0 PLASTERING
7.0 WHITE WASHING, COLOUR WASHING & PAINTING
8.0 FLOORING, PAVING & FACING WORKS
9.0 WOODWORK
10.0 METAL DOORS, WINDOWS & VENTILATORS
11.0 GLAZING
12.0 WATER SUPPLY, DRAINAGE, SEWERAGE & SANITATION
13.0 WATER PROOFING, DAMP PROOFING
14.0 CEILING AND LINING
15.0 ROAD WORK

GENERAL
1.1 The method of measurement of the various items of work shall be in accordance
with IS : 1200 (Part 1 to 28) - 1971 to 1993 unless otherwise mentioned in this
part or in the schedule of items or in preamble or in the specification.
1.2 If there is any contradiction in meaning between any portion of this part and that
of IS :1200 (Part 1 to 28) - 1971 to 1993, the stipulation of this part shall prevail.
1.3 The descriptions and explanations given herein have as much forces as though
they are incorporated into the description of the items themselves in the schedule
of items.
2.0 EARTH WORK & SAND FILLING
2.1 General
2.1.1 Each dimension upto 25 m shall be measured to nearest 0.01 m and to nearest 0.1
m for dimensions over 25 m. Areas shall be worked out to the nearest 0.01 m2
and cubical contents to the nearest 0.01 m3.
2.1.2 Shoring and strutting shall not be measured separately unless otherwise specified.
2.1.3 Dewatering for earth work and sand filling work shall not be measured separately
2.1.4 For classification of soils, relevant clauses of Technical specification

(workmanship and other requirements ) is to be followed.
2.2 Requirements for particular works
2.2.1 Site levelling
2.2.1.1 For site levelling levels shall be taken jointly before start & after completion of
work and the quantity computed based on the levels. Measurements shall be made
only for excavation and no separate measurement for filling shall be made except
where earth, borrowed from elsewhere for site levelling work, will be measured
separately only for that borrowed portion of earth.
2.2.1.2 In cases where it is not possible or convenient to take measurements from

excavated cuts or borrow pits, excavation shall be worked out from filling based
on the levels to be taken before and after completion of works. Deduction of 10
percent will be made for voids, however for consolidated fills done through heavy
mechanical means, the deduction for voids shall be 5% in place of 10%.
2.2.1.3 In exceptional cases where the quantity is measured on the lorry measurement,
loose stacks, boxes or any other similar method with the approval of the Engineer
the deduction for voids shall be 20 per cent from the actual quantity.
2.2.2 Excavation

2.2.2.1 Before commencing excavation of foundations for buildings and structures, the
initial ground levels shall be jointly recorded. The depth of excavation and the
calculation of lift shall be based on this. Normally the initial ground level shall be
considered as the level of the site as handed over to the contractor. In case
excavation is planned and approved to be taken up subsequent to terracing, the
terrace level shall be treated as initial ground level.
2.2.2.2 Excavation of foundations, trenches, basements, pits etc., shall be measured to the
dimensions shown in the excavation plan, if any, or of the lowest concrete or
masonry course, as the case may be and the actual depth. Working space and
slopes shall not be measured.
2.2.2.3 Excavation of rock shall be measured from stacks of excavated rock with a
deduction of 50 per cent for voids or measured in the solid based on levels.
2.2.2.4 In case of following works, no measurement will be recorded for the excavation
beyond drawing / specification.
(a) In work which will be covered externally with damp proof covering.
(b) In work which requires formwork.
(c) In work which requires workmen to operate from the outside and for
guniting and post tensioned concrete, ground beams etc.
However, if there is a specific provision otherwise in the

item/specification/preamble, for authorised working, it shall be measured
accordingly. This working space may be 60 cm. measured from the face of the
structure at lowest level, unless otherwise mentioned.
2.2.2.5 Surface Dressing
Trimming of natural ground, excavated surface and filled up area to remove

vegetation and/or small in equalities not exceeding 15 cm deep shall be described
as surface dressing and measured in square metres unless otherwise specified in
the schedule of items/ preamble.
2.2.2.6 Lead
The distance for removal shall be measured over the shortest practicable route and
not necessarily the route actually taken.
The description of the item shall include loading and unloading.
For the purpose of the measurement of the lead, the area excavated shall be
divided in suitable block and for each block the distance from the centre of the
block to the centre of the placed earth pertaining to this block shall be taken as
lead.

2.2.3 Back filling/filling
2.2.3.1 In foundations, trenches, basements, pits, etc. and in other like areas, the
measurements shall be the theoretical volume of the filling computed from
drawings i.e. the volume measured under excavation minus the volume occupied
by the structure and part filling if any, done otherwise.
2.2.3.2 In filling under floors the measurements shall be the theoretical volume as per
drawings after deducting the part filling if any, done otherwise.
2.2.3.3 In embankments, the work shall commence only after recording jointly the initial
ground levels and the measurements shall be made on the basis of finished cross
section and initial ground levels. Where controlled compaction by mechanical
compaction is done, 5% deduction for voids shall be made. In case controlled
compaction by mechanical means is not done then deduction for voids shall be
10%.
2.2.3.4 Filling/Back filling shall not be measured separately for items of excavation,
where filling/back-filling is a part of the composite item and as such is included in
excavation item itself.
3.0 ANTI-TERMITE TREATMENT
Measurement shall be the plinth area of the ground floor of the building treated.
Dimensions shall be measured to the nearest 0.01 m and area to nearest 0.01 m2.
4.1 Concrete
4.1.1 Dimensions shall be measured to nearest 0.01 m except for the thickness of slab,
which will be to nearest 0.005 m. Areas shall be worked out to nearest 0.01 m2
and cubic contents to nearest 0.01 m3.
4.1.2 The concrete shall be measured as per drawings except in the cases of approved
variations which will be measured separately.
No deductions shall be made for the following :
i) Ends of dissimilar materials such as beams, rafters, purlins etc., upto 500
cm2 in cross section.
ii) Openings upto 0.1 m2 in area (In calculating area of an opening, the
thickness of any separate lintel or sill shall be included in the height. No
extra labour for forming such opening or voids shall be measured).
iii) Volume occupied by reinforcement or other embedments such as anchors,

inserts, conduits or volume occupied by pipes, sheathing etc. not
exceeding 100 sq. cm. each in cross sectional area or as specified.
iv) Small voids not exceeding 40 cm2 each in cross section.

v) Moulds, drip moulding, chamfer, splay, beds, grooves and rebates upto 10
cm in width or 15 cm in girth.
4.1.3 Columns shall be measured from top of column base to underside of first floor
slab and from top of floor to underside of floor slab above thereafter. Beams shall
be measured from face to face of columns and will include haunches. Depth of
beam shall be measured from bottom of slab and in the case of inverted beams
from top of slab. Chajjas and other cantilevers shall be measured from the face of
the projection.Where vertical fins are combined with chajja, the latter shall be
measured clear between fins. In case chajja is not combined with lintel, beam or
slab, it shall be measured inclusive of bearing.
4.2 REINFORCEMENTS
4.2.1 Norms for Steel Consumption
The requirement of mild and high strength deformed bars for various works like
reinforcement, guard bars, fan hooks etc. shall be calculated as mentioned below :
i) As per drawing including
(a) Authorised laps, bends, standard hooks and deviations etc.
(b) Spacer bars, chairs, hangers, supports, spacer blocks dowels etc.
are to be considered for wastage only and not to be measured for payment
purpose.
ii) Quantity upto 0.5% of (i) above towards unaccounted wastages, plus
iii) Quantity upto 3% of (i) above towards cut pieces, which shall be pieces
below 2m. length. These cut pieces shall not be taken back even though
steel has been issued by the client/owner.
4.2.2 Reinforcements shall be measured in lengths to the nearest 0.01 m for various
diameters of bar and converted into weight in tonnes to the nearest kg. on the basis
of standard weights as per IS : 1786-1986. No allowance shall be made in the
weight for rolling margin.
4.2.3 Authorised laps, standard hooks, bends shall be measured.
4.2.4 Sapacer bars, chairs, hangers, supports, spacer blocks and unauthorised laps etc.
shall not be measured unless otherwise specified.
4.2.5 Dowels neither shown on the drawings nor instructed by the Engineer, but
required for construction facilities shall not be measured for payment.
4.2.6 Modification of already embedded reinforcement, if required due to faulty

fabrication or placement, shall not be measured for payment.

4.2.7 The measurements of reinforcements (including authorised laps, hooks, bends)

shall be taken only from Bar bending lists or from the drawings except in the cases
of approved variations which will be measured as per 4.2.2.
4.2.8 Wire netting and fabric reinforcement shall be described (including meshes and
wire/strands) and measured in square metre, unless otherwise specified in the
schedule of item. Authorised laps shall be measured. Raking or circular cutting
and waste shall be included in the description of item.
4.2.9 Hoop iron shall be fully described and measured in running metres unless
otherwise specified in the schedule of item.
4.2.10 Binding wire for the reinforcement shall not be measured separately and shall be
included in the item of reinforcement.
4.3 ADMIXTURE
Admixture will be measured separately as specified or on the basis of the

requirement as approved by the Engineer.
4.4 FORMWORK
Each dimension shall be measured to the nearest 0.01 m and area to the nearest
0.01 sq.m.
4.4.1 Formwork shall be measured as the actual surface in contact with concrete and
paid in sq.m. unless included in the rate for concrete in specific item of work.
4.4.2 All the measurements shall be computed from the drawings except in the cases of
approved variations which will be measured separately.
4.4.3 Formwork shall not be measured separately for precast concrete work, grouting
and damp proof course which shall be included in the concrete rates.
4.4.4 No measurement for formwork in construction joints shall be made.
4.4.5 Openings upto 0.1 sq.m. shall be neglected, as if non - existent, for the purpose of
formwork measurement.
4.4.6 No extra measurement or payment shall be made for making the form work water
proof or for supports, scaffolding, staging, centering, approaches etc.
4.4.7 No measurement shall be taken for the formwork in pockets, openings, chambers,
chases etc., in concrete if the cross sectional area is less than or equal to 0.1 sq.m.
in each case. If the cross section area of any opening exceeds 0.1 sq.m. the actual
area of the formwork shall be measured for payment.
4.5 EMBEDDED PARTS
4.5.1 These shall be measured on the basis of standard theoretical weight of the
complete insert according to the drawing/direction.

4.5.2 Embedded steel, which are the integral parts of the embedment according to
drawing and are required for anchoring the embedded parts in concrete shall be
measured on the basis of the theoretical standard weight. In case of anchor bolts
the theoretical weights of the nuts, lock nuts, check nuts and washers shall be
added in the measurement for payment.
4.5.3 All bye-works such as jigs, fixtures, templates and other arrangements which are
not integral parts of the embedded parts, but necessary to secure those (embedded
parts) in position shall not be measured for payment.
4.5.4 Anti-corrosive paint over the exposed surfaces and protection of the anchor bolts
with grease tc., shall not be measured for payment.
4.5.5 Modification works necessary to rectify the mistake of already placed embedded
parts shall not be measured.
4.6 GROUTING
4.6.1 Grouting shall be measured in volume except in the cases of grouting by special
cement compound or epoxy compound which will be measured by number.
4.6.2 Measurement shall be computed from the drawings except in the cases of
approved variations which shall be measured separately and subsequently added to
or deducted from.
4.6.3 Necessary formwork shall not be measured for payment.
4.7 DAMP PROOF COURSE
4.7.1 Measurement shall be in sq.m. stating thickness and computed from the drawings
except in the cases of approved variations which will be measured separately.
4.7.2 Necessary formwork shall not be measured for payment.
5.0 MASONRY
5.1 Dimensions shall be measured to nearest 0.01 m, areas to nearest 0.01 m2 and
cubic contents to nearest 0.01 m3.
5.2 No deduction shall be made for :
(i) Ends of dissimilar materials such as joints, beams, posts, girders, trusses,
lintels, purlins etc., upto 0.1 m2 in section.
ii) Openings upto 0.1 m2 in area.
(iii) Wall plates, bed plates, bearing of slab etc., thickness not exceeding 10
cm. and bearing not extending over the full thickness of wall.
(iv) Cement concrete blocks for holdfasts and the like.

(v) Iron fixtures such as pipes etc. upto 300 mm. dia. and hold fasts for doors
and windows.
5.3 Dressed stonework such as in sills, cornices , column caps, copings etc., shall be
measured as the smallest rectangular block from which the finished stone can be
worked.
5.4 Honeycomb openings shall not be deducted from the area of honeycomb
brickwork.
5.5 Brickwork of full brick width or more shall be measured in cu.m. while of
thickness of half brick or less shall be measured in sq.m., unless otherwise
specified.
5.6 Reinforcements for reinforced brick work shall be measured separately, unless
otherwise specified and no deduction for reinforcement shall be made from brick-
work.
6.0 PLASTERING & POINTING
6.1 All plastering and pointing shall be measured in sq.m. unless otherwise described.
Dimensions shall be measured to nearest 0.01 m and areas to 0.1 sq.m.
6.2 Ceiling shall be measured between walls or partitions (dimensions before

plastering) shall be taken. Measurement of wall plastering shall be taken between
walls or partitions for length (dimension before plastering) and from top of floor
or skirting to ceiling for height.
6.3 The methods of measurement including the deductions for openings etc., shall be
according to the relevant part of IS : 1200 (Part 1 to 28) - 1971 to 1993.
7.0 WHITE WASHING, COLOUR WASHING, PAINTING & OTHER

FINISHES.
The method of measurement shall be according to the relevant part of IS : 1200

(Part 13 & 15) - 1987.
8.0 FLOORING, PAVING & FACING WORKS
8.1 The work shall be measured as a complete finished item including necessary
underbed, adhesives, dividing strips, joint sealing and necessary grinding,
polishing and finishing where specified. The subgrade or the base course shall be
measured separately against respective item unless otherwise specified.
8.2 All works shall be measured net, dimensions being measured to nearest 0.01 m
and areas to nearest 0.01 sq.m. Any opening less than 0.1 sq.m. in area shall not
be deducted nor any extra payment made for that.
8.3 Building paper or water proofing by bituminous felts/mastic asphalt treatment,

where specified to be laid below floor, shall be measured separately for payment

8.4 Laps and seams in sheet finishing (linoleum, cork, PVC, rubber & like) shall be
deemed to be included in the item itself even if not described explicitly and shall
not be measured and paid separately.
9.0 WOODWORK
9.1 All work shall be measured net for finished dimensions as fixed, that is no extra
measurement or allowance shall be made for shape, joints, wastage etc. subject to
specific provision made in the IS : 1200 (Part 21) - 1973 and for dimensions
supplied beyond those specified in the drawing.
9.2 Wooden frame
rought, finished and fixed shall be measured net for overall length nearest to 0.01
m, width and thickness to the nearest 2mm or as specified in the drawing and
cubic contents calculated in cubic metres to the nearest three places of decimals.
Wooden shutters of all types
Length and width of the shutters shall be measured net as fixed to the nearest cm.
in closed position covering the rebates of the frame but excluding the gap between
the shutter and the floor and the area calculated in square metre upto two places of
decimal.
Over lap of two leaves of shutter shall not be measured separately.
Hand rails
Hand rails of finished width and depth as specified in the item shall be measured
in running metres upto two places of decimal.
9.3 Painting and polishing, unless otherwise described in the schedule of items, shall
be measured separately for payment.
9.4 Builder's hardware and fittings for doors windows and ventilators shall be
measured separately, unless stated otherwise in the Schedule of Items. Hardware
and fittings shall be measured according to IS : 1200 (Part-VII) - 1972.
9.5 Hold fasts for door, window and ventilator frames shall be measured separately.
9.6 Timber Partitions
This shall be measured in area calculated in sq. m. to the nearest two places of
decimal.
9.7 Glazed shutters and glazed partitions (Wooden)
Glazed shutters/glazed partitions with wooden frames shall be measured as a

single item in area calculated in sq.m. to the nearest two places of decimal. No
separate measurement for glazing/glass panes shall be made.

9.8 Provision of making holes/opening/chases in masonry/ concrete flooring etc. for

fixing and making good of the same shall not be measured separately for payment.
9.9 Bitumen painting or approved wood preservative of the timber surfaces in

contact with masonry/concrete floor etc. shall not be measured for payment.
10.0 METAL DOORS, WINDOWS & VENTILATORS
10.1 Door, window and ventilator/louvers as fixed, shall be measured net as clear width
between jambs and clear height between floor/sill and underside of lintel, but
excluding the gap between door shutters and floor. Dimensions shall be calculated
to the nearest 0.01 m., area calculated in sq.m. upto two places of decimal.
10.2 For MS collapsible shutter/gate, rolling shutter sliding folding door, length and
breadth shall be measured to the nearest cm. for the clear area of opening as per
drawing in which they are installed and calculated in sq.m. to the nearest two
places of decimal.
10.3 M.S. Rolling grills, doors of steel plate, sliding door louvered ventilators, gates,
grills, as fixed, shall be measured and computed to weight from the size as per
drawing unless otherwise specified.
10.4 Glazed doors, windows, louvers, partitions (both steel and aluminium) shall be
measured in sq.m. to the nearest two places of decimal. No separate measurement
for glazing/glass panes shall be made for payment.
11.0 GLAZING
11.1 Glazing shall not be separately measured for doors, windows and ventilators
11.2 North light and roof glazing shall be paid as the area from outside to outside of
glazing including frames, to the nearest 0.01 sq.m.
11.3 Glazing, where shown in the schedule of items as a separate item, shall be
measured from edge to edge of glass as fixed.
12.0 WATER SUPPLY, DRAINAGE, SEWERAGE & SANITATIONS
12.1 All the pipelines buried under soil/masonry/floors/ concrete, laid

over/underground/along masonry/along under floor shall be measured in metres
along the centreline together with fittings/specials upto two places of decimal
against respective schedule of items for different diameter (the diameter as
specified shall mean nominal bore except PVC pipe) unless otherwise specified.
12.2 All necessary earth work in trenches for laying pipe lines including dewatering,
levelling and trimming to the gradient, sand filling in the trenches before laying
the pipe, back filling either by sand or by approved borrowed soil after laying the
pipe lines including necessary compaction by spraying water and
levelling/dressing the same shall not be measured separately for payment unless
otherwise specified.

12.3 All required specials, i.e. bends tees, shoes cowls, plug, elbows, unions, caps,
checkout and the like excluding valves shall not be measured separately for
payment unless otherwise specified.
12.4 All fixing and supporting arrangement of the pipes like the supports, saddles,
brackets, clamps, cleats, covering the pipes with concrete in case of pipes laid over
ground, special arrangement for supporting the pipe like while coming out from
the building to the trenches etc. shall not be measured separately for payment,
12.5 All the arrangement in road crossing like cutting the road, diverting the road and
drains, concealing the pipes with suitable approved measures, backfilling the area,
covering and making good of the road with similar materials/design shall not be
measured separately for payment, unless otherwise specified.
12.6 Septic tanks, inspection pits, manholes etc., shall be considered as a composite
single item including excavation, dewatering, concrete, masonry, back filling,
protection of other service lines and all the like works unless otherwise specified.
12.7 All the valves and all the bathroom/W.C./Kitchen fixtures like bib tap, stop cock,
shower, all sanitary wares, towel rails, mirrors etc., shall be measured separately
under respective item in the schedule, unless otherwise specified.
13.0 WATER PROOFING, DAMP PROOFING
13.1 Water proofing for roofs
13.1.1 Length and breadth shall be measured in metre upto two places of decimal and
area calculated in sq.m. upto two places of decimal.
13.1.2 Measurement shall be made for the net covered area. No measurement shall be
made for overlapping for end and side joints and for bends around/along the
corners, ends and for special treatment around pipes, rain water gulleys, steel
structure and the like etc. No deduction shall be made in the measurement for the
opening of area less than 0.1 m2 each and no extra payment shall also be made for
any special works made around such openings.
13.1.3 Water proofing treatment shall be considered as a single composite item including
priming painting coat, water proofing felts, binding bituminous coats, top
bituminous coat and pea size gravel or sand finishing etc.
13.1.4 For lime concrete terracing the consolidated thickness shall be considered for
measurement.
13.2 For Water proofing treatment in basement
13.2.1 With bituminous felts
13.2.1.1 Length and breadth shall be measured in metre upto two places of decimal and

13.2.1.2 Measurement shall be made for the net covered area. Measurement shall be made
from the drawing, except in certain special cases where it is impossible to compute
from drawing and the measurement shall be made as executed. No measurement
shall be made for overlaps, special measures around projected pipes, sealing the
bends/rounds and in other cases, necessary projection/ overlap for the connection
between vertical and horizontal junction etc.
13.2.1.3 Water proofing treatment shall be considered as a single composite item, including
priming painting coat, water proofing felts, binding bituminous coats and top
bituminous coat etc.
13.3 Mastic Treatment
13.3.1 Length and breadth shall be measured in metres upto two places of decimal and
13.3.2 Measurement shall be made for the net covered area. No deduction in
measurement shall be made for opening of area upto 0.1 sq.m. each and no extra
payment shall be made for any special treatment around such openings. No
measurement shall be made for extra payment for the special works necessary for
junctions, corners, roundings, bends for the works around pipes and the like.
14.0 CEILING & LININGS
14.1 Dimensions shall be measured to the nearest 0.01 m., areas to be worked out to the
nearest 0.01 sq.m.
14.2 Work formed to circular surfaces shall be measured separately unless otherwise
specified.
14.3 All work unless otherwise described shall be measured as flat in sq.m.
14.4 No deduction in measurement shall be made for openings not exceeding 0.4 sq.m.
and no extra measurement shall be made for forming such openings.
15.0 ROAD WORK
15.1 Dimensions shall be measured to nearest 0.01 m. Where the thickness is less than
20 cm., it shall be measured to nearest 0.005 m. Areas shall be worked out to
nearest 0.01 sq.m. and cubic contents to the nearest 0.01 cu.m.
15.2 Where thickness is measured, it shall be the minimum thickness after compaction.
15.3 Cement concrete bases and roads shall be measured either in sq.m. or cu.m. as
specified.
15.4 Unless otherwise specified, expansion and dummy joints shall be described and
measured separately and given in running metres stating the thickness and depth
of the joints.

PART – VI SAFETY REQUIREMENTS FOR

CONSTRUCTION WORKS
GENERAL
This specification deals with the subject matter of safety and protection to be
observed in the Civil Construction. This shall be followed along with all related
statutory requirements/obligation including Governmental byelaws, codes,
ordinance of local or central authorities related to the construction work.
In case of complicated work like deep excavation, intricate shuttering and

formwork, excavation in loose soil and below water table, stacking of excavated
earth etc., work plan with necessary drawings and documents have to be prepared
by the Contractor and got approved by the Engineer.
Necessary reference shall be made to the following Indian Standard Codes on

safety requirements for various type of work :
Indian Standard
4081 - 1986 Blasting & Drilling.

5916 - 1970 Construction with Hot Bituminous Materials.
4130 - 1991 Demolition of Buildings.
3764 - 1992 Excavation Work
5121 - 1969 Piling & Other Deep Foundations.
4014 - (P-II) - 1967 Scaffolding, Steel Tubular.
3696 - (P-I & P-II) Scaffolds and Ladders.
1987 to 1991
6922 - 1973 Structures Subject to Underground Blasts.
4756 - 1978 Tunneling Work.
5499 - 1969 Underground Air-raid Shelters in Natural Soil.
4138 - 1977 Working in Compressed Air.
7293 - 1974 Working with Construction Machinery
8989 - 1978 Erection of Concrete Framed Structures.
2.0 BLASTING
2.1 Detonators and other explosive for blasting shall be taken to the blasting area in
the original container or any separate non-metal container. This shall not be
carried loose or mixed with other materials. Detonators and explosives must be
kept separately.
2.2 No shot for blasting shall be fired except by persons licensed to do so.
2.3 Drilling shall not be resumed after a blast has been fired unless a thorough
examination has been made to make sure that there is no unexploded charge.

2.4 Before firing a shot, sufficient warnings by means of whistling and/or otherwise
shall be given to get men off the danger area. Blasting areas shall be cordoned off
& red flags during day time and red lights during night time displayed
prominently marking off the cordoned area.
2.5 All people except those who have actually to light the fuses must be removed to a
safe distance of not less than 200 metres as a rule.
2.6 Wherever possible, blasting mats should be used.
2.7 Contractors doing blasting work must have licence and an approved magazine to
store explosives.
2.8 Blasting operations shall be carried out during fixed hours of the day which shall
be notified in writing.
2.9 Provisions in explosives Rules 1940 as amended from time to time, Indian
Explosives Act 1844 (IV of 1884), and others shall be strictly followed.
3.0 EXCAVATIONS
3.1 Sides of all excavations must be sloped to a safe angle, not steeper than the angle
of repose of the particular soil. If it is not possible to give a proper slope, the sides
of the excavation where there is a danger of fall or dislodgement of earth or any
material, shall be securely supported by timber or other type of shoring.
3.2 No excavation or earth work below the foundation level of an adjoining building
shall be taken up unless adequate steps are taken to prevent damage to the existing
structure or fall of any part.
3.3 Every accessible part of an excavation, pit or opening in the ground into which
there is a danger of persons falling shall be suitably fenced with a barrier upto a
height of one metre suitably placed from the edge of the excavation as far as
practicable.
3.4 No material or load shall be placed or stacked near the edge of the excavation or
opening in the ground. The excavated material shall not be placed within 1.5 m of
the trench or half of the depth of the trench whichever is more.
3.5 Cutting shall be done from top to bottom. No undercutting of sides of excavation
shall be allowed.
3.6 All narrow trenches 1.2 m or more depth, shall at all times be supplied with atleast
one ladder for each 30m in length or fraction thereof. Ladder shall be extended
from bottom of the trench to atleast one metre above the surface of the ground.
The side of the trenches which are 1.5 m or more in depth shall be stepped back to
give suitable slope, or securely held by planking, strutting and bracing so as to
avoid the danger of side collapse.

3.7 Materials shall not be dumped against existing walls or partition to a height that
may endanger the stability of the walls.
3.8 While withdrawing piled materials like loose earth, crushed stone, sand, etc., from
the stock piles, no over hanging shall be allowed to be formed in the existing
dump.
3.9 No material on any of the sites of work shall be so stacked or placed as to cause
danger or inconvenience to any person or public or any other agency at work.
4.0 DEMOLITION
4.1 On every demolition job, danger signs shall be conspicuously posted all round
the structure and all doors, openings giving access to the structure shall be kept
barricaded or marked except during the actual passage of workmen or
equipment. However, provision shall be made for at least two independent exits
for escape of workmen during any emergency.
4.2 During night, red lights shall be placed on or about all the barricades.
4.3 Where in any work of demolition it is imperative, because of danger existing to

ensure that no unauthorised person shall enter the site of demolition outside
working hours, a watchman should be employed. In addition to watching the site
he shall also be responsible for maintaining all notices, lights and barricades.
4.4 All the necessary safety appliances as per IS ;4130 shall be issued to the workers
and their use explained. It shall be ensured that the workers are using all the
safety appliances while at work.
4.5 The removal of a member may weaken the side wall of an adjoining structure and
to prevent possible damage, these walls shall be supported until such time as
permanent protection is provided. In case any danger is anticipated to the
adjoining structure the same shall be got vacated to avoid any danger to human
life.
4.6 The power on all electrical service lines shall be shut off and all such lines cut or
disconnected at or outside the property line, before the demolition work is started.
Prior to cutting of such lines the necessary approval shall be obtained from the
electrical authorities concerned. The only exception will be any power line
required for demolition work itself.
4.7 All gas, water, steam and other service lines shall be shut off and capped or
otherwise controlled at or outside the building line, before demolition work is
started.
4.8 All the mains and meters of the building shall be removed or protected from
damage.
4.9 If a structure to be demolished has been partially wrecked by fire, explosion or

other catastrophe, the walls and damaged roofs shall be shored or braced suitably.

4.10 Walkways and passage ways shall be provided for the use of the workman who
shall be instructed to use them and all such walkways and passageways shall be
kept adequately lighted, free from debris and other materials.
4.11 All nails in any kind of lumber shall be withdrawn, hammered or bent over as
soon as such lumber is removed from the structure being demolished, and placed
in piles for future cleaning or burning.
4.12 All the roads and open area adjacent to the work site shall either be closed or
suitably protected.
4.13 No electric cable or apparatus which is liable to be a source of danger or a cable or

apparatus used by the operator shall remain electricity charged.
4.14 All practical steps shall be taken to prevent danger to persons employed from risk
of fire or explosion or flooding. No floor, roof or other part of the building shall
be so overloaded with debris or materials as to render it unsafe.
5.0 VEHICLE
5.1 No person shall board any vehicle or equipment when it is in motion.
5.2 Suitable blocks shall be placed against the wheels of a vehicle when it is used for
tipping materials into excavation or a pit or over the edge of any embankment or
earthwork to avoid the danger of its running over the edge.
5.3 All workers shall stand clear of the vehicle while it is dumping. If the material
being dumped is very heavy or sticky, dump hooks shall be used or dumper shall
be clamped to prevent any danger of its tripping.
5.4 Materials shall not be allowed to be loaded in a vehicle so as to project

horizontally beyond the sides of the body of the vehicle. All materials projecting
beyond the front or rear shall be indicated by a red flag in the day and with red
light in the night.
5.5 Driver of the truck or any heavy vehicle shall not reverse it unless assisted by a
signal man who shall have a clear view of the driver and the area beyond the truck
during reversing operation.
5.6 Maximum speed of a heavy vehicle must not exceed 15 km. per hour.
6.0 SCAFFOLDING, GANGWAYS, LADDERS & SHUTTERING
6.1 For all work that cannot be done from the ground level or from part of any
permanent structure or from other available means of support, soundly constructed
scaffoldings of adequate strength shall be used as a safe means of access to places
of work.
6.2 All scaffolding shall be securely supported or suspended and wherever necessary
be properly braced to ensure stability.

6.3 Chains, ropes or other lifting materials used for the suspension of scaffoldings
must be of adequate strength and shall be of tested quality.
6.4 All such chains and ropes used for the suspension of scaffoldings shall be properly
fastened to safe anchorage points.
6.5 The platform of a suspended scaffolding shall be sufficiently wide. Suspended

scaffolding shall have hand rail on 3 sides of about 1.0 m height.
6.6 All working platform and stages from which workers are liable to fall shall be of
adequate width depending on the type of work done and closely boarded and
planked.
6.7 Scaffolding or staging more than 3.5 m above the ground or floor, suspended from
an overhead support or erected with stationary support shall have a guard rail
properly attached, bolted, braced and otherwise secured atleast 1 m high above the
floor or platform of such scaffolding or staging and extending along the entire
length of the outside ends thereof with only such opening as may be necessary for
the delivery of materials. Such scaffolding or staging shall be so fastened as to
prevent it from swaying from the building or structure. The platform shall also be
provided with toe boards of atleast 150 mm high so placed as to prevent the fall of
materials and tools from there.
6.8 All platforms or gangways, runways and the stairs shall be kept free from
unnecessary obstructions, materials or junk.
6.9 Working platforms, gangways & stairways shall be so constructed that they shall
not sag unduly or unequally, and if the height of the platform or the gangway or
the stairway is more than 3.5 m above ground level or floor level they shall be
closely boarded, shall be of adequate width and shall be suitably fenced.
6.10 Every opening in the floor of a building or in a working platform shall be provided
with suitable fencing or railing whose minimum height shall be 1 m to prevent the
fall of persons or materials.
6.11 Every ladder shall be securely fixed at top and bottom. A ladder more than 5 m
long shall have a prop.
6.12 All ladders used shall be of good construction, sound materials and adequate
strength. Ladders with defective or missing rungs shall not be brought into use.
The spacing of rungs shall not exceed 30 cms and these shall be recessed atleast
12 mm into rails.
6.13 All ladders or rungs used for vertical height of more than 10 m shall have an
intermediate landing. All such intermediate landings shall be provided with guard
rails to a height of atleast 1 m.
6.14 Every ladder shall be securely placed so that it cannot move either at the top or at
the bottom and it shall rise to a height of atleast 1.2 m above the place of landing.
6.15 No portable single ladder shall be over 8 m in length.

6.16 Spacing between the side rails of the ladder shall not be less than 300 mm for
ladders upto 3 m in length. For longer lengths, this shall be increased at 6 mm for
each additional 0.3 m of length.
6.17 Metal ladders must not be used for electrical work or near electric circuit of
equipments.
6.18 All scaffolds, ladders and other safety devices mentioned or described herein shall
be maintained in safe condition and no scaffold, ladder or equipment shall be
altered or removed while it is in use.
6.19 Unfinished scaffolding which is under construction shall be prominently marked

as unsafe and any access points shall be closed.
6.20 All Planking and Decking on walkways and scaffolds should be adequately
supported at each end of the plank and intermediately if necessary. Planks should
not be allowed to cantilever beyond the last support but should be overlapped if
necessary on to the next plant.
6.21 Shuttering
The above remarks shall be applicable for this also. Shuttering, particularly for
slabs, should be treated as a scaffold. Unfinished shuttering should be marked as
dangerous similarly the finished formwork should be adequately supported, care
being taken to avoid trap door effects.
7.0 MOBILE LIFTING APPLIANCES
7.1 No mobile lifting appliances shall used on a sloping surface unless adequate
precautions are taken to ensure stability.
7.2 Adequate precautions shall be taken to see that jib of the mobile crane does not
come in contact with overhead electric transmission line.
7.3 Only one person shall give signals to the operator of mobile lifting appliances.
7.4 Maximum load to be lifted by lifting appliances shall be marked in a position

where it can be clearly seen by the crane driver and the operator.
7.5 No load shall be raised, lowered or suspended from a chain or rope having a knot
in any of the part.
7.6 No chain which is joined to another chain by means of bolt and nut shall be used
for raising, lowering or suspending any load.
7.7 All chains, ropes and lifting gears shall be carefully examined and tested by a
competent Maintenance Engineer atleast once in every quarter.

7.8 When the work is stopped or when the mobile lifting equipment is not in
operation, the boom must be lowered to the horizontal position and tied securely
in place to prevent accidental drop.
7.9 No person shall walk under a load which is swinging by a lifting equipment.
Guide rope must be attached to the load to prevent its swinging.
7.10 The foot blocks of the crane before starting work shall be securely supported and
firmly anchored to prevent its movement in any direction.
7.11 Use of Hoisting machines and tackle including their attachments, anchorage and
supports shall conform to the following standards of condition.
7.11.1 These shall be of good mechanical construction, sound material and adequate
strength and free from defect and shall be kept in good working order.
7.11.2 Every rope used in hoisting or lowering materials or as a means of suspension

shall be of durable quality and adequate strength and free from patent defects.
7.11.3 Every crane driver or hoisting appliance operator shall be properly qualified and
no person under the age of 21 years shall be in charge of any hoisting machine or
give signals to the operator.
7.11.4 In case of every hoisting machine and every chain ring hook shackle swivel and
pulley block used in hoisting or lowering or as means of suspension the safe
working load shall be ascertained by adequate means, every hoisting machine and
all gears referred to above shall be plainly marked with the safe working load. In
case of hoisting machine having a variable safe working loading, each safe
working load of the conditions under which it is applicable shall be clearly indicat-
ed. No part of any machine or of any gear referred to above in this paragraph shall
be loaded beyond the safe working load except for the purpose of testing. Mobile
cranes shall have the working load and the radius of jib for the load marked on it.
7.11.5 The top pulley for hoisting a load shall be opened monthly and the spindle
inspected to see if any undue wear has taken place and for greasing.
7.11.6 In case of departmental machine, the safe working load shall be notified by the
Engineer concerned. As regards contractor's machines the Contractor shall notify
the safe working load of the machine to the Engineer whenever he brings any
machinery to site of work and get it verified by the Engineer concerned.
7.12 Motors, gearing, transmission, electric wiring and other dangerous part of hoisting
appliances shall be provided with efficient safeguards. Hoisting appliances shall
be provided with such means as will reduce to the minimum, the risk of accidental
descent of the load. Adequate precautions shall be taken to reduce to the
minimum, risk of any part of a suspended load becoming accidentally displaced.

8.0 RIVETTING, WELDING & GAS CUTTING & STEEL ERECTION
8.1 Rivetting
8.1.1 Bolts covered with wet or slippery compounds shall not be used in fabricating
structural work.
8.1.2 The rivet heater must keep the rivet heating equipment as near as possible to the
place of work.
8.1.3 A pail of water shall always be kept ready for quenching fire when stopping
rivetting work.
8.1.4 Hot rivet shall not be thrown across aisles and shaftways.
8.1.5 Metal buckets for catching hot rivets must have false wooden bottoms to prevent
rivets from rebounding.
8.1.6 All rivets, bolts, nuts, and other tools must be kept in boxes and not left loose, (For
any further safety measures relevant Indian Standards and safety specifications of
structural section shall be referred to).
8.2 Welding & Gas Cutting
8.2.1 All cylinders must be used and stored in upright position only.
8.2.2 Cylinders must be stored away from open flames and other source of heat.
8.2.3 Oxygen cylinders must not be stored near other cylinders containing gas or oil,
grease or other combustible materials.
8.2.4 While the cylinder is in use, the cylinder valve key or wrench must be placed on
the valve spindle.
8.2.5 Before a cylinder is moved, the cylinder valve must be closed.
8.2.6 Gas cutting torches must be lighted by means of friction flames or similar other
methods and not with matches.
8.2.7 When torches are being changed or welding stopped for some time valves for all
cylinders must be closed.
8.2.8 The coloured lenses used for welding or gas cutting must be of proper shade for
the work being done.
8.2.9 Suitable eye protection equipment such as goggles, hand shields etc., must be used
by persons engaged in welding or gas cutting operations.
8.2.10 Before any heavy structural member is gas cut, make sure that it is cleared and
supported by ropes, cables, chains or any other means to prevent its dropping or
swinging.

8.2.11 Cylinder valves and connections are not to be lubricated. All oily or greasy
substances must be kept away from cylinders.
8.2.12 Substantial and incombustible screen must be used below or near the welding
operations, if there is a possibility of a spark falling on other workmen engaged in
work closely.
8.2.13 All air pipe lines and air hoses must be frequently inspected. Air hoses shall not
be used for dusting or for cooling purposes.
8.3 Steel Erection
8.3.1 All persons shall stand clear when a crane is sorting or shifting steel girders or
other structural materials.
8.3.2 No person shall stand, walk or work beneath any suspended load.
8.3.3 Guide rope must be used for guiding lifting loads.
8.3.4 When guiding a beam or fabricated structure or erection it shall be so held that the
employees hands do not get jammed against other objects.
8.3.5 Safety belts equipped with suitable life lines must be used by persons working at
heights and standing on structural members. Life line must be tied to an
independent support. For any further safety measures, for Structural Steel Works,
IS : 7205 - 1974 shall be referred to.
9.0 SAFETY APPLIANCES
9.1 Workers employed on mixing asphaltic materials, cement and lime mortars, shall
be provided with protective footwear and protective goggles.
9.2 Those engaged in white washing and mixing or stacking of cement bags or any
materials which is injurious to the eyes, shall be provided with protective goggles.
9.3 Those engaged in welding works shall be provided with welder's protective eye-
shields.
9.4 Stone breakers shall be provided with protective goggles and protective clothing
and seated at sufficiently safe intervals.
9.5 When workers are employed in sewers and manholes which are in use, the
Contractor shall ensure that the manhole covers are opened and chambers are
ventilated atleast for an hour before the workers are allowed to get into the
manholes, and the manholes so opened shall be cordoned off with suitable railing
and provided with warning signals or boards to prevent accident to the public.
9.6 The Contractor shall not employ men below the age of 18 and women on the work
of painting with products containing lead in any form. Whenever men above the
age of 18 are employed on the work of lead painting the following precautions
shall be taken :

9.6.1 No paint containing lead or lead products shall be used except in the form of paste
or ready made paint.
9.6.2 Suitable face mask should be supplied for use by them when paint is applied in the
form of spray on a surface having lead paint dry rubbed and scraped.
9.6.3 Overalls shall be supplied by the Contractors to the workmen and adequate
facilities shall be provided to enable the working painters to wash during the
cessation of work.
9.7 The workers going into inspection chamber shall have gas masks, gum boots and
rubber gloves while working inside. After coming out they shall have some disin-
fectant from the first aid box for proper washing
9.8 All necessary personnel safety equipment such as safety helmets, safety boots,
safety belts, leather gloves for welders, clear glass safety goggles etc., as
considered adequate by the engineer have to be kept available for the use of
persons employed at the site of work and maintained in condition suitable for
immediate use and Contractor shall take steps to ensure proper use of equipment
by the workers.
9.9 All the persons entering the tunnel shall be provided with protective wear, such as
helmets, steel toe safety shoe, gum boots or other suitable type of protective foot
wear. In the case of steeply inclined tunnels and inshafts, safety belts shall also be
provided.
9.10 Sign boards 1 x 1.5 m in size with the following wording shall be erected at the
access to these areas. "CONSTRUCTION AREA, HELMET REQUIRED
BEYOND THIS POINT"
9.11 No loose garments or ragged clothing shall be worn by the personnel engaged in
tunneling operation.
9.12 A telephone system shall provided to ensure a positive and quick method of
communication between all control location inside tunnel and portal of the tunnels
when longer than 500 m and for shafts when longer than 50 m
9.13 Irrespective of length and bends in the tunnel, arrangements shall be made for
transmitting of warning signals by any one of the following means.
9.13.1 By electrically operated bells, operated by battery/dry cells with the bell placed
outside the tunnel and the position of the switch shifting with the progress of the
tunneling work. The position of the operating switch although temporary shall be
so chosen as to ensure proper accessibility and easy identification.
9.13.2 By the use of two field (magnet type) telephone.
9.13.3 Any other suitable arrangement like walkie-talkie.
9.14 Arrangement for rendering prompt and adequate first aid to the injured persons
shall be maintained at every work site under the guidance of a medical officer-in-

charge of the project. Depending upon the magnitude of the work the availability
of an ambulance at a very short notice (at telephone call) shall be ensured.
9.15 First-aid arrangements commensurate with the degree of hazard and with the
number of workers employed shall be maintained in a readily accessible place
throughout the working hours. At least one experienced first-aid attendant with
his distinguishing badge shall be available on each shift to take care of injured per-
sons. Arrangements shall be made for calling the medical officer, when such a
need may arise. It is recommended that foreman/assistant foreman/supervisor/
permanent workmen who are normally present at each working phase in each shift
are given adequate training on first-aid methods to avoid employment of a
separate attendant.
9.16 Stretchers and other equipment necessary to remove injured persons shall be
provided at every shift.
9.17 Where there are more than 50 persons working in a shift, effective artificial
respiration arrangements shall be provided, with trained men capable of providing
artificial respiration.
10.0 ELECTRICAL
10.1 Only authorised persons shall handle or otherwise interfere with electrical
equipment. Any person detecting electrical apparatus being handled by an
unauthorised person or equipment in unsafe condition must report the matter to the
Engineer concerned.
10.2 No person shall work on any live electric conductor or apparatus and no person
shall assist such person on such work, unless he is authorised in that behalf.
10.2.1 After isolating the equipment from the source of supply before the work begins, a
sign 'DONT'T SWITCH ON' must be hung on or near the switch to avoid its being
accidentally or inadvertently switched on when persons are working.
10.2.2 Take out the fuses and keep in safe custody.
10.2.3 The switch may be locked if locking arrangement exists.
10.2.4 Earth the equipment, before work, to discharge it and short the terminals as a
precautionary measure against accidental switching ON.
10.2.5 After the work is finished take out Earthing and shorting link.
10.2.6 Remove all tools and materials from the site of work. Replace the fuses and
unlock the switch.
10.2.7 The switch shall only be put 'ON' by the person who switched it 'OFF' or by the
person authorised by him in writing.

10.3 When working on live equipment use one hand only whenever possible, it is
advisable to keep the other hand behind the back. Shocks from hand to hand are
most dangerous.
10.4 All persons handling electrical gear in elevated position must use safety belts.
Even a slight shock may cause loss of balance and fall.
10.5 No one shall attempt to extinguish a fire on or near a live electrical apparatus with
water. Water is a good conductor of electricity. Use extinguishers wherever
provided. Use sand and blankets etc., if available.
10.6 No person shall use any part of electrical equipment for storing or hanging clothes,
umbrellas or other articles. Serious accidents occur from this practice.
10.7 For attending the work on O.H. lines or equipment use wooden ladders. Metallic
ladders shall not be used.
10.8 Use insulated tools and ensure the insulation is in proper condition periodically at
least once in three months. Use rubber gloves wherever possible.
10.9 As far as possible verbal instructions shall be avoided in case of pre-arranged shut-
down of electrical apparatus.
10.10 When workers are employed for electrical installations which are already
energised, insulating mats, wearing apparel such as gloves, sleeves and boots as
may be necessary shall be provided. The workers shall not wear any rings,
watches and carry keys or other materials which are good conductors of
electricity.
11.0 MISCELLANEOUS
11.1 The Contractor shall provide necessary fencing and lights to protect the public
from accident.
11.2 Fire extinguishers adequate in number shall be kept by the Contractor at the site of
works where there is risk of fire hazard.
11.3 Adequate washing facilities shall be provided near the place of work.
11.4 When the work is done near any place where there is risk of drowning, all
necessary equipments shall be provided and kept ready for use and all necessary
steps taken for prompt rescue of any person in danger and adequate provisions
shall be made for prompt first aid treatment of all injuries likely to be sustained
during the course of the work.
11.5 These safety provisions shall be brought to the notice of all concerned by
displaying on a Notice Board at a prominent place at the work spot. The persons
responsible for compliance of the code shall be named therein by the Contractor.
11.6 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangements made by the Contractor shall be open to inspection
by the Engineer and Owner.

11.7 Not withstanding the above clauses there is nothing in those to exempt the
Contractor from the operations of any other Act or Rule in force in the Republic of
India.
11.8 All storage, handling and use of flammable liquids shall be under the supervision
of qualified persons. Flammable liquid shall not be stored inside the tunnel
11.9 All sources of ignition shall be prohibited in areas where flammable liquids are
stored, handled and processed. Suitable warning and 'NO SMOKING' signs shall
be posted in all such places. Receptacles containing flammable liquids shall be
stacked in such a manner as to permit free passage of air between them.
11.10 All combustible materials shall be continuously removed from such areas where
flammable liquids are stored, handled and processed. All spills of flammable
liquids shall be cleared up immediately. Containers of flammable liquids shall be
tightly capped.
12.0 REPORTING OF ACCIDENT
All accidents, major or minor must be reported immediately. The Contractor, will
provide first aid to the injured person immediately and the injured person shall
report to the first aid station along with the 'INJURED ON WORK' form duly
filled in quintuplicate and submit to the Medical Officer of the First Aid Station".
Serious Injury
In case of serious injury, the following procedure shall be adopted by the Contractor
:
1. Provide First Aid at his own First Aid Station.
2. Take the injured person to the Hospital along with the "INJURED ON
WORK" form duly filled in.
3. Reporting the accident to the Owner/Engineer by the Contractor.
Fatal Accident
Fatal accident must be reported immediately to the Engineer/Owner as well as to

the Police.
Penalty
Failure to observe the Safety Rules will make the Contractor liable to penalty by
way of suspension of work, fine and termination of contract.

ANNEXURE- A
LIST OF IS & IRC CODES REFERRED
List of IS codes referred is this document were indicted below however latest revisions of codes in
used shall be followed.
IS 383 – 1970 : Specification for coarse & fine aggregates from natural sources
for concrete.
IS 2386 (Part 1 to 8) – 1963 : Method of Test for aggregates for concrete
IS 456 – 2000 : Code of practice for plain and reinforced concrete.
IS 712 - 1984 : Specification for building limes.
IS 3182 – 1986 : Specification for broken brick (burnt clay ) fine aggregate for use
in lime mortar.
IS 269 – 1989 : Specification for 33 grade ordinary Portland Cement.
IS 455 – 1989 : Code of practice for Portland Slag Cement.
IS 1489 – 1991 : Specification for Portland Pozzolana Cement.
IS 8041 – 1990 : Specification for rapid hardening Portland Cement.
IS 8043 – 1991. : Specification for Hydrophobic Portland Cement
IS 12330 – 1988 : Specification for Sulphate resisting Portland Cement.
IS 6452 – 1989 : Specification for high alumina cement for structural use.
IS 8042 – 1989 : Specification for White Portland Cement.
IS 3535 – 1986 : Methods of sampling Hydraulic Cement.
IS 4031 (Part 1 to 15) - 1988 to 1991 : Methods of test for Hydraulic Cement.
IS 4032 – 1985 : Method of Chemical Analysis of Hydraulic Cement.
IS 2645 – 1975 : Specification for Integral Cement Waterproofing Compounds.
IS 1599 – 1985 : Method of Bend Test.
IS 1608 – 1972 : Method of Tensile Testing of Steel Products.
IS 6925 – 1973 : Method of test for determination of Water Soluble Chlorides in
concrete admixtures.
IS 432 – 1982 : Specification for mild steel and medium tensile steel bars and hard
drawn steel wire for concrete reinforcement.
IS 1786 – 1985 : Specification for high strength deformed steel bars and wires for
concrete reinforcement.
IS 1566 – 1982 : Specification for hard drawn steel wire fabric for concrete
reinforcement.
IS 280 – 1978 : Mild steel wire for general engineering purposes.
IS 2062 – 1992 : Structural steel (Standard Quality).
IS 1161 – 1979 : Steel Tubes for Structural purposes.
IS 5624 – 1970 : Foundation bolts.
IS 1363 - (Part 1 to 3) - 1992 : Hexagon Head bolts, screws, nuts.
IS 2016 – 1967 : Plain washers.
IS 3063 – 1972 : Single coil rectangular section spring washers.
IS 1239 (Part 1&2)-1990 : Mild Steel Tubes and other wrought steel pipe fittings.
IS 1367 – 1980 : Technical supply conditions for threaded steel fasteners.
IS 1030 – 1989 : Carbon steel castings.
IS 3480 – 1966 : Flexible steel conduit for electrical wiring.
IS 2667 – 1988 : Fittings for rigid steel conduits for electrical wiring.

IS 9537 (Part 3) – 1983 : Conduit for electrical installations - Rigid Plain conduits of
insulating materiel.
IS 6946 – 1973 : Flexible non-metallic conduits for electrical installations.
IS 3419 – 1989 : Fittings for rigid non-metallic conduits.
IS 5913 – 1989 : Methods of tests for Asbestos Cement Products.
IS 2098 – 1964 : Specification for asbestos cement building boards.
IS 2096 – 1992 : Specification for asbestos cement flat sheets.
IS 9537 (Part 2) – 1981 : Conduit for electrical installations - Rigid steel conduits.
IS 2614 – 1969 : Method for sampling of fasteners.
IS 1592 – 1989 : Specification for asbestos cement pressure pipes.
IS 9627 – 1980 : Specification for asbestos cement pressure pipe (Light duty).
IS 6908 – 1991 : Specification for asbestos cement pipes and fittings for sewerage
and drainage.
IS 1626 (Part 1 to 3) - 1980 to 1991 : Specification for asbestos cement building pipes & pipe fittings
and roofing fittings
IS 459 – 1992 : Specification for unreinforced corrugated and semi corrugated
asbestos cement sheets
IS 1077 – 1992 : Specification for common burnt clay building bricks.
IS 3495 (Part 1 to 4) -1992 : Method of Test for burnt clay building bricks.
IS 3620 – 1979 : Specification for laterite stone block for masonry.
IS 1121- 1974 : Method of test for determination of strength properties of natural
building stone.
IS 1124 – 1974 : Method of test for determination of water absorption Sp. Gr. etc.
of building stones
IS 1125 – 1974 : Method of test for determination of weathering of natural building
stones.
IS 1126 – 1974 : Method of test for determination of durability of building stone.
IS 1127 – 1970 : Recommendation for dimensions and workmanship of natural
building stones for masonry work.
IS 2185 ( Part-1)-1979 : Specification for concrete masonry unit Hollow and solid concrete
blocks.
IS 2116 – 1980 : Specification for sand for masonry mortar
IS 1542 – 1992 : Specification for sand for plaster.
IS 2185 (Part-2)-1983 : Specification for concrete masonry unit-Hollow and solid light
weight concrete blocks.
IS 2185 (Part-3)-1984 : Specification for concrete masonry unit - Auto claved Cellular
Aerated concrete blocks.
IS 6041 – 1985 : Code of practice for construction of Auto claved Cellular concrete
block masonry.
IS 6441 (Part 1 to 9) - 1972 & 1973 : Method of Test for Auto claved Concrete Products.
IS 3068 – 1986 : Specification for broken brick (burnt clay) coarse aggregates for
use in lime concrete.
IS 2114 – 1984 : Code of practice for laying in-situ terrazo floor finish.
IS 460 (Part 1 to 3)-1985 : Specification for Test Sieves.
IS 1237 – 1980 : Specification for cement concrete flooring tiles.
IS 777 – 1988 : Specification for glazed earthen ware wall tiles.
IS 1129 – 1972 : Recommendation for dressing of natural building stone.
IS 1130 – 1969 : Specification for Marble (blocks, slabs and tiles).
IS 809 – 1992 : Specification for rubber flooring materials for general purposes.
IS 3462 – 1986 : Specification for unbacked flexible PVC flooring.
IS 3461 – 1980 : Specification for PVC asbestos floor tiles

IS 2818 – 1990 : Indian Hessians.

IS 653 – 1992 : Linoleum sheets and tiles.
IS 5389 – 1969 : Code of practice for laying hard wood parquet and wood block
flooring.
IS 210 – 1978 : Grey Iron Castings.
IS 2114 – 1984 : Code of practice for laying in-situ terrazzo finish.
IS 1198 – 1982 : Code of practice for laying of linoleum flooring.
IS 1003 (Part-2)-1983 : Specification for timber panelled & glazed shutters, windows and
ventilator shutters.
IS 1141 – 1973 : Code of practice for seasoning of timber.
IS 1003 (Part-1) - 1983 & 1991 : Specification for timber panelled & glazed shutters - Door
shutters.
IS 287 – 1973 : Recommendation for maximum permissible moisture content of
timber used for different purposes.
IS 2202 (Part-1) - 1983 & 1991 : Specification for wooden flush door shutters (Solid core type).
IS 2191 (Part-1&2)-1983 : Specification for wooden flush door shutters (cellular and hollow
core type).
IS 3087 – 1985 : Specification for wood particle boards (Medium density) for
general purposes.
IS 3478 – 1966 : Specification for high density wood particle boards.
IS 3097 – 1980 : Specification for veneered particle boards
IS 303 – 1989 : Specification for plywood for general purposes.
IS 1328 – 1982 : Specification for veneered decorative plywood.
IS 205 – 1992 : Specification for non-ferrous metal butt hinges.
IS 1341 – 1992 : Specification for steel butt hinges.
IS 362 – 1991 : Specification for parliament hinges.
IS 453 – 1973 : Specification for double acting spring hinges.
IS 3818 – 1992 : Specification for continuous (Piano) hinges.
IS 206 – 1992 : Specification for Tee and Strap hinges.
IS 281 – 1991 : Specification for mild steel sliding door bolts for use with
padlocks.
IS 1019 – 1974 : Specification for rim latches.
IS 2681 – 1979 : Specification for non-ferrous metal sliding door bolts for use with
padlocks.
IS 204 (Part 1&2)-1991&92 : Specification for tower bolts - Ferrous and Non-ferrous metals.
IS 208 – 1987 : Specification for door handles.
IS 2209 – 1976 : Specification for mortice locks (vertical type).
IS 6607 – 1972 : Specification for rebated mortice locks (vertical type).
IS 1823 – 1980 : Specification for floor door stoppers.
IS 1837 – 1966 : Specification for fan light pivots.
IS 207 – 1964 : Gate and shutter hooks and eyes.
IS 6343 – 1982 : Specification of door closers (peneumatically regulated) for light
door weighing upto 40 Kg.
IS 8756 – 1978 : Specification for ball catches for use in wooden Almirah.
IS 6315 – 1992 : Specification for floor springs (hydraulically regulated) for heavy
doors.
IS 7197 – 1974 : Specification for Double action floor spring (without oil check)
for heavy doors
IS 364 – 1993 : Specification for fan light catch.
IS 3828 – 1966 : Specification for ventilator chains.
IS 363 – 1976 : Specification for hasp and staples.

IS 9899 – 1981 : Specification for hat, coat and wardrobe hooks.

IS 729 – 1979 : Specification for drawer locks, cup-board locks and box locks.
IS 3564 – 1986 : Specification for door closers (Hydraulically regulated).
IS 4351 – 1976 : Specification for steel door frames.
IS 419 – 1967 : Putty for use on window frames.
IS 5187 – 1972 : Specification for flush bolts.
IS 3847 – 1992 : Specification for mortice night latches.
IS 4621 – 1975 : Specification for indicating bolts.
IS 1038 – 1983 : Specification for steel doors, windows and ventilators.
IS 1977 – 1975 : Structural steel (ordinary quality).
IS 1361 – 1978 : Specification for steel windows for industrial buildings.
IS 7452 – 1990 : Hot rolled steel sections for doors, windows and ventilators.
IS 1948 – 1961 : Specification for aluminium doors, windows and ventilators.
IS 1148 – 1982 : Specification for hot rolled rivet bars for structural purposes.
IS 1949 – 1961 : Specification for aluminium windows for industrial buildings.
IS 204 (Part 1) – 1992 : Specification for tower bolts-non-ferrous metal.
IS 733 – 1983 : Wrought aluminium and aluminium alloy bars, rods and sections
(for general engineering purposes).
IS 6248 – 1979 : Specification for metal rolling shutters and rolling grills.
IS 1081 – 1960 : Code of practice for fixing and glazing of metal doors, windows
and ventilators.
IS 2339 – 1963 : Specification for Aluminium Paint for general purpose in dual
containers.
IS 2835 – 1987 : Flat Transparent sheet glass.
IS 5437 – 1969 : Wired and figured glass.
IS 101 (Part 1 to 8) - 1964 to 1993 : Method of sampling and test for paints, varnishes and related
products.
IS 2074 – 1992 : Ready mixed paint, air drying, red oxide zink chrome, priming.
IS 5410 – 1992 : Cement paint, colour as required.
IS 427 – 1965 : Distemper, dry, colour as required.
IS 428 – 1969 : Distemper, oil emulsion, colour as required.
IS 348 – 1968 : French polish.
IS 5411 (Part 1&2) - 1972 to 1974 : Plastic emulsion paint.
IS 702 – 1988 : Industrial Bitumen.
IS 73 – 1992 : Paving Bitumen.
IS 217 – 1988 : Cut Back Bitumen.
IS 454 – 1961 : Specification for Digboi type cutback bitumen.
IS 5467 – 1986 : Specification for shellac Wax.
IS 3384 – 1986 : Specification for Bitumen primer for use in water proofing and
damp proofing.
IS 290 – 1961 : Specification for Coal Tar Black Paint.
IS 341 – 1973 : Specification for Black Japan, Type A, B & C.
IS 1322 – 1982 : Specification for bitumen felts for water proofing and damp
proofing.
IS 218 – 1983 : Specification for creosote oil for use as wood preservative.
IS 3037 – 1986 : Specification for Bitumen mastic for use in water proofing of
roofs.
IS 1580 – 1991 : Specification for Bituminous compound for water proofing and
caulking purposes.
IS 8542 – 1977 : Specification for polish for wooden furniture paste.
IS 9862 – 1981 : Ready mixed paint, brushing etc.

IS 782 – 1978 : Specification for caulking lead.

IS 405 (Part 1&2) – 1992 : Lead sheet and strips.
IS 5134 – 1977 : Bitumen impregnated paper.
IS 2849 – 1983 : Specification for non load bearing gypsum partition blocks.
IS 8591 – 1977 : Specification for floor polish paste.
IS 2095 – 1982 : Specification for gypsum plaster boards.
IS 77 – 1976 : Specification for linseed oil, boiled for paints.
IS 533 – 1973 : Gum Spirit of turpentine (oil of Turpentine).
IS 1504 – 1974 : Bees Wax.
IS 3536 – 1966 : Ready mixed paint, brushing, wood primer pink.
IS 8273 – 1984 : Specification for gypsum plaster for use in the manufacture of
fibrous plaster board.
IS 5871 – 1987 : Specification for bitumen mastic for tanking and damp proofing.
IS 651 – 1992 : Specification for salt glazed stoneware pipe and fittings.
IS 1729 – 1979 : Sand cast iron spigot and socket soil pipe.
IS 771 (Part 1 to 7) - 1979 to 1985 : Specification for glazed fire clay appliances.
IS 1230 – 1979 : Cast iron rain water pipes and fittings.
IS 774 – 1984 : Flushing cisterns for water closets and urinals.
IS 2548 (Part 1&2) – 1983 : Specification for plastic seats and cover for water closet.
IS 1726 – 1991 : Specification for cast iron manhole cover and frames.
IS 1239 (Part 1&2)-1990 to 1992 : Mild steel Tubes and fittings.
IS 4984 – 1987 : Specification for high density polyethylene pipes for potable
water supplies: Sewerage and industrial effluents.
IS 2556 (Part 1 to 15) - 1972 to 1985 : Specification for vitreous sanitary appliances (vitreous china).
IS 7328 – 1992 : High density polyethylene materials.
IS 4985 – 1988 : Specification for unplasticised PVC pipes for potable water
supplies.
IS 3076 – 1985 : Specification for low density polyethylene pipe for potable water
supplies.
IS 9762 – 1981 : Specification for polyethylene floats for ball valve.
IS 3395 – 1984 : Code of practice for fire safety of industrial buildings.
IS 7834 (Part 1 to 8) – 1987 : Specification for injection moulded PVC fittings with solvent
cement joint for water supplies.
IS 8008 (Part 1 to 7) – 1976 : Specification for injection moulded HDPE fittings for potable
water supplies.
IS 8360 (Part 1 to 3) - 1977 : Specification for fabricated high density polyethylene fittings for
potable water.
IS 784 – 1978 : Specification for prestressed concrete pipe.
IS 1703 – 1989 : Specification for copper alloy float valves (horizontal plunger
type) for water supply fittings.
IS 12234- 1988 : Specification for plastic equilibrium float valve for cold water
services.
IS 778 – 1984 : Specification for copper alloy gate, globe and check valves for
water works purposes.
IS 1536 – 1989 : Centrifugally cast (spun) iron pressure pipes.
IS 1537 – 1976 : Vertically cast iron pressure pipes for water, gas and sewage.
IS 1538 (Part 1 to 23) – 1976 : Sand cast iron spigot and socket soil, waste and ventilating pipes,
fittings and accessories.
IS 3589 – 1991 : Electrically welded steel pipes for water, gas and sewage.
IS 781 – 1984 : Specification for cast copper alloy screw down bib taps and stop
valves for water services.

IS 1239 (Part 1&2) - 1990 to 1992 : Mild steel tubes and fittings.
IS 779 – 1978 : Specification for water meters.
IS 1795 – 1982 : Specification for pillar taps for water supply purposes.
IS 1363 (Part 1 to 3) - 1992 : Dimensions for screw thread run-outs and undercuts.
IS 2016 – 1967 : Plain washers.
IS 638 – 1979 : Sheet rubber jointing and rubber insertion jointing.
IS 4127 – 1983 : Code of practice for laying of glazed stoneware pipes.
IS 458 – 1988 : Specification for precast concrete pipes.
IRC 19 – 1981 : Standard specification and code of practice for water Bound
macadam.
IRC 29 – 1988 : Tentative specification for 4 cm Asphaltic concrete surface
course.
IRC 15 – 1981 : Standard specification and code of practice for construction of
concrete roads.
IS 6313 – 1981 : Code of practice for antitermite measures in building.
IS 1054 – 1962 : Dieldrin emulsifiable concentrates.
IS 1308 – 1984 : Aldrin dusting powders.
IS 6439 – 1978 : Hepta chlor emulsifiable concentrates.
IS 2632 – 1964 : Crotonaldehyde.
IS 1791 – 1985 : Specification for batch type concrete mixers.
IS 10262- 1982 : Recommended guidelines for concrete mix design.
IS 7861 (Part 1) – 1975 : Code of practice for extreme weather concreting - Recommended
practice for hot weather concreting.
IS 1199 – 1959 : Methods of sampling and analysis for concrete.
IS 516 – 1959 : Method of test for strength of concrete.
IS 7861 (Part 2) – 1981 : Code of practice for extreme weather concreting. Recommended
practice for cold weather concreting.
IS 2502 – 1963 : Code of practice for bending and fixing of bars for concrete
reinforcement.
IS 2751 – 1979 : Recommended practice for welding of mild steel plain and
deformed bars for reinforced construction.
IS 800 – 1984 : Code of practice for general construction in steel and deformed
bars.
IS 816 – 1969 : Code of practice for use of metal arc welding.
IS 814 – 1991 : Covered electrodes for manual metal arc.
IS 3370 (Part 1&2)-1965 : Code of practice for concrete structures for the storage of liquids.
IS 2911 (Part 1 to 4) – 1979 to 1985 : Code of practice for design and construction of pile foundations.
IS 1343 – 1980 : Code of practice for prestressed concrete.
IS 1785 (Part 1&2)-1983 : Specification for plane hard drawn steel wires for prestressed
concrete.
IS 2250 – 1981 : Code of practice for preparation and use of masonry mortars.
IS 1635 – 1992: : Code of practice for field slaking of building lime.
IS 2212 – 1991 : Code of practice for brick work.
IS 1597 (Part 1&2)-1992 : Code of practice for construction of stone masonry.
IS 4101 (Part 1 to 3) - 1967 to 1985 : Code of practice for external facing and veneer.
IS 737 – 1986 : Wrought aluminium and aluminium alloys, sheet and strips ( for
general engineering purposes ).
IS 2572 – 1963 : Code of practice for construction of hollow connect block
masonry.
IS 1661 – 1972 : Code of practice for application of cement finishes.
IS 5766 – 1970 : Code of practice for laying of burnt clay brick flooring.

IS 5491 – 1969 : Code of practice for laying of in-situ granolithic concrete flooring
topping.
IS 3316 – 1974 : Specification for structural granite.
IS 1196 – 1978 : Code of practice for laying bitumen mastic flooring.
IS 1195 – 1978 : Specification for bitumen mastic for flooring.
IS 3462 – 1986 : Specification for unbacked flexible PVC flooring.
IS 1198 – 1982 : Code of practice for laying fixing and maintenance of linoleum
floor.
IS 848 – 1974 : Specification for synthetic resin adhesive for plywood.
IS 4457 – 1982 : Specification for ceramic unglazed vitreous acid resisting tiles.
IS 851 – 1978 : Specification for synthetic resin adhesive for construction work
(non structural) for wood.
IS 2202 (Part 1&2) - 1981 to 1991 : Specification for wooden flush door shutters.
IS 102 – 1962 : Ready mixed paint.
IS 1081 – 1960 : Code of practice for fixing and glazing of metal doors.
IS 6248 – 1979 : Specification for metal rolling shutters and rolling grills.
IS 1868 – 1982 : Anodic coatings on aluminium and its alloys.
IS 2065 – 1983 : Code of practice for water supply in buildings.
IS 2064 – 1993 : Code of practice for selection, installation and maintenance of
sanitary appliances.
IS 7634 (Part 1 to 3) – 1975 : Code of practice for plastic pipes.
IS 1742 – 1983 : Code of practice for building drainage.
IS 5330 – 1984 : Criteria for design of anchor blocks for penstocks with expansion
joints.
IS 3114 – 1985 : Code of practice for laying of cast iron pipes.
IS 783 – 1985 : Code of practice for laying of concrete pipes.
IRC-SP11- 1977 : Hand book of quality control for construction of roads and run-
ways.
IRC-63 – 1976 : Tentative guidelines for use of low grade aggregates and soil
aggregate mixtures in road pavement construction.
IRC-60 – 1976 : Tentative guidelines for use of Lime Fly Ash Concrete as
pavement base or sub-base.
IRC-74 – 1979 : Tentative guidelines for use of Lean Cement Concrete and lean
concrete Fly Ash Concrete as pavement base or sub-base.
IS 6509 – 1985 : Code of practice for installation of joints in concrete pavement.
IS 1838 (Part 1) – 1983 : Specification for performed filler for expansion joint in concrete
pavements and structures.
IRC-43 – 1972 : Recommended practice for Tools, Equipment and appliances for
concrete pavement construction.
IRC-15 – 1970 : Standard specifications and code of practice for construction of
concrete road.
IS 3036 – 1992 : Code of practice for laying lime concrete for a water proofed roof
finish.
IS 1346 – 1991 : Code of practice for water proofing of roofs with bitumen felts.
IS 1609 – 1991 : Code of practice for laying damp proofing treatment using
bitumen felt.
IS 4365 – 1967 : Code of practice for application of bitumen mastic for
waterproofing of roofs.
IS 9103 – 1979 : Specification for admixtures for concrete.
IS 2645 – 1975 : Specification for integral cement water proofing compounds.
IS 1834 – 1984 : Specification for hot applied sealing compound for joint in

concrete.
IS 278 – 1978 : Specification for Galvanized barbed wire for fencing.
IS 2721 – 1979 : Specification for Galvanized steel chain link fabric.
IS 280 – 1978 : Specification for Mild steel wire.
IS 4826 – 1979: Specification for hot dipped galvanized coating on round steel
wires.
IS 1200 (Part 1 to 28) - 1971 to 1993 : Method of measurement of building and Civil Engineering Works.
IS 4081 – 1986 : Safety code for blasting.
IS 5916 – 1970 : Specification for cast iron gratings for drainage purposes.
IS 4130 – 1991 : Safety Code for demolition of building.
IS 3764 – 1992 : Safety code for excavation work.
IS 5121 – 1969 : Safety code for piling.
IS 4014 (Part 2) – 1967 : Code of practice for steel tubular scaffolding.
IS 3696 (Part 1&2) - 1987 to 1991 : Safety code of scaffolds and ladders.
IS 6922 – 1973 : Criteria for safety and design of structures subject to underground
blast.
IS 5499 – 1969 : Code of practice for construction of underground raid shelter.
IS 4138 – 1977 : Safety code for working in compressed air.
IS 7293 – 1974 : Safety code for working with construction machinery.
IS 8989 – 1978 : Safety code for erection of concrete framed structures.
IS 4756 – 1978 : Safety code for Tunneling work.
IS 7205 – 1974 : Safety code for erection of structural steel works.

NMDC LIMITED

FOR
ACVS & AIR POLUTION CONTROL SYSTEM
(GS – 08)
MECON LIMITED
RANCHI - 834002


Sl.
Description Page No.
No.
1. SYSTEM SPECIFICATION OF AIR CONDITIONING SYSTEM (SS1) 3-09
2. SYSTEM SPECIFICATION OF DUST EXTRACTION SYSTEM (SS2) 10-17
3. SYSTEM SPECIFICATION OF DUST SUPPRESSION SYSTEM (SS3) 18-23
4. SYSTEM SPECIFICATION OF VENTILATION SYSTEM (SS4) 24-26
5. ES1 - AIR HANDLING UNIT / FAN COIL UNIT 27-31
6. ES2 - AIR WASHER UNIT 32-35
7. ES3 - BAG FILTER 36-42
8. ES4 - CENTRIFUGAL FAN 43-47
9. ES5 - CENTRIFUGAL PUMP 48-52
10. ES6 -VAPOUR ABSORPTION M/C (VAM) BASED CHILLER PLANT 53-59
11. ES7 - VAPOUR COMPRESSION BASED CHILLER PLANT 60-67
12. ES8 - CHAIN PULLEY BLOCK 68-69
13. ES9 - COOLING TOWER 70-72
14. ES10 - CYCLONES, MULTI-CLONES & PRE-COLLECTOR 73-74
15. ES11 - DAMPERS FOR AIR FLOW CONTROL 75-80
16. ES12 - DUCTING NETWORK OF DUST EXTRACTION SYSTEM 81-84
17. ES13 - DUCTING NETWORK FOR HVAC SYSTEM 85-89
18. ES14 - ELECTROSTATIC PRECIPITATOR 90-97
19. ES15 - FILTER DRY TYPE 98
20. ES16 – VOID 99
21. ES17 - THERMAL & ACOUSTIC INSULATION FOR HVAC (INSULATION 100-103
Chapter 8 Air conditioning & ventilation Page 1 of 129

Sl.
Description Page No.
No.
FOR COLD APPLICATION )
22. ES18 - INSULATION FOR HOT APPLICATION 104-107
23. ES19- PACKAGED AIR CONDITIONER 108-110
24. ES20 - PROPELLER FAN 111
25. ES21 - SCRUBBER FOR DUST EXTRACTION SYSTEMS 112-114
26. ES22 - STACK 115-117
27. ES23 - TUBE AXIAL FLOW FAN 118-120
28. ES24 - WATER LINE VALVES 121-124
29. ES25- WINDOW / SPLIT / DUCTABLE SPLIT TYPE AIR CONDITIONER 125-127
30. ABBREVIATION 128-129

1.0 SYSTEM SPECIFICATION OF AIR CONDITIONING SYSTEM (SS1)
01. General
This specification outlines the minimum requirement for design, engineering, selection, manufacture,
testing and supply/fabrication of Air Conditioning System with all accessories required to be
installed for HVAC application to achieve desired performance in all respects. Specific technical
requirement of Air Conditioning System if any, shall be mentioned in the job specification/data
sheet as furnished along with the Technical Specification.
Brief description of Air Conditioning System is given below under clause No. 02. The point wise
list of data to be furnished by the tenderer along with the offer is mentioned below under clause No.
03.
Description
This specification specifies general requirement of refrigeration and air-conditioning system for different
applications.
In general following equipment for air conditioning systems shall be considered as described in
respective equipment specification.
- AIR HANDLING UNIT / FAN COIL UNIT – ES1

- CENTRIFUGAL FAN – ES4
- CENTRIFUGAL PUMP – ES5
- VAPOUR ABSORPTION M/C (VAM) BASED CENTRAL A/C – ES6
- VAPOUR COMPRESSION BASED CENTRAL A/C – ES7
- COOLING TOWER – ES9
- DAMPERS – ES11
- DUCTING NETWORK FOR HVAC SYSTEM – ES13
- FILTER-DRY TYPE – ES15
- THERMAL & ACOUSTIC INSULATION FOR HVAC APPLICATION – ES17
- PACKAGE TYPE A/C SYSTEM – ES19
- WATER LINE VALVES – ES24
- WINDOW & SPLIT TYPE A/C SYSTEM – ES25
Design Consideration:
Following Indian Standards shall be followed for designing Air Conditioning System:
IS 655: 2006 HVAC System duct

IS-659-1964 (RA-2001) Safety code for air conditioning system
IS 778:1984 (RA 2005) Specification for Copper Alloy Gate, Globe and
Check Valves for Waterworks Purposes
IS 1239 : Part 1 : 2004 Steel Tubes, Tubulars and Other Wrought Steel
Fittings - Specification - Part 1 : Steel Tubes
IS 1239 : Part 2 : 1992 (RA 2002) Mild steel tubes, tubulars and other wrought steel

fittings, Part 2 Mild steel tubulars and other wrought

steel pipe fittings
IS 1391 : Part 1 : 1992 (RA 1999) Room Air Conditioners - Specification - Part 1 :
Unitary Air Conditioners
IS 1391 : Part 2 : 1992 (RA 1999) Room air conditioners: Part 2 Split air conditioners
IS 2712 : 1998 (RA 1999) Gaskets and packings - compressed asbestos fibre
jointing
IS 3588 : 1987 (RA 1999) Specification for Electric Axial Flow Fans
IS 3589 : 2001 (RA 2006) Steel Pipes for Water and Sewage
(168.3 to 2 540 mm Outside Diameter) -
Specification
IS 3677 : 1985 (RA 2006) Specification for Unbonded Rock and Slag Wool for
Thermal Insulation
IS 4671 : 1984 (RA 2004) Expanded polystyrene for thermal insulation
purposes
IS 4894 : 1987 (RA 1999) Centrifugal fans
IS 5312 : Part 1 : 2004 Swing Check Type Reflux (Non-Return] Valves for
Water Works Purposes - Specification - Part 1 :
Single-Door Pattern
IS 5822 : 1994 (RA 2000) Code of Practice for Laying of Electrically Welded
Steel Pipes for Water Supply
IS 7613 : 1975 (RA 2001) Method of testing panel type air filters for air
conditioning and ventilation purposes
IS 7896 : 2001 Data for Outside Design Conditions for Air
Conditioning for Indian Cities
IS 8148 : 2003 Package air conditioner
IS 8183 : 1993 (RA 2004) Thermal Insulation – Bonded Mineral wool
IS 10470 : 1983 (RA 2000) Specification of air cooled heat exchanger
IS 11304 : 1985 (RA 2003) Code of practice for control of air pollution in iron
and steel plants
IS 11327:1985 Requirements for refrigerants condensing units
IS 11329 : 1985 Specification for Finned Type Heat Exchanger for
Room Air Conditioner
IS-11338-1985 (RA-1991) Specification for Thermostats for Use in
Refrigerators, Air Conditioners, Water Coolers and
Beverage Coolers
IS 11446: 1985 Method of Measurement of Airborne Noise Emitted
by Compressor Units Intended for Outdoor Use
IS 11461 : 1985 Code of practice for compressor safety
ASHRAE Handbook ‘Fundamentals’
‘Equipment’
CARRIER Handbook Air Conditioning System Design by ‘Carrier Air
Conditioning Company’
ISHARE Handbook ISHRAE Handbook

For specific internal heat load due to equipment, lighting, solar radiation, occupancy and inside design
conditions refer job requirement of technical specification. The air-conditioning system will be designed
to operate continuously round the clock twenty four (24) hours a day for all seasons of the year.
The following design ambient data shall be considered for selecting and sizing various equipment for
chilled water plant and air conditioning systems :
SEASON TEMPERATURE RELATIVE

0
C (DBT) HUMIDITY (%)
SUMMER
Hot Zone side (20 m from 60
hot metal/liquid steel
handling)
Other zones 42.6 27
MONSOON 34.1 50
WINTER 6.4 -
Unless otherwise specified in the technical specifications, all air conditioned premises shall be
maintained at 23±2 C and 55±5 % RH.
All window glasses in air-conditioned premises shall be double glass type and airtight double door entry
provision shall be kept for these premises.
For improved water quality in refrigeration system chemically treated water shall be considered as
make-up for corrosion protection. Alternatively captive soft water plant shall be installed for make-up
water supply to A/c system.
Chilled water pipe line shall be laid over ground. For better distribution of chilled water in the network,
ring main shall be considered. Alternatively reverse return line shall be considered for vertical chilled
water distribution at different floor. At the end of main supply and return chilled water line provision
shall be kept with isolation valve for hooking up with adjacent plant chilled water network.
Preferably Exhaust fan RPM shall not exceed 900. All pumps (above 15m³/hr capacity) shall be
horizontally split type with maximum RPM of 1500. Monoblock pump can be used for capacity less
than 15 m³/hr
Remote monitoring from central control room through main automation system for all critical areas
under AC systems shall be provided. Provision for monitoring of chilled water flow quantity,
temperature and served premises temperature shall be kept from central control room station .
Chilled water plant shall be selected such that it shall have 20 % more capacity rating than design
calculation for future scope and interconnection with other adjacent plants.
Duct line velocities shall be as mentioned in ES13
Noise level generated in Central AC plant, Package AC plant, AHU and duct line shall not be
transmitted to the served premises. Noise level in the served premises will not exceed 65 dB (A).

Make up air supply to AHU / package AC plant room shall be provided with filter and damper.
Filter: Efficiency of pre filter will be 90% down to 10 micron and fine filter will be 99% down to 5
micron. High efficiency filter will be installed in the supply air duct at the discharge end of blower in
line with job specification requirement. For details refer ES15.
Local control of fan, pump, blower shall be provided near installation area for ON/OFF operation as
required.
For control of temperature and dehumidification of the conditioned premises, thermostat and humidistat
will be provided in the package A.C. plant room/ AHU Room .
Strip heater box for humidity Control:
The strip heater will be installed in the supply air duct at the discharge end of blower for
dehumidification purpose and the strip heater will be interlocked with the blower unit to prevent
independent control/ switching of heaters. Safety thermostat shall be installed in the duct line near strip
heater for safety precaution. Strip heater box will comprise of finned heater, mounting plate, heater
box/ casing made of 20 SWG G.I. sheet, cable terminal, terminal box with handle, 40x40x3 MS
angle flange/ frame. Strip heater box will be placed/ inserted in supply air duct. Safety thermostat
will be mounted on strip heater package to prevent overheating.
Humidification kit (Pan Humidifier) for humidity control:
Pan type humidifier shall be installed in the AHU / Package AC room for adding moisture if required
for critical control of R.H. Level. The humidification kit will comprise of a pan, immersion heaters (3
Nos.), immersion heater cover box with handle, 15 NB pipe connection with float valve for make up
water, 15 NB pipe connection for over flow, 15 NB pipe connection with valve for drain, thermostat,
earth stud, etc. Over flow pipe and drain pipe will be connected together after/ below the valve of
drain pipe. The humidifier will be insulated with 50mm thick mineral wool (T.F. quality). Safety
thermostat will be provided in the pan humidifier to prevent it from dry heating.
Condenser cooling circuit.
Centrifugal pump and cooling tower for condenser cooling shall be supplied in line with job
specification requirement for water-cooled type condensing unit. For air cooled condenser unit selection
maximum ambient temperature factor shall be considered for capacity selection
Rubber/Neoprene gaskets will be used on all bolted joints as a seal against water leakage.
Water pipe line will be of MS Heavy ( C ) Class as per IS 1239 : Part 1 : 2004 upto a size of 150 NB
and for sizes beyond 150 NB MS, spirally welded, 6mm thick & conforming to IS 3589: 2001 (RA
2006) shall be provided. Pipe fittings up to 150 NB will be as per IS 1239 : Part 2 : 1992 (RA 2002).
Fabricated fittings manufactured from pipes shall be provided for pipes of size 200 NB & above.
Velocity of water in pump suction line and delivery line will be within 1 and 2 m/sec respectively.

Pot /Duplex strainer will be provided in suction line of pump and ball valve/ butterfly valve will be
provided in the delivery side of pump.
Butterfly valve/ ball valve will be provided in water pipeline at condenser inlet & outlet, AHU cooling
coil inlet & outlet, pump inlet & outlet.
For better distribution of chilled water in the network in vertical line reverse-return line shall be
provided for balancing of water flow at consumer points. However for multiple consumer points in
horizontal line balancing valve shall be provided at chilled water return branch line .
Insulated drain piping network is to be included as required for steam condensate drain, with isolation
valves at proper places.
Pipe supports will be fabricated from mild steel and coated with appropriate rust preventive primer and
finish paint. Where pipe and clamp are of dissimilar material a gasket will be provided in between.
All piping will be tested to hydrostatic test pressure of at least one and half times the maximum of
operating pressure for period of not less than 2 hours.
Thermal and acoustic insulation :
For details refer ES17. Thermal and acoustic insulation for air conditioning systems shall be considered
in line with job specification requirement. However, following minimum insulation work shall be
considered.
a) Inside surface of the packaged a/c blower/AHU Blower section.

b) Supply air tail end duct to prevent condensation
c) All supply air and return air duct line passing through non-air conditioned premises.
d) Acoustic insulation of duct line at blower outlet up to 5 m length minimum.
e) Condensate drain
f) Under deck insulation of sunlit exposed roof
g) Chilled water pump, chilled water pipeline, valves, chiller, expansion tank
Fire safety
Combustible materials, like insulating material will be used with utmost care for fire safety. No other
than combustible material will be used anywhere in the entire air-conditioning system. AC system
blower and motorized fire dampers / solenoid operated fire dampers in the duct, shall be inter locked
with fire detection system to stop air flow in case of fire.
Control & Instrumentation
The following instrumentation and necessary interlock and controls shall be provided for air
conditioning system :
a. HP/LP cutout switch.

b. Cooling thermostat, heating thermostat, Operating and antifreeze thermostat & Humidistat.
c. Pressure gauge & temperature gauge (150-mm dial type)

d. Water flow switch /differential pressure switch with interlock and signal in chilled & condenser
water systems.
e. Dry bulb & wet bulb thermometer for all major air conditioned premises.
f. Thermostatic expansion valve, sight glass, refrigerant strainer,
g. Steam pressure and flow control of Vapor Absorption based system .
h. Flow meter to measure chilled water flow and condenser cooling water flow rate
i. Flow control valve in chilled & condenser water line
j. Any other instrumentation not specifically mentioned above, but required for the air conditioning
system will be indicated & provided by the Tenderer.
Guidelines to eliminate interference between ducts, lighting and false ceiling
Minimum clearances for duct routing will be as follows :
A minimum clearance of 100 mm will be provided between beam bottom and top of duct to take care of
duct erection, flanges, insulation and allowances for civil construction.
Minimum clearance of 200 mm will be provided between duct bottom and false ceiling to take care of
collar fitting, variation in levels of false ceiling and floor levels, if any.
The successful Tenderer will study the false ceiling drawing and carry out any additional grid work, if
found necessary, based on diffuser sizes. Size of the diffuser color will match with false ceiling grid. For
served premises, return air recess may be provided at the periphery all around.
Sequence of preparation of drawings
i) Duct routing drawing will be prepared based on air conditioning requirement.

ii) Duct routing and diffuser locations will be checked for interference if any with light fittings
and false ceiling grid as per the Architectural/Electrical drawings. The diffusers and light
fittings will be in different rows, as far as possible.
iii) The finalized duct/diffuser layout drawing will be drawn on the false ceiling grid drawing
before submission for approval.
Construction supervision
Interference during construction stage due to lack of supervision and co-ordination etc., will be corrected
during erection by the Successful Tenderer of AC system. The false ceiling Tenderer will draw the grid
on the ceiling. The Successful Tenderer of AC system will make the exact location of diffusers on the
ceiling. Similarly, locations of light fittings on the ceiling shall be considered. The Successful Tenderer
of AC system will co-ordinate in this regard with other Contractors to avoid any interference at a later
stage. By using plumb, from locations of diffusers drawn on ceiling, the duct fabricator will erect the
main and branch ducts. However, collars should be cut only after the false ceiling is properly leveled.
Suggested sequence of operation
a. Under deck insulation shall be completed.

b. Main duct will be erected by the Successful Tenderer.
c. Hangers for false ceiling & lighting etc., will be placed.

d. Skeleton false ceiling with grid main runners will be erected.

e. Branch duct to be erected as per center lines of grid/main runner.
f. False ceiling to be leveled and grid to be provided for lights and diffusers.
g. Collars to be cut by the Tenderer to match the false ceiling grid and level.
h. Fixing of diffusers on to the collars after leveling the false ceiling.
i. The diffuser level and false ceiling level will be properly matched for good aesthetic appearance.
The false ceiling panel opening will be done by the Tenderer for diffuser fixing.
j. The AC system Tenderer will plan the activities of duct erection in consultation with other
Tenderers, (namely, Electrical and Civil) so as to avoid delays and extra work by all concerned.
k. Concerted efforts will be made by the AC system Tenderer together with other agencies for proper
erection of ducting and diffusers avoiding any interference with electrical works and false ceiling
grid.
03. Data to be furnished by the Tenderer along with Offer
The following data shall be furnished by the tenderer along with their offer.
Type of refrigeration / air conditioning system

Total capacity of air conditioning system
Make of equipment
Design cooling load
Indoor climatic condition shall be maintained
Total power requirement
Total water requirement
Any specific design consideration
Noise level at 1m distance from the AC equipment
Noise level at served premises

2.0 SYSTEM SPECIFICATION OF DUST EXTRACTION SYSTEM (SS2)
01 General
test and supply/fabrication of Dust Extraction System with all accessories required to be installed to
achieve desired performance in all respects. Specific technical requirement of Dust Extraction
System if any, shall be mentioned in the job specification/data sheet as furnished along with the
Technical Specification.
Brief description of Dust Extraction System is given below under clause No. 02. The point wise list
of data to be furnished by the tenderer along with the offer is mentioned below under clause No. 03.
02. Description
Dust extraction systems shall comprise of suction fan, dust extractor, ducting network, dust disposal
system, electrics, instruments & controls. This specification specifies general requirement of Dust
Extraction System for different applications. In general following equipment for dust extraction
systems shall be considered as described in respective equipment specification.
- BAG FILTERS – ES3

- CYCONES, MULTI-CLONES, PRE-COLLECTOR – ES10
- DUCTING NETWORK FOR DE SYSTEM – ES12
- ELECTROSTATIC PRECIPITATORS – ES14
- THERMAL INSULATION FOR HOT APPLICATION – ES18
- SCRUBBER FOR DE SYSTEM APPLICATION – ES21
Design Criteria
All the rotating parts shall be statically and dynamically balanced. Monitoring ports in ducting and
stack with platforms, approach ladders/ stairs and other requirements shall be strictly as per the
latest emission standards published by Central Pollution Control Board.
The efficiency of the dust cleaning equipment shall be such that the emission from stack should not
be more than 50 mg/Nm3 unless other wise specified in the job specification. The average inlet air
dust concentration may be taken as 10~15 gm/Nm3 unless otherwise specified in the job
specification.
The dust extraction systems shall be such that the work zone dust concentration for Total Suspended
Particulate Matter (SPM) shall be limited to 5mg/Nm³ over background level and Respirable
Particulate Matter ( RPM ) of particle size less than 10 microns should be limited to 2mg/Nm3 over
background level unless otherwise specified in the job specification.
The capacities of the dust extraction systems shall be selected considering at least 10% excess
margin over the calculated values.

Following Indian Standards shall be followed as design guidelines:
IS 638 : 1979 (RA 1999) Specification for Sheet Rubber Jointing and Rubber
Insertion Jointing
IS 800 : 1984 (RA 1998) Code of practice for general construction in steel
IS 822 : 1970 (RA 2003) Code of procedure for inspection of welds
IS 875 : Part 1 to Part 5 : Structural design

1987 (RA 2003)
IS 1239 : Part 1 : 2004 Steel Tubes, Tubulars and Other Wrought Steel Fittings -
& Specification - Part 1 : Steel Tubes
IS 1239 : Part 2 : 1992 (RA &
2002) Mild steel tubes, tubulars and other wrought steel fittings,
Part 2 Mild steel tubulars and other wrought steel pipe
fittings
IS 1364 : Part 1 to Part 6: Hexagonal nuts & bolts
2002
IS 2062 : 2006 Hot Rolled Low, Medium and High Tensile Structural
Steel
IS 2309 : 1989 (RA 2005) Code of practice for the protection of buildings and allied
structures against lightning
IS 2712 : 1998 (RA 1999) Gaskets and packings - compressed asbestos fibre jointing
IS 4894 : 1987 (RA 1999) Centrifugal fan
IS 6392 : 1971 (RA 1998) Steel pipe flanges
IS 8183 : 1993 (RA 2004) Bonded mineral wool insulation

IS 9240 : 1979 Purchaser's data sheet for gas scrubber cooler or absorber
IS 9241 : 1979 Purchaser's data sheet for electrostatic precipitators
IS 10919 : 1984 Glossary of Terms for Electrostatic Precipitators
IS 11304 : 1985 (RA 2003) Code of practice for control of air pollution in iron and
steel plants
IS 14164 : 1994 (RA 2001) Industrial application and finishing of thermal insulation
material at temperature above -80 deg C and up to 700 deg
C - Code of practice
The duct lines shall be designed as self balanced systems. Successful tenderer has to furnish pressure
drop calculation and system capacity selection calculation before carrying out detail engineering of
DE system.
The dust extraction system shall be designed based on norms specified in the Hand Book of
American Conference of Governmental Industrial Hygienists (ACGIH) with fines factor and to meet
the required fugitive emission standard based on the party’s experience.
The Successful Tenderer should calculate and decide the systems capacities of their own using the
standard norms. However, in no case, the systems capacities should be less than as specified in job
specification.

The dust extraction equipment shall be located near to the building. Approach, handling and hoisting
facilities shall be provided for the equipment. Monitoring port holes of 100mm diameter with plug,
platforms, approach ladders/ stairs, power socket of single phase, 50 Hz, 230 V, 15 A and monitoring
equipment lifting facilities shall be provided as per the Emission Regulations Part-III, published by
the Central Pollution Control Board (CPCB).
The height of the stack shall be as per CPCB norms or 2 to 3m above the nearest highest building or
minimum 45 m or as specified in the job specification, whichever is higher. The efflux velocity from
the stacks for dust extraction systems shall be maintained around15m/s (approx.). For rain
protection, concentric duct shall be provided on the top of stack, designed such that it restricts rain
water entry into stack but allows the gases to move vertically upward with the above mentioned
efflux velocity.
Generally the following air velocities shall be considered for the dust extraction systems.
At hood inlet 1.5 m /sec (max)

Ducting 18-25m/ sec
Suction hood for the dust extraction systems shall not be less than 5 mm thick MS sheet. The ducting
shall be of circular cross section.
Duct lines shall have cleaning hatches of size 100mm x 75mm with air tight seals for easy cleaning
of accumulated dust near bends & inter connections.
Horizontal duct shall be avoided as far as possible. Vertical/ inclined ducting shall be provided.
The Successful Tenderer shall include duct supports in their scope as follows:-
a) In-house ducting shall be suitably supported at approx. 3m intervals. Ducting inside

the building shall be supported on the floor or from the column/ civil beam/building
structure/technological structure etc. as applicable. The location and type of
supporting arrangement shall be decided by the Successful Tenderer in consultation
with purchaser / purchaser’s consultant.
b) Trestle supports shall be provided on ground for the ducting outside the building.
The dust extraction system shall be interlocked with the technological equipment/ conveyors. The
sequence of operation shall be such that the dust extraction system shall start 5 minutes before start
of the technological equipment and shall stop 5 minutes after stoppage of the technological
equipment.
Dust Disposal System
Dust disposal system shall include chain / screw conveyors, double cone valve / rotary air lock valve,
dust moistener / telescopic chute, dust storage hopper / rotary feeder etc.
a) Chain / screw conveyors and double cone valves will be provided below the dust extraction
equipment hoppers for disposal of dust. Chain / screw conveyors will have bearings with
outside greasing terminal, protected from dust by packing around the glands. All the

vulnerable parts requiring frequent attention will be readily accessible. If two flights of a
screw are coupled then, overlapping of each flight at center point shall be made for smooth
flow of material.
b) Double cone valves will be made of cast iron with the carrying side hard faced. The double
cone valve will be complete with shaft of EN8, cast iron housing, geared drive, geared
box/geared motor etc.
c) Chain conveyors shall have the following specifications unless otherwise specified in the job
specifications.
- Forge link chain material = 16 Mn Cr5

- Strength of link (Breaking load) = 20 t.
- Length to suit design requirement
- Hardness of chain link - 55-60 HRC.
- Flight thickness - 10 mm.
- Bottom Plate - IS 2062: 2006 - 8 mm thick with 10 mm Hard Liner.
- Side Plate - IS 2062: 2006 - 6mm thick with 10mm Hard Liner.
- Top cover - IS 2062: 2006 - 3.15 mm thick.
- Liner hardness shall be minimum 500 BHN
- Capacity: not less than 3 t/ hr or as specified in the job specification
- Chain speed: not more than 0.06 m/ sec
d) Zero speed switches will be provided for all dust disposal system drives.
e) Compensator / Expansion Joint between rotary feeder and the chain conveyors, between two
conveyors and between dust moistener and rotary feeder will be provided to facilitate
maintenance. Slide gates will be provided before all the double cone dust valves/rotary
feeder. For calculation and design of structural members, accidental fill up of dust up to top
of hoppers in worst case will be considered by Successful Tenderer.
f) Dust hopper/ Holding hopper
Dust storage hoppers shall be provided for each dust collector. The hopper shall be of
pyramidal construction with 65° valley angles. The hopper shall have a 2 days’ dust storage
capacity. Rack and pinion sliding gate (motorised) arrangement / rotary air-lock valve shall
be provided at the hopper discharge. Dust conditioner of double screw type / disc palletizer
with controlled moisture addition shall be provided at storage hopper outlet. Adequate
motorised bin vibrators shall be provided in each hopper. Disposal of dust to the closed truck
/ pneumatic system shall be done through telescopic chute. Manually operated slide gate
shall be provided above each rotary air-lock valve / rack & pinion slide gate for isolation
purpose for maintenance. Necessary hopper heating arrangement and hopper insulation shall
be provided to avoid condensation especially in ESP based systems.
g) Rotary Air Lock Valve
Rotary air lock valve shall be provided below each bag filter hopper for disposal of dust.
Rotary air lock valve shall be made of cast iron with the carrying side hard faced. The rotary
air lock valve shall be complete with shaft of EN8, cast iron housing, rotor blade etc. Rotary

air lock valve is directly coupled to gear box & motor. Rotary air lock valve capacity shall
be based on 50% filling volume. Rotor blade shall be of MS construction and hard faced.
Face of blades shall be hard faced by 20x15 diamond weld beads (2 to 3 mm ht) to achieve
250-300 BHN hardness.
Casing thickness : 6 mm min.

Rotor blade thicknes : 5 mm min.
Minimum Capacity : 0.4 t/h for RAV of each module hopper of bag filter /
ESP
: 50 t/h below dust storage hopper
RPM of RAV : Not more than 20
Capacity of RAV may increase as per requirement of job specification.
h) Pug Mill / Telescopic Chute :
Pug mill will be provided below storage hopper of minimum capacity 50 t/h unless specified
otherwise in the job specification. RPM shall not be more than 20. Water spray arrangement
shall be provided inside the pug mill. Piping, nozzles, valves and all other accessories shall
be provided. A solenoid valve shall be provided in water line and interlocked with pug mill
drive. Pug mill shall be totally enclosed, twin paddle type mixer. Parallel mixing paddles
will be mounted on individual shaft. The unit shall be directly coupled with a gear box &
motor. All the material will be conveyed through the mixing chamber and water spray on the
material through a series of header located along the top of the chamber. Each header shall
be provided with a number of spray nozzles.
In case of discharge into closed trucks, telescopic chute shall be provided for discharging the
dust from the storage hopper.
i) Following minimum Instrumentation shall be provided apart from any additional

requirement mentioned in the job specifications.
High level/ Intermediate level switch in hopper.

Hopper heating units as required.
Temperature and pressure transmitter as required,
Pressure gauge at inlet & outlet of each dust extractor module and overall.
Differential pressure switch across dust extraction equipment.
Master controller and pulsing solenoid valves as required for bag filter.
Sequential Timer for bag filter application as required.
Compressed air pressure gauge and pressure regulator as required.
U – Tube manometer across each module of dust extraction equipment.
Continuous monitoring of Particulate matter from stack.
Dry running protection of wet system.
j) Platforms and access stair case
The minimum platform width shall be 1.2 meters. The platforms shall be located at the top
of hoppers, level, at the top of the gas cleaning equipment, and at the different levels
required for maintenance and operation of the equipment and dampers. A safe guard rail

should be provided on the platform. Safe and easy access to the platform shall be provided
by providing stairways and railing. Intermediate platforms shall be provided for the bag
filters. Following minimum structural member shall be considered.
Hand rail : 25 NB, IS 1239: 2004
Post : 32 NB, IS 1239: 2004
Access grating : 40 depth, 6 thick,
Stair : 40 C/C, 38° slope
Stair treat : 250 mm
Max. ht. of riser : 200 mm
Operating Criteria
As the technological equipment starts dust generation starts at material handling / transfer
points.
Duct isolation dampers shall be opened / closed as required, to activate duct routes as per
active technological equipment.
The manual butterfly balancing dampers connected to the suction hoods shall be adjusted for
adequate suction of dusty air from all the hoods as per design requirement so as to control
the escaping of dusts at the dust generation points.
Electrical Interlocking for starting of dust extraction system shall be as follows:
Interlocking to be considered in the MCC to make sure the following sequential starting
before the start of technological equipment:
a) Start Screw / Chain Conveyor and Rotary Airlock / Double Cone valve.
b) Activate dust extraction system
c) Start Fan Motor.
d) Open Fan Inlet Damper after appropriate time delay of fan motor starting.
e) Activate duct line Isolation Damper in ducting network to minimize idle
suction from non-operating points as per system requirement.
In normal condition, switching off operation of DE system should be followed as per

following sequence:
a) Stopping of Technological Equipment

b) Stop Fan Motor after 30 minutes to allow dust removal from duct.
b) Close Fan inlet damper
c) Stop Rotary Air Lock / Double cone valve after appropriate time delay.
d) Stop Screw / Chain Conveyor
e) Deactivate Dust Extraction Equipment
Note : In case the RAL/Double Cone Valve trips the fan motor should also trip to avoid
uncontrolled accumulation of collected dust in Dust Extraction Equipment hopper which
otherwise may result into choking/clogging of Dust Disposal System. The Successful
Tenderer will examine the above logic and operating principle of the DE system and
changes, if any, necessary for trouble free operation of the system being offered by the
party shall be indicated.

03. Data to be furnished by the Tenderer along with offer
Type of dust extraction system

Total capacity of dust extraction system
Make of equipment
Design suction quantity
Outlet emission quantity
Work zone dust concentration
Noise level at 1m distance from the dust extraction equipment
Space requirement (L x B x H)
Support / Structure / Weathering shed DE system
Dust Disposal Arrangement
• Conveyor, Type, nos. capacity tph
• Rotary air lock valve capacity tph & nos.
• Slide gate (Manual)
• Expansion joint at outlet of RAV
• Rotary feeder
• Dust moistener / Telescopic chute
• Water requirement m3/h at kg/cm2
• Dust bin
• Storage Hopper
a) Volume in m3
b) Type
c) Size (L x B x H)
d) Motor rating kW & Pole of rack and pinion type discharge gate.
e) Material / thickness of hopper
• Zero speed switch of drives
Instrumentation
• Bearing & winding temperature monitor of fan & motor
• Pressure transmitter
• Temperature transmitter
• Level switch
• Thermostat for heaters
Weight of Dust Extraction Equipment & structure

• Structures
• Dust Extraction Equipment - casing, hopper, internals, Insulation & cladding as
applicable, storage hopper, expansion joints & dust disposal equipment
• Fan with drive & accessories
• Duct, suction hood & duct line damper
• Steel stack
• Auxiliary equipment as per job specification requirement

3.0 SYSTEM SPECIFICATION OF DUST SUPPRESSION SYSTEM (SS3)
01 General
test and supply/fabrication of Dust Suppression System with all accessories required to be installed
to achieve desired performance in all respects. Specific technical requirement of Dust Suppression
System if any shall be mentioned in the job specification/data sheet as furnished along with the
Brief description of Dust Suppression System is given below under clause No. 02. The point wise
list of data to be furnished by the tenderer along with the offer is mentioned below under clause No.
03.
02. Description
There are essentially three types of dust suppression systems applied to control pollution in bulk material
handling. They are spraying of only water at material transfer points, spraying a solution of water &
chemical compound at material transfer points, a dual fluid water and compressed air supplied through
nozzle for production of ultra fine water particles, i.e. fog at material transfer points.
02.1 Plain water type dust suppression system
In plain water dust suppression system in general plain water at high pressure is sprayed over
stockpile area. This type of system is envisaged for the stockpile area to suppress the generated dust
due to stacking / reclamation. Spray water header will be provided along the stockpiles. Dust
suppression system is to be designed to prevent lift of dust from stockpiles. Water spray over the
stockpile area is produced by sufficient number of sprinklers suitably installed in a header to cover
the entire stockpile area. Plain water may be sprayed at transfer station as per job specification
requirement.
The sprinklers should be of swiveling type. Each sprinkler operation cycle is to be controlled by a
sequential timer to have optimum consumption of water. Water will be stored in a feed water tank.
In the supply waterline to feed water tank float valve shall be provided. One additional quick fill line
to water storage tank shall be provided. Water from feed water tank shall be supplied to different
spray headers by a high-pressure pump. Sprinkler posts of required height should be installed on the
spray header along one or both sides of ores/ coal stock pile area. Before each sprinkler globe valve
& solenoid valve shall be provided for manual control and automatic control respectively. The water
pump is interlocked with low level switch of feed water tank to prevent the pump from dry running.
A pressure switch at the pump discharge line shall be provided to by pass water to storage tank. A
solenoid valve in by pass line shall be energized by high-pressure signal from pressure switch. In
specific requirements, manual control of sprinklers may be provided as per job specification.
02.2 Chemically treated water type dust suppression system
Chemically treated dust suppression system works on the principle of agglomeration. Dust particles
released from material handling become air borne and are made to pass through a blanket of
extremely fine water droplets. The dust particle and the droplets collide and adhere to each other,

thus increasing their mass. After a series of such collision the dust particles mass become heavy.
The system involves spraying of chemical compound wetting agent and water mixture in certain ratio at
each material transfer point. Chemical solution at the pressure of about 4 kg/cm² is supplied at the
atomising nozzles. The wetting agent (chemical compound) from drum is transferred to solution tank
with the help of metering pump (one working and one reserve). Chemical compound is added in
measured quantity in the feed water line to solution tank. The tank is provided with high, low and very
low level switch. There are two-solution pumps (one working and one reserve). Any one of the
solution pumps can be started if the tank is filled above the low level switch of solution tank and any one
of the solenoid valve at spray point is energised. Feed water pump will start when solution level in
solution tank reaches low level. Metering pump operation is interlocked with feed water pump. Feed
water pump will stop when water level in solution tank reaches high level. In case of very low level in
solution tank solution pump will stop. In case of low level in water storage tank feed water pump will
stop. A pressure switch at the solution pump discharge line shall be provided to by pass water to
solution tank. Solenoid valve in by pass line shall be energised by high-pressure signal from pressure
switch. Solenoid valve shall be installed in pipeline in a box at each junction house point to cater to
solution spray at belt discharge point and belt receiving point. Solenoid valve operation should be
interlocked with conveyor motor and load sensor unit. Conveyor motor running under load will draw
high current compared to conveyor running under no load. A current transformer located in the power
cable circuit will monitor conveyor motor current and shall be interlocked with the operation of solenoid
valve.
Chemically treated dust suppression system should be provided for the material transfer points in
junction houses.
02.3 Dry Fog Dust Suppression System
The Dry Fog Dust Suppression (“DFDS”- water atomization with compressed air) system works on
the principle of agglomeration. Water and compressed air are mixed in atomizing nozzles which
produces ultra fine droplets size fog when sprayed and achieve dust suppression though
agglomeration. Dust particles released from a material handling or processing plant which becomes
air borne, are made to pass through a blanket of extremely fine fog. The dust particles and the
micronic sized fog droplets collide and adhere to each other, thus increasing their mass. After a
series of such collisions, the mass becomes heavy enough to cause settlement of the agglomerates on
to the larger mass of the material being handled.
The System uses an air Driven Acoustic Oscillator Nozzle which is capable of producing supper fine
atomization of water droplets that greatly increase the dust particle to water droplet contact resulting
in settlement of dust. The fine droplets evaporate before wetting anything but the dust. The
approximate water addition is 0.1% of the weight of material being handled.
Description of Scheme
The DFDS system comprises main equipment installed at the application points and auxiliary
equipment installed at central water and compressed air supply point. Brief components of both types
of equipment are mentioned below:

• Main Equipment
The Main Equipment will include Spray Bar Assemblies fitted with Dual-fluid air Driven
Acoustic Oscillator Atomizing Nozzles, Pressure Regulating Units and Flow Activation
Stations for ON-OFF Control of the System and Instrumentation for Auto Operation.
• Auxiliary Equipment
The Auxiliary Equipment will include Water Storage and Pumping Unit with duplex Water
Filter, Compressors with air receivers and Associated Electrical Works, Air and Water
Piping, Enclosures etc.
02.4 Elements of dust suppression system
In general following equipment for dust suppression systems shall be considered as described in
respective equipment specification.

Spray nozzles
Spray nozzles for dust suppression systems shall be of fog-jet type and shall have a solid cone spray
pattern with a round impact area and minimum spray angle of 60º.
The nozzles should produce spray distribution of fine sized droplets at the given flow rate and
pressure and should provide complete coverage of the spraying area or zone.
The nozzle housing shall be made of cast aluminium alloy and the tip shall be of stainless steel
conforming to AISI-410 or SS-304 with SS strainer
The nozzles should be of self cleaning type with in-built filters made of brass or stainless steel.
Sprinklers
Circular swiveling type sprinklers shall be provided for dust suppression system of stockpiles to
spray water and prevent fugitive dust emission.
The brief specification of the sprinklers is as follows:
Size of inlet connection : To suit stand-post pipe size and fittings.
Sprinkler type : Circular swiveling type
Material : Cast Steel swing arm

Cast aluminum alloy body
SS nozzle

Throw : To suit size of stockpile and coverage
02.5 Design Criteria
1. The dust suppression systems shall be such that the work zone dust concentration for Total
Suspended Particulate Matter (SPM) shall be limited to 5mg/Nm³ over background level and
Respirable Particulate Matter ( RPM ) of particle size less than 10 microns should be limited to
2mg/Nm³ over background level unless otherwise specified in the job specification.
i. The capacities of the dust suppression systems shall be selected considering at least 10%
excess margin over the calculated values.
ii. Following Indian Standards shall be followed as design guidelines:
a. IS 638 : 1979 (RA 1999) Specification for Sheet Rubber

Jointing and Rubber Insertion Jointing
b. IS 800 : 1984 (RA 1998) Code of practice for general
construction in steel
c. IS 822 : 1970 (RA 2003) Code of procedure for inspection of
welds
d. IS 875 : Part 1 to Part 5: 1987 Structural design
(RA 2003)
e. IS 1239 : Part 1 : 2004 Steel Tubes, Tubulars and Other
& Wrought Steel Fittings - Specification
IS 1239 : Part 2 : 1992 (RA - Part 1 : Steel Tubes
2002) &
Mild steel tubes, tubulars and other
wrought steel fittings, Part 2 Mild steel
tubulars and other wrought steel pipe
fittings
f. IS 1364 : Part 1 to Part 6: 2002 Hexagonal nuts & bolts
g. IS 2062 : 2006 Hot Rolled Low, Medium and High
Tensile Structural Steel
h. IS 2712 : 1998 (RA 1999) Gaskets and packings - compressed
asbestos fibre jointing
i. IS 10221 : 1982 (RA 2006) Code of practice for coating and
wrapping of underground mild steel
pipelines
j. IS 11304 : 1985 (RA 2003) Code of practice for control of air
pollution in iron and steel plants
iii. The pipelines shall be self balanced without use of valves.
iv. The Successful Tenderer should calculate and decide the system capacities on their own
using the standard norms. However, in no case, the system capacities should be less than as
specified in job specification.

v. The dust suppression equipment shall be located near to the application area. Approach,
handling and hoisting facilities shall be provided for the equipment.
vi. The water line velocity for dust suppression systems shall be limited to within 1 m/s for
suction line and 2 m/s for delivery lines.
vii. Pipeline shall be of heavy class construction .
viii. The Successful Tenderer shall include pipe supports in their scope as follows-
a) In-house piping shall be suitably supported at approx. 2.5m intervals. Piping inside
the building shall be supported on the floor or from the column/ civil beam/building
structure/technological structure etc. as applicable. The location and type of
supporting arrangement shall be decided by the Successful Tenderer in consultation
with purchaser/or purchaser’s consultant.
b) Outdoor piping shall mostly be led through underground trench work with wrapping
coating arrangement. Overground trestles or pedestals may be used for specific
applications.
ix. Instrumentation
a) High level / Intermediate level / Low level switch in water tanks.

b) Pressure gauge at pump outlet of dust suppression system
c) Pressure/ flow switch at pump outlet
d) Sequence timer for sprinkler operation control as required.
e) Load monitoring switch for noting conveyor running on load
f) Flow meter and totaliser at pump discharge line for large DS system or as specified
in the job specification.
g) Flow activation station and Pressure regulating station for DFDS
h) Dry running protection for pumps.
03 Data to be furnished by the Tenderer along with offer
The following data shall be furnished by the tenderer along with offer.
Type of dust suppression system

Total capacity of dust suppression system
Make of equipment
Design water flow quantity
Work zone dust concentration
Noise level at 1m distance from the dust suppression equipment
Space requirement (L x B x H)
Support / Structure / Weathering shed for DS system
List of drives
Spray nozzle make rating, quantity
Spray nozzle material of construction

Sprinkler make, rating, quantity, throw

Sprinkler coverage diagram for stockpiles
Sprinkler material of construction
Load monitoring switch type, quantity and rating
Sequence timer type, quantity and rating
Solenoid valve type, quantity and rating
P&ID

4.0 SYSTEM SPECIFICATION OF VENTILATION SYSTEM (SS4)
01. General
test and supply/fabrication of Ventilation System with all accessories required to be installed to
achieve desired performance in all respects. Specific technical requirement of Ventilation System if
any shall be mentioned in the job specification/data sheet as furnished along with the Technical
Specification.
Brief description of Ventilation System is given below under clause No. 02. The point wise list of
data to be furnished by the tenderer along with the offer is mentioned below under clause No. 03.
02. Description
Ventilation system shall be provided to maintain proper working condition environment compatible with
human hygienic requirements and to maintain conditions necessary for proper storage of materials and
working of plant and equipment. The ventilation system shall generally include one or more items of
equipment and accessories such as fans, air filters, duct work, pumps, air washer, air supply grills,
dampers, insulation, instrumentation and controls, electrics, etc.
Ventilation system will be designed considering the climatic conditions prevailing in the region and the
plants will generally be installed in separate plant rooms independent of the served premises. The plant
rooms will be provided integral with and adjacent to the served premises at proper locations on
considerations of convenience of routing of ducts/pipes, availability of fresh uncontaminated air and
creating least disturbance to the adjacent premises in terms of vibration and noise.
Ventilation system will be provided with adequate measures for safety and fire fighting for fire
hazardous areas and shall be of flame proof/explosion proof construction.
In general following equipment for ventilation systems shall be considered as described in respective
equipment specification.
- AIR WASHER – ES2

- CHAIN PULLEY BLOCK – ES8
- DAMPER – ES11
- DUCTING NETWORK FOR HVAC SYSTEM – ES13
- FILTER DRY TYPE – ES15
- THERMAL INSULATION FOR HVAC APPLICATION – ES17
- PROPELLER FAN – ES20
- TUBE AXIAL FAN – ES23

Ventilation facilities
Buildings and shops will generally be designed to provide adequate natural ventilation. Mechanical
ventilation will be provided for premises where adequate ventilation cannot be provided by natural
means alone. Depending upon the specific requirement, the shops/buildings will be provided with
either exhaust ventilation or plenum ventilation. The system design will take into account the
requirements of air change as well as excess heat removal. Filters will be provided with plenum
systems. By plenum ventilation, the served premises will be pressurised to 2-3 mmWC to avoid
ingress of dusty air. Hot work areas will be provided with portable man-coolers for spot cooling.
Man-coolers will be provided also in a few other areas where the premises are manned and have high
heat radiation. General details and types of system to be considered is mentioned below. However,
specific requirement of ventilation system shall be provided in line with job specification
requirement.
The temperature of the Electrical premises and other premises served with washed air ventilation
shall not exceed 38°C right through the year. A minimum of 15 air changes shall be considered for
washed air system irrespective of heat load. Mist eliminator in air washer shall be made of PVC .
The temperature of the areas provided with dry pressurized ventilation or exhaust ventilation shall
not exceed 3 deg C above the ambient at any part of the year. A minimum of 20 air changes shall be
considered for dry pressurized and exhaust ventilation systems irrespective of heat load.
In cases where ventilation is provided using propeller or tube axial fans, care shall be taken to
provide multiple number of fans of equal capacity and spacing to ensure proper distribution of air.
The following design ambient data shall be considered for selecting and sizing various equipment for
ventilation systems :
SEASON TEMPERATURE RELATIVE

0
C (DBT) HUMIDITY (%)
SUMMER
Hot Zone side (20 m from 60
hot metal/liquid steel
handling)
Other zones 40.6 30
MONSOON 32.2 58
WINTER 6.4 -
Ventilation facilities for different premises
Location/Shop Facilities
Electrical premises, Switch gear rooms, Cable Pressurised ventilation with or without air washer
basements of Electrical sub stations as per job specification requirement
Compressed air stations Exhaust ventilation
Battery rooms Exhaust ventilation with acid proof fan and
explosion proof motor

Overground Pump houses Exhaust ventilation

Underground Pump houses Push-Pull type ventilation with 50% exhaust of
supply air.
Cable and Pipe tunnels Push-Pull type ventilation with 50% exhaust of
supply air. Fire barrier wall shall be provided to
sectionalize cable tunnels as per statutory norms
and site conditions
Hydraulic rooms Exhaust ventilation
Toilets / Stores / Pantry rooms Exhaust ventilation
Hot working spots Portable ventilation with man coolers
Following Indian Standards shall be followed as design guidelines:
IS 638 : 1979 (RA 1999) Specification for Sheet Rubber Jointing and Rubber Insertion
Jointing
IS 800 : 1984 (RA 1998) Code of practice for general construction in steel
IS 822 : 1970 (RA 2003) Code of procedure for inspection of welds
IS 875 : Part 1 to Part 5: 1987 Structural design
(RA 2003)
IS 1239 : Part 1 : 2004 Steel Tubes, Tubulars and Other Wrought Steel Fittings -
Specification - Part 1 : Steel Tubes
& &
IS 1239: Part 2: 1992 (RA Mild steel tubes, tubulars and other wrought steel fittings, Part
2002) 2 Mild steel tubulars and other wrought steel pipe fittings
IS 1364 : Parts 1 to 6: 2002 Hexagonal nuts & bolts
IS 2062 : 2006 Hot Rolled Low, Medium and High Tensile Structural Steel
IS 2712 : 1998 (RA 1999) Gaskets and packings - compressed asbestos fibre jointing
IS 4894 : 1987 (RA 1999) Centrifugal fans
IS 3588 : 1987 (RA 1999) Specification for Electric Axial Flow Fans
IS 8183 : 1993 (RA 2004) Bonded Mineral Wool Insulation
IS 2312 : 1967 (RA 2000) Propeller type AC ventilating fans
The following data shall be furnished by the tenderer along with the offers.
Type of ventilation system

Total capacity of ventilation system
Make of equipment
Design cooling load
Indoor climatic condition shall be maintained
Air change/hr
Noise level at 1m distance from the ventilation equipment
Noise level at served premises

5.0 ES1 - AIR HANDLING UNIT / FAN COIL UNIT
01. General
This specification outlines the minimum requirement for design, engineering, selection,
manufacture, test and supply of Air Handling Unit (AHU) / Fan Coil Unit (FCU) with all
accessories to make operation of Air Handling Unit (AHU)/Fan Coil Unit (FCU) complete in
all respects. Specific technical requirement of Axial Flow Fan if any shall be mentioned in
the job specification/data sheet as furnished along with the Technical Specification.
Brief description of the Air Handling Unit (AHU) / Fan Coil Unit (FCU) is given below
under clause No. 02. The equipment-wise list of data to be furnished by the tenderer along
with the offer is shown below under clause No. 03.
Job specification of the project shall be referred for any specific requirement.
02. Description
Air Handling Units (AHUs)
The AHUs shall be of fabricated construction, draw through type. The housing/casing shall be
of double skin construction. The frame work shall be of extruded aluminium profile frames
and peralluman nylon glass fibre reinforced corner joints. Double skin sandwich panels shall
be fabricated from inside with 22g galvanised sheet steel and outside with 22g high polymer
polyester coated (pre painted) galvanised sheet steel with protection films on top. Minimum
zinc deposition shall conform to Grade 275 of IS 277: 2003. The 25 thk. panels shall be PUF
injected with PUF density of 40 kg/m3 to ensure high rigidity and sound attenuation
characteristics. The unit sections shall be mounted on galvanized sheet steel channel &
aluminium die cast legs. Panels shall be fitted to Al frame work with neoprene gaskets &
screws. The framework of AHU casing shall be assembled by means of reinforced nylon
corners. Necessary supports shall be provided to slide the coil in the drain pan. Outlet shall
be provided on both sides of the drain pan. The fan section of the casing shall be provided
with access door. Aluminium die cast / Chrome plated hinges & handles shall be used in
access door. The AHU shall comprise of the following sections :
Filter section.
Cooling coil section
Fan section:
Filter section shall house 48-50 mm thk. pleated filters conforming to EU-3 Class. These
filters shall be vertically arranged in the frame and all mounted directly on AHU for ease of
removal.
Cooling coil section shall have chilled water cooling coils constructed with copper tubes and
fins of aluminium. Thickness of Cu tubes shall be minimum 0.75 mm. Fin spacing shall be
minimum 10 fins per inch and minimum thickness of fins shall be 0.16 mm. The fins of the
coil shall have a mild ripple with die formed directional guide channels to improve heat
transfer efficiency. Cooling coil header shall be of GI. Chilled water coils shall be provided

with suitable vent and drain connections. Drain pan shall be fabricated from minimum 22 G
stainless steel sheet and stainless steel nipple for drain connection. Necessary slope shall be
provided to facilitate fast removal of condensate. Drain pans shall be thermally insulated.
The entire assembly shall be mounted on PUF insulated bottom panel. Condensate drain
pipe of required length with sealing loop shall be provided and insulated. The drain from
drain pan shall be connected to floor drain. Air velocity through cooling coil shall not
exceed 2.5 m/sec and pressure drop across the coil shall not exceed 15 mmWC. Water
pressure drop through cooling coil shall be limited to 5 mWC. Normally AHUs shall have 6
rows of cooling coil. However, for 100 % fresh air application, 8 rows of cooling coil shall
be provided.
Fan section shall house centrifugal fan(s), which shall be forward curved, multiblade double
width double inlet type. Impeller blades shall be fabricated from heavy gauge galvanised
sheet steel or MS with spray galvanized. The wheel & housing shall be fabricated from
heavy gauge galvanised steel. The fan section shall be mounted above the coil section. Fan
speed shall not be more than 750 RPM. Flexible connection & volume control damper
(opposed blade type) shall be provided at fan outlet.
Blower fan shall be statically and dynamically balanced as per ISO1940 Gr 2.5. The first
critical speed of the rotating assembly shall be at least 25% above the operating speed. The
motor & blower assembly shall be isolated from the main frame by means of spring. Motor
& fan assembly shall be mounted on base frame and fixed on antivibration rubber mounts.
Motor shall be mounted on a slide rail to adjust the belt tension. Fan shall be coupled to
motor by V belts . V belts shall be provided with guards that do not impede the air flow to
the fan inlet. Fan static pressure shall be minimum 65 mmWC or more (as required based on
pressure drop calculation). All the AHUs shall be selected on the basis of min. 500 CFM/TR.
Chilled water flow through AHU will be controlled by 3 way mixing valve. A bypass line
around 3 way valves shall be provided. Make of 3 ways valve shall be Honeywell/ Johnson/
Siemens/ Sauter. Typical AHU connection details shall be as shown below:

Drain to nearest Drain Point
Temperature control in AHU shall be provided by modulating the chilled water flow in the
cooling coils by 3-way mixing valve.
Temperature switch and transmitter for monitoring of chilled water and served premises
temperature shall be provided.
Fan Coil Units (FCUs)
Fan coil units (FCUs) shall be of fabricated construction. They shall be wall mounted or
ceiling suspended type and shall be installed inside the served premises for small isolated
cabins / rooms. The following points shall be taken care of in FCUs.
• G.I. casing and powder coated components shall be provided.

• The fan deck assembly shall have easy access for maintenance.
• The unit shall be provided with 3 / 4 speed motor.
• The units shall be fabricated of minimum 1 mm thick galvanised steel duly powder coated
with polyester powder in broken white shade.
• The coil shall be minimum 3 row deep copper with internal groove for efficient heat transfer.
Minimum O.D. of the tube shall be 9 mm. The coil shall be provided with copper fins.
• Centrifugal forward curve fan, statically and dynamically balanced, shall be provided.
• The unit shall be provided with S.S. insulated drain pan of minimum thickness 0.8 mm The
insulation shall be cladded with 26G aluminium sheet.
• EU-3 class synthetic, woven washable type filters in aluminium frame shall be provided.
• Chilled water flow control and Remote operation shall be provided

A. General
a) Make & Model No.

b) Type of unit (Horizontal/vertical)
c) Overall dimensions (mm)
d) Weight (kg)
e) Noise level at 1 meter distance in dB(A)
f) Vibration level
g) Vibration isolations details
B. Fan Section
a) Air quantity (m3/hr)

b) Total/static pressure (mmWC)
c) Fan speed (RPM)
d) Fan dia (mm) & number
e) Balancing (Static and dynamic)
f) Fan motor (KW)
g) Type of fan/size/make
h) kW
i) Type of starter
C. Cooling coil
a) Coil fin materials

b) Tube dia (mm) and thickness
c) Fin size (mm)
d) No. of fins per inch
e) Outside coil surface (m2)
f) Face area (m2)
g) Row deep
h) ADP (deg C)
i) Bypass factor
j) Selected air velocity across coil (m/sec)
k) Make of cooling coil
l) Water through coil in m3/hr.
m) Water velocity through coil in m/sec.
n) Water coil pressure drop in kg/cm2
o) Water temperature in/out in degree C.
D. Filter section Pre filter
a) Type & make

b) Gross filter area (m2)

c) Velocity through filter (m/sec)
d) Pressure drop through filter when dirty & when clean (mmWC)
e) Efficiency with micron size
f) Filter box construction details
g) Overall dimensions & No. of filters
h) Fixing frame details
i) Recommended methods of cleaning

6.0 ES2 – AIR WASHER UNIT
01. General
manufacture, test and supply of Air Washer Unit with all accessories required to be installed
for HVAC application to achieve desired performance in all respects. Specific technical
requirement of Air Washer Unit if any, shall be mentioned in the job specification/data sheet
as furnished along with the Technical Specification.
Brief description of Air Washer Unit is given below under clause No. 02. The point wise list
of data to be furnished by the tenderer along with the offer is mentioned below under clause
No. 03.
02 Description
Air washer unit comprises of intermediate chambers at inlet and outlet and cell deck pad
chamber with water tank. Adapter section shall be provided for connecting air washer unit
with other equipment. Description of these items are given below:
The evaporative cooler shall be a self contained, single skin housing unit consisting of MS
intake louver of 75 mm deep with bird mesh, dry filter section , wet section and fan section .
The dry filter are 6 ply HDPE as specified . The wet section shall consist of cooling media,
water delivery system and sump including piping. The fan section shall consist of fan with
motor, drive arrangement to deliver specified air volume against specified static pressure.
Housing
The housing shall be constructed from 16G GSS whereas the tank shall be of SS304. Hinged
access panel shall be provided in the fan section of the housing on both sides. The access
panel shall be gasketed or formed to preclude air or water leakage into the interior of the
housing. The opening shall provide easy access to the blower to allow for service of the
motor, belt adjustment, bearing and possible shaft replacement. The housing shall be airtight
and waterproof.
The wet section shall consist of a sump, sides and top. A side lift – off or hinged panel for
media access and service of the float valve assembly for make up water shall be provided.
Removal and replacement of the media can be made through either a side lift off panel, top
removal, intake or discharge side of the section as the case may be . The wet section shall be
mechanically attached through the frame work to the fan section housing and shall be
supported across it’s entire width.
Internal components of the wet section shall be cooling media, water delivery system,
internal plumbing including a header pipe, make –up water, overflow and drain fittings.

Fan Section
The fan shall be heavy duty centrifugal type, DIDW backward curved impeller blades with
non- overloading characteristics and shall be capable of delivering air volume at external
static pressure as per requirement. The fan shall be AMCA certified for performance, noise
level with balancing grade of G6.3. The fan shall have solid, ground and polished C45 steel
shaft with self-aligning type bearing on both ends.
Vibration isolation shall be provided under the fan and motor and shall be of spring type.
Isolators shall be selected for minimum deflection. Flexible neoprene rubberized steel
impregnated connection shall be provided between the fan discharge and the housing at the
outlet duct connection.
Wet Section
Sump construction in wet section shall include TIG (fusion) welded corners and joints. The
sump shall be leak proof without the use of fillers, sealants or coatings. A media support
channel shall be included. This channel shall extend across the full width of the media. The
channel shall provide a minimum of 50% open area for water to flow freely from the media
into the sump.
An air bypass inhibitor plate shall be provided from the intake bottom of the media and
designed to preclude any untreated air flow under the media.
Stainless steel couplers with female pipe thread shall be welded into the sump and side to
provide for make-up water, overflow and drain. Make up, overflow and drain connection of
suitable size shall be provided.
Water distribution system shall be pump recirculating system with mechanical float valve
assembly to maintain water level in the sump. A bleed – off system shall be provided. Bleed-
off rate shall be minimum of 20% of evaporation rate. Pump shall be sized to deliver water
flow rate at the head and pressure required. Flow rate shall be determined at three (3) times
the evaporation rate plus the bleed-off rate. Pump shall be vertical submersible type of SS
construction. One working plus one standby pump shall be provided for each air washer.
Water distribution system shall incorporate perforated SS deflector trough to redirect the
water from the header pipe discharging upwards back on to the media to attain even
distribution across the full width of the media. A union shall be provided in the riser pipe
below the header pipe to facilitate removal of the header pipe.
Cooling media shall be celdek or glacier-cor or approved equivalent imported makes having
rigid media12” thick . This media shall be cross- fluted pad of cellulose material
impregnated with anti-rot slats and rigidifying saturants and wetting agents with at least 123
square feet of evaporative surface area per cubic foot of media. The transverse flutes shall be
60 degree and 30 degree with water flow in the direction of the 60 degree flute against the
air flow and air flow in the direction of the 30 degree flute with the direction of air flow.
Media shall have no more than 0.7” w.g. air pressure drop at 500 feet per minute face
velocity and shall develop a saturation efficiency of not less than 95% for 12” thick media.

Media access and removal shall be accomplished through a removable side or top panel
provided for this purpose or from the intake or discharge side of the media by removing
retaining rails provided for media support and removal purposes as specified.
Dry Filters
A Dry filter stage will be provided to cover the entire intake face area of the cooling module.
Filters are extended surface, pleated type , with 90% average dust arrestance efficiency, 2”
thick cleanable type with maximum velocity of 500 FPM. Filters shall be removable from
the intake side of the frame using bracketless lift and remove rack system or side removable
from a hinged panel provided for this purpose.
Low water level pump protection
A low water level protection system with float type level switch shall be used to provide dry
run protection for the pump.
Moisture drift eliminator
A moisture drift eliminator stage will be provided to prevent entrainment of water droplet in
the air stream from the cooling media. The mist eliminator shall be made of HDPV
Magnehelic Gauge
Magnehelic differential pressure gauge shall be provided to measure the pressure drop across
the cooling media to indicate the change in the resistance to air flow which relates to the
cooling media condition. The detector tubing shall be placed immediately upstream and
downstream of the media. Gauge shall be mounted externally on the unit for manual reading
of the pressure drop.
a) Air washing chamber with water tank

1. Make & Model No.
2. Overall dimensions (mm)
3. Weight (kg) with and without water
4. Air flow capacity in m3/h & Air flow velocity in m/s
5. Total Pressure drop, kgf/ m2
6. MOC, diameter and numbers of spray header pipes and nozzles
7. Make up water requirement
8. Details of make up, over flow, drainage, supply and return water pipe lines
9. Saturation efficiency
10. Amount of water and its pressure at the nozzle
11. Material of construction and thickness of casing, tank, air distributor plate
12. Water tank capacity
13. Details of mist /droplet eliminator : MOC, material thickness and depth.
b) Intermediate chamber

1. Size, Material of construction & Thickness of material
c) Adapter section
1. Size, Material of construction & Thickness of material
d) Re-circulating water system

1. Pump capacity & head, motor KW
2. Details of piping, fittings, strainer, valves
3. Instruments – pressure gauge, temperature gauge, water flow switch

7.0 ES3 – BAG FILTER
01. General
manufacture, test and supply/fabrication of Bag Filter with all accessories required to be
installed for Dedusting System application to achieve desired performance in all respects.
Specific technical requirement of Bag Filter System if any shall be mentioned in the job
specification/data sheet as furnished along with the Technical Specification.
Brief description of Bag Filter System is given below under clause No. 02. The point wise
list of data to be furnished by the tenderer along with the offer is mentioned below under
clause No. 03.
02. Description
Constructional Features
The bag filter assembly shall generally consist of the following : -
- Module shell.
- Hopper for each module with RAVs/Screw conveyor with RAVs.
- Storage hopper with rack & pinion gate valves
- Housing and roof panels.
- Tube plate.
- Compressed air / Nitrogen distribution system
- Access doors.
- Filter bags and cages.
- Inlet and outlet manifolds.
- Inlet & outlet dampers (Pneumatic or as specified in job specification)
- PTFE laminated filter bags / Pleated cartridge bags (for very fine dust application
like cast house dedusting, stock house dedusting, etc.)
- Nomex bags (for high temperature applications like lime kiln waste gas dedusting)
The bag filter shall have a plenum chamber, which distributes the incoming gas onto an
array of fabric filter bags. Dust particles shall be entrapped on the filter fabric, cake lining
the bag surface by straining, impingement, interception and electrostatic attraction. Rotary
air lock valves shall be provided at the bottom of bag filter hopper for dust removal & air
sealing. Manual slide gate shall be provided above each RAV to facilitate maintenance.
Normally bag filter casing thickness shall be 5 mm with sufficient stiffeners to withstand
design static pressure inside Bag filter chamber. Thickness of hopper shall be minimum 6
mm.
The inlet air plenum for the fabric filter should feature a tapered feed duct in order to ensure
uniform gas flow distribution to all cells.

Air entry to the cells should be directed uniformly by angles / deflection louvers to ensure
complete bag usage within the cell. Cross horizontal flows shall not impinge on the bags in
any area.
The bag fixing arrangement shall be such so as to enable easy and quick changing of bags.
Bags shall be hung as near as practicable to vertical so that the bags are not touching
anywhere along their length. The Bag filter shall have antistatic Bags and spark proof design
for the coke / coal and other explosive dust applications.
Particular attention shall be paid to the layout of the bags. A minimum distance of 75 mm
between the bags and the closest metallic surface such as walls or columns of the casing
shall be provided. The spacing between the bags shall be 50 mm (minimum). Relaxation in
bag spacing may be allowed as per manufacturer’s recommendation with proper
justification.
A weathering shed shall be provided on the top of the bag filter with sufficient clearance to
allow removal of bags for maintenance.
Required Air/cloth ratio
The contractor should design the pulse-jet fabric filter dust collector to operate under design
flow conditions with a gas/air to cloth ratio as 1.25 m³/min/m² unless otherwise specified in
the project specification. However, the same can vary from 1.0 to 1.8 depending on fabric
and dust material to be handled. In case of pleated cartridge bags, air to cloth ratio shall be
around 0.8.
Bag Cleaning
The bag filters shall be of on line / off line cleaning pulse-jet type as specified in the job
specification. Material of construction of bags shall be selected based on operating
temperature, dust quality, quantity, composition and air quality. The cleaning of bags shall
be carried out in a predetermined cycle by high-pressure pulse of dry compressed air or
nitrogen by automatic operation of solenoid valve with timer.
A differential pressure measurement system shall be provided across the bag house. As the
dust collects over the bags, the pressure drop shall be sensed by this system. As this drop
exceeds a preset value the differential pressure measurement system shall send a pulse to
start the bag cleaning operation.
Compressed air / Nitrogen shall be the cleaning medium and this shall enter the bags in short
surges thus inflating the bags. The dust shall collect in the hoppers provided and shall be
transferred by RAVs / conveyors to holding hopper. In general centralized Compressed air
network with air drier shall be provided to ensure supply of dirt and moisture free
compressed air for bag cleaning. Alternatively, surplus Nitrogen if available, may be
provided on case to case basis.

The successful tenderer shall supply compressor along with drive and accessories safety
valve, pressure gauge, air filter cum moisture separator unless otherwise specified in the job
specification.
The differential pressure across each module of bag filter shall not exceed 150 mmWC and
the bags shall be selected accordingly depending on the particle size of dust handled. In case
of pleated cartridge bags, the differential pressure across each module shall not exceed 120
mmWC.
Dust hopper/ Holding hopper
A dust storage hopper for each fabric filter module shall be provided. A inverted pyramidal
hopper with 65° valley angles shall be installed to collect the settled dust. Each of the bag
filter hoppers and storage silos shall be provided with 2 motorized bin vibrators. For hot gas
cleaning system hopper heater with thermal insulation shall be provided to reduce chance of
condensation in hopper. Normally storage hopper thickness shall be 8 mm unless defined in
the TS . 4.5m clear height shall be provided below pug mill / telescopic chute to facilitate
truck entry to collect dust
Platforms and access stair case
The minimum platform width shall be 1.2 meters. The platforms shall be located at the top
of hoppers, at the top of the bag filter unit and at the different levels required for
maintenance and operation of the equipment and dampers. A safe guard rail should be
provided on the platforms. Providing stairways and railing shall provide safe and easy access
to the platforms. Intermediate platforms shall be provided for the bag filters. Following
minimum structural members shall be considered.
Hand rail : 25 NB, IS:1239-1990

Post : 32 NB, IS:1239-1990
Access grating : 40 depth, 6 thick,
Stair : 40 C/C, 38° slope
Electrics & Instrumentation for Bag Filter System
The Electrics & Instrumentation for bag filters will consist of control panel, pressure switch
cum indicator in the compressed air line, differential pressure switches, solenoid valves, and
all other associated equipment. The brief specification of the major components will be as
given below :
Control panel for Bag filter
The control panel will be free standing, floor mounting, fabricated from 2.0 mm thick CRCA
sheet steel on a base channel of ISMC - 75), provided with cable gland plates, having synthetic
rubber gasketting, provided with double door & canopy and enclosure conforming to IPW-55.
The control panel will be factory assembled, wired with 1.1 kV grade PVC flexible wire of
copper conductor (minimum size 2.5 sq.mm), factory painted. The control panel will be
provided with following major equipment:

a) Incoming switch (minimum 32A, AC23 duty) with operating handle interlocked with the
door, HRC fuses, contactors, MCBs in the various circuits.
b) Control transformer of required VA rating having +/-5 percent and +/- 2.5 percent tappings
in the primary side of the control transformer with Isolating switches/MCBs in the primary
& secondary sides.
c) 24V DC full wave power pack complete with filter and protective elements and also
isolation cum short circuit protection both at AC and DC sides for power supply to solenoid
valves.
d) Auxiliary contactor for control power supply monitoring, interlocking, and controls etc.
e) Auto-manual selector switches, push button switches, indication lamps, various monitoring
devices, terminals (with 20 percent spare terminals) and other circuit elements required for
control and monitoring.
f) Solid state Bag filter timer.
The bag filter timer will be a solid state device suitable for dusty, tropical and specified
aggressive environment. The bag filter timer will be provided with internal semi-conductor
fuse protection and will have provision for pulse frequency setting and pulse duration setting
through independent operating knobs. The number of contacts in the timer will be equal to
number of solenoid operated valves so that the timer will energize only one solenoid valve at
a time and shall operate in sequence.
The Bag Filter Timer will provide timed sequential energisation of 24V DC operated
solenoid valves of bag filters. LEDs for each solenoid energisation, power ON in PCB, feed
back relay will be provided with potential free contacts which will close under following
conditions :
i) Fault in the PCB.
ii) Open contact in the output side connected to individual solenoid valves. The contact
will not close in the event of power failure to the controller.
iii) The sequential control (i.e. process) will start when the Differential Pressure (DP)
switch is actuated at the first set point for normal operation. The process will
continue till the pressure differential drops below the set value. When again the DP
switch is actuated the process will continue from the previous position (i.e. next
solenoid valve). However, when the power supply to sequential controller trips, the
process will stop and sequential controller is reset to first load position enabling the
process to start from the beginning.
iv) Apart from the DP mode operation defined above, the sequential timer shall also be
capable of operating under pre-set timer mode irrespective of differential pressure.

v) Sufficient space will be provided for installation of bag filter panel with required
front clearances for operation and maintenance including side and back clearances as
required.
Differential Pressure Switch
i) The differential pressure switch will have two sets of independent micro-switches. The first
set will be used for normal sequential cleaning operation of the bag filters as per lower set
value of differential pressure. This set point will be independently adjustable.
ii) The second set of N.O. contact will close at upper set value of differential pressure
representing clogged condition of bag filter and will be used for signaling and monitoring.
This set point will also be independently adjustable. The contacts will be rated for 5 Amp,
240V AC.
iii) The DP switch will be suitable for outdoor installation. The DP switch casing will be made of
pressure die cast Aluminum with enclosure conforming to IP-66.
iv) One number differential pressure switch with two set points will be provided across the Bag
filter for initiation of bag cleaning operation and for signaling and monitoring of clogged
condition.
v) Manometers shall be provided across each module and across the complete filter.
Solenoids
i) The solenoid coil will have encapsulated coil Class `F' insulated with a water proof (IP-65)
plug-on connector. The coil will be suitable for 24V DC having + 10 % to -15 % voltage
variations. The coil will be made of copper conductor.
Air Pressure Switch cum indicator
i) One number compressed air pressure switch cum indicator will be provided for each bag
filter system in the incoming compressed air pipeline of the bag filter. The pressure range
will match with the operating pressure. The switches will be snap action type with 1NO +
1NC contacts of 5A, 240 V AC. These contacts will be wired up to terminals in the bag
filter control panel. The enclosure of the air pressure switch will be pressure die cast
aluminum conforming to IP-65.
General Electrical Logic and Operating Principle of Bag Filter System
A. Mainly the differential pressure will govern the Dedusting Bag Filter system across the
Dedusting Modules.
The total electrical logic will be controlled by the Devices like Differential Pressure Switch
(DPS), solid-state sequential multi channel timer, solid-state master card, solenoid operated
Diaphragm valves, inlet compressed air line pressure switch (P.S.) etc. DPS will be connected
across the clean and dirty Air Chamber of the Bag Filter Module to measure the Pressure
Differential. As the Filtration process commences, there is a gradual build up of dust on the

Filter Bags which generates Differential Pressure. When this Differential Pressure attains a
pre-set value based on inlet dust concentration, type of dust and its particle size distribution, the
differential pressure switch will get energized and send signal to the master card located in the
control panel.
The master card will actuate the timer whose channels are connected with solenoid valves
mounted on the compressed air header-Air Manifold Tank. Through the timer, the solenoid coil
gets magnetized and makes an opening for the compressed air to flow from air manifold tank to
pulse header pipe.
The pulse duration time will be adjustable. During this time the solenoid coil will remain
energised allowing pulse air to flow. Energisation of next solenoid will take place in
sequence one after the other. The time gap between the two-solenoid energisation will also
be adjustable.
The process continues till the pressure differential drops below the set value. The D.P.
Switch then gets de-energised which in turn cuts off the timer resulting in de-energisation of
solenoid valves. The process will repeat again from the next solenoid valve based on the
pressure differential switch and signal from the master card.
A pressure switch mounted on the compressed air line will sense the available pressure and
dedusting system/ centrifugal fan will be switched off in case the available pressure falls
below the specified pressure in compressed air line.
B. Following sequential steps of operation will be followed before actually switching on the
main technological equipment to be dedusted:
1) Screw conveyor drives along with rotary air lock drive will be started first.
2) a) Setting differential pressure in differential pressure switch at the initial time

of commissioning and for re-commissioning after long gap with clean Filter
bags.
b) Power to timer to be switched ON
3) Fan motor to be started in the inlet Damper closed condition. After appropriate time
delay, fan inlet damper to be opened.
Bag filter
1. Make, type and quantity

2. Model No.
3. Type of bag filter
4. Capacity in m3/hr
5. Filtering area in m2

6. Fabric type
7. No. of bags
8. Diameter & length of bags in mm
9. Filtering velocity m/sec.
10. Pressure drop in mm WC
11. Weight of bag filter in kg (without dust)
12. Weight of bag filter in kg (with dust)
13. Efficiency of bag filter Vs particle size
14. Material / thickness of bag filter casing in mm.
15. Material / thickness of bag filter hopper in mm.
16. Compressed air requirement m3/hr.
17. Compressed air pressure
18. Compressed air quality
19. Velocity of air at inlet / outlet in m/sec.
20. Fixing arrangement of filter bags
21. Space requirement (L x B x H)
22. Rotary Air Lock Valve details
a) Quantity
b) Capacity in m3/hr (at 50% filling)
c) Speed in rpm
d) Motor rating kW & Pole.
23. Storage Hopper
f) Volume in m3
g) Type
h) Size (L x B x H)
i) Motor rating kW & Pole of rack & pinion type discharge gate.
j) Material / thickness of hopper
24. Support / Structure / Weathering shed for bag filter

8.0 ES4 – CENTRIFUGAL FAN
01. General
manufacture, test and supply of different type of Centrifugal Fan required to be installed for
HVAC, Dust Extraction, Combustion System process application with all accessories to
achieve desired performance. Specific technical requirement of Centrifugal Fan if any shall
be mentioned in the job specification/data sheet as furnished along with the Technical
Specification.
Brief description of different type of Centrifugal Fan is given below under clause No. 02.
The point wise list of data to be furnished by the tenderer along with the offer is mentioned
below under clause No. 03.
02. Description
Generally the fans shall be of limit load design. Centrifugal Fan design shall conform to IS
4894: 1987 (RA 1999). The fan shall be provided with drive motor, drive coupling/V-belt,
belt pulley, belt guard, fan inlet and outlet flexible connections, Guide plate (to prevent
direct contact of flexible fabric with air flow), variable inlet vane (VIV) damper, slide rails,
foundation plates, gaskets, base frame, vibration isolators, Anchor / foundation bolts and
nuts, fan inlet protection screen and other standard accessories unless otherwise specified in
the job specifications. In case standby fans or multiple working fans are connected to the
same duct line, fan outlet dampers shall also be provided in addition to VIVs. Further, all fan
inlet and outlet dampers shall be motorized or pneumatically operated in case of dedusting,
process and hot applications. All these items/materials and accessories shall be supplied with
the fan.
The fan shall be of rugged steel construction, industrial duty type and suitable for the
proposed project/plant. Capacity and static pressure of fan shall be as per job specification
requirement. Fan housing shall be of welded construction and provided with flanges at inlet
and outlet sides for duct connections. The housing shall be provided with lifting eye for ease
of handling and bolted type access door. The equipment shall be designed to permit ease of
access during inspection, maintenance and repair.
The fan unit shall be free from undue noise and vibration during operation; normally the fan
speed shall not be more than 1500 RPM, preferably less than 1000 RPM.
The fan shall be both statically and dynamically balanced as per ISO:1940. In general
HVAC system application balancing grade shall be of 6.3 and for process application
balancing grade shall be of 2.5
Casing & Impeller
Casing and inlet box shall be fabricated from mild steel (IS 2062: 2006) plate with
continuous welded joints and external stiffening to prevent vibration. Flanged, bolted and
gasketed access doors are to be provided in the equipment scroll and inlet box. The casing

and inlet box of each equipment / fan shall be split with bolted flange joints to allow for
removal of the impeller and shaft without removal of installed connecting ductwork.
Shaft seals shall be provided at the casing and the inlet box. The housing shall be fitted with
a bottom drain, not less than 50 mm dia. The equipment units and drive motors shall be
assembled on a common structural steel base plate wherever practical, to ensure mounting
rigidity.
Fan inlet / outlet velocity shall be limited to 15 – 22 m/s.
The fan impeller may be backward curved for clean air application and backward curved
radial tipped for dedusting applications unless otherwise specified in the job specification.
The impeller shall be of welded steel, designed for heavy duty and having non-overloading
(limit-load) power characteristics. The first critical speed of the rotating assembly shall be at
least 25% above the operating speed.
Fans for ventilation systems shall have following minimum thickness of materials for
different parts unless otherwise specified in job specification
a) Capacity below 20,000 m3/hr :
Casing : 3.15 mm
Back plate : 4 mm
Impeller : 2.5 mm
b) Capacity above 20,000 m3/hr and below 50,000 m3/hr
Casing : 4 mm
Back plate : 6 mm
Impeller : 3.15 mm
c) Capacity above 50,000 m³/hr
Casing : 6 mm
Back plate : 8 mm
Impeller : 6 mm
For dedusting and process applications, thickness and material of construction will be
defined in the job specification depending upon specific.
Shaft
Shaft shall be steel bar stock or forging made of material conforming to EN 8 and machined
all over. The shaft with equipment impeller and half coupling mounted is to be dynamically
balanced.
Drive Coupling
The fan shall be directly driven. The drive coupling from the motor to fan shaft is to be of

flexible type suited for heavy duty and industrial application. A protective guard is to be
fitted over exposed drive shafts and coupling. Belt drive may be allowed only in case of
ventilation fans on specific approval of purchaser / consultant.
Bearings
The bearings are to be outside of the equipment casing and inlet box shaft seals and shall be
of heavy duty, self aligning, anti-friction, sump oil / grease lubricated type with readily
accessible lubrication points. Adequate temperature protection shall be provided for the
bearings in order to avoid running the unit without lubrication. Bearings shall be selected
with ample safety factor for longer life.
Bearing housings are to be split horizontally, fitted with multiple seals to exclude dust while
retaining lubricant and shall have provision for mounting temperature and vibration sensors.
Guards
For all external rotating parts like coupling, belts, pulley etc., guards fabricated out of sheet
metal shall be provided.
Base Frame
Fabricated steel bracket of M.S. angles, channels and chequered plates shall be provided to
take static and dynamic load of the fan and motor assembly. The base frame shall be
fabricated of mild steel and shall support equipment housing, bearing pedestals, coupling
guards and drive motor where ever practical. All support mounting faces are to be
machined after all welding is completed. Jacking screws are to be provided wherever
necessary, to allow both lateral and longitudinal movement of equipment.
Noise Emission
The noise level of fan shall not exceed 85dB(A) at a distance of 1 m when running at full
load.
Vibration Standard
The fans and duct work shall be designed for minimum vibration. Maximum allowable
vibration level shall be as per VDI – 2056 guide lines. Sufficient number of suitable
vibration isolators of approved make shall be provided to ensure isolation of vibration from
the equipment to foundation as per requirement.
Vibration and Temperature Sensors
For all dedusting and process applications, two (2) vibration sensors and two (2) temperature
sensors (RTD) shall be provided for each fan and eight (8) temperature sensors (RTD) shall
be provided for each motor.

03. Data to be furnished by the Tenderer along with offer:-
a) CENTRIFUGAL FAN
1. Make & Model No.

2. Quantity, no.
3. Type of blade
4. Capacity, m³/h
5. Static pressure and total pressure, mm WC
6. Operating speed, RPM
7. Critical speed, RPM
8. Shaft power, kW
9. Total Efficiency, %
10. Motor rating, kW / pole
11. Fan Characteristic Curves
12. Impeller Diameter in mm
13. Impeller weight in kg.
14. GD2 value
15. Velocity at inlet & outlet of fan, m/sec
16. Static weight & dynamic weight of fan and motor, kg
17. Coupling details/V-belt details
18. Vibration level
19. Vibration isolator type & quantity.
20. Outlet damper size
21. Material of construction & thickness of scroll, blade, shroud,
back plate, shaft diameter in mm
22. Noise level at 1m distance in dB(A)
23. Bearing details
24. Acoustic lagging / silencer, if included :
i) Material of construction
ii) Insertion loss
25. Overall size
26. Drive Motor rating suggested
27. Special constructional feature, if any
a) FAN DRIVE MOTOR DETAILS
1. Type & make

2. Voltage, phase & frequency
3. Rated power, kW
4. Speed, RPM
5. Starting/ pull out torque
6. Starter details
7. Line current
8. Starting current
9. Overall efficiency
10. Class of insulation
11. Type of enclosure
12. Any other information

b) VIV Damper
1. Make, model and type

2. Diameter of VIV
3. Type of actuator
4. Motor kW/pole
5. Material of construction and thickness

9.0 ES5 – CENTRIFUGAL PUMP
01. General
manufacture, testing and supply / fabrication of Pumps with all accessories required to be
installed to achieve desired performance in all respects. Specific technical requirement of
Pumps if any shall be mentioned in the job specification / data sheet as furnished along with
the Technical Specification.
Brief description of Pumps is given below under clause No. 02. The point wise list of data
to be furnished by the tenderer along with the offer is mentioned under clause No. 03.
02. Pumps
The pumps shall be designed, manufactured and tested as per following applicable IS
standards:
IS 5120: 1977 (RA 2001) Technical requirements for rotodynamic special

purpose pumps
IS 9137:1978 (RA 2002) Code for acceptance test for centrifugal, mixed
flow and axial pumps - Class C
IS 6595: Part 2: 1993 (RA 2002) Horizontal centrifugal pumps for clear, cold water:
Part 2 General purposes other than agricultural and
rural water supply - Specification
In case any other international standards are used, the same shall be subject to approval of
the Purchaser and the pumps shall be suitable for the duty conditions and capacities as
indicated in the job specifications.
The centrifugal pumps along with their auxiliary equipment shall be suitable for the required
duty conditions and shall be designed and manufactured for continuous duty at full load.
All the pumps shall be capable of developing the required total head at rated capacity for
continuous operation. The pumps shall operate satisfactorily at any point on the H-Q
characteristic curve over a range of 50% to 130% capacity or capacity corresponding to 75%
of the total head whichever is lower.
Capacity vs discharge pressure curve for each pump shall preferably be continuously
drooping from the shut-off point to the rated operation point and be suitable for parallel
operation. The pumps shall be designed to avoid cavitation at any of the operating points.
The required duty range for a pump shall be on stable portion of its head-capacity curve
close to the best efficiency point. The head developed at the best efficiency point shall be
close to the required differential pressure so that throttling is not required at pump discharge.
The equipment and auxiliaries shall be designed for quick and economical maintenance.
The equipment shall be easily dismantleable without disturbing the suction and delivery pipe
connections.

The equipment design shall incorporate provisions for reduction in noise level.
The rotating elements of the pumps shall be checked for critical speed in bending as well as
torsion. The critical speeds shall be at least 30% above the normal speeds for units with
flexible shafts and at least 20% above the maximum operating speed in case of stiff shafts.
All passages inside the pump casing and impellers, which may be inaccessible to machining,
shall be ground to a smooth finish as far as practicable.
All pumps preferably shall be horizontally split / end suction type with maximum RPM of
1,500. However, mono-block type pump may be provided only in case of small pumps of
capacity less than 15 m³/h for air washer applications. Multistage pumps shall be provided
for low flow high head applications like dust suppression.
Material of construction
Casing - C.I
Impeller - Bronze
Bearing Bracket - C.I
Shaft protection sleeve - Bronze
Wearing ring - Bronze
Shaft - EN8
Common base frame for pump & motor - M.S
The direction of rotation shall be clearly marked either by incorporating it on the casing or
by an arrow on a separate metal plate securely fitted to the casing.
A stainless steel name plate of 2 mm thickness shall be provided and securely attached by
stainless steel pins at an easily accessible point on the pump. The plate shall be stamped
with the following minimum information :-
a) DESIGN CAPACITY
b) TOTAL HEAD
c) SPEED
d) MOTOR RATING
e) MODEL NUMBER
f) MANUFACTURER’S SERIAL NUMBER
g) WEIGHT OF EQUIPMENT
h) TAG NUMBER
The total head-capacity curve shall be continuously rising towards the shut-off. The shut-off
head shall be at least 110% of the total head.
The required NPSH at duty point shall be at least 1.0 m lesser than the available NPSH .
The velocity of vibration shall be within 4.5 mm/sec.
The power rating of the pump motor shall be larger of the following

a) 110% of the power required at the duty point.
b) For parallel operation, motor rating should be sufficient enough for running of single
pump also.
The common base frame for pump and motor shall be in one piece with suitable holes for
grouting. Adequate space shall be provided between pump drain connections and base plate
for installation of minimum 15mm drain piping. Pumps shall be supplied with suitable drain
pans or drain rim type base plates with valved drain connections.
Coupling guard, made of expanded metal and bolted to the base plate shall be supplied for
all pumps.
Pumps will be supplied with flexible coupling. Back-pull out type pump shall be provided
with spacer type coupling.
Standard hydrostatic test shall be conducted on the pump casing with water at 1.5 times the
maximum discharge head or twice the rated discharge head whichever is higher. The
hydrostatic tests on the casing shall be conducted for a minimum duration of 30 minutes.
Casing
The casing shall be of cast iron and shall be designed for a pressure not less than the shut-off
pressure at the highest operating speed plus the maximum pressure that may be encountered
at the pump inlet. In addition, CI casing shall have corrosion allowance of not lower than 3
mm.
Impellers
Impeller shall be of bronze. Impellers and balancing drums (if provided) shall be statically
and dynamically balanced. Dynamic balancing shall be at the operating speed of the pump.
For multi stage pumps, all the impellers shall be assembled together for balancing.
Provision shall be made for adjusting the clearance between the impeller and the casing to
compensate for wear. The impeller shall be keyed or screwed on to the shaft in such a way
that it does not come-out due to reverse rotation of the pump.
Shaft
The shaft shall be of EN-8 or equivalent and shall be designed for critical speed. The ratio of
critical speed to speed of shaft shall be not less than 1.3 for solid shafts.
The deflection in line shaft shall not exceed 1 mm per meter of length. All shafts above 150
mm diameter shall be ultrasonically tested. Shafts shall be checked for endurance and
strength. Change of sections in shafts if considered shall be made with due allowance for
stress concentration. Shafts shall be machined to close tolerance for mounting on impeller
bearings, shaft seal, shaft sleeve, shaft coupling etc. The magnitude of shaft deflection at the
face of the shaft seal shall not exceed 50 microns.

Coupling and coupling guard
Horizontal pump sets shall be provided with flexible couplings of pin and bush type and
shall be constructed of metallic materials except for bush which shall be of rubber materials.
Coupling shall be properly keyed in place and the cylindrical fit shall allow simple removal
of the coupling in the field. Spacer type couplings shall be provided for end suction pumps.
Removable coupling guards shall be supplied and mounted. Guards shall be sufficiently
heavy and rigid to provide adequate safety for working personnel.
Shaft sealing
Shaft seals shall be provided to prevent leakage out of, or into, a pump over the range of
specified operating conditions. The seals shall be suitable for variations in inlet conditions
that may prevail during start-up and shut down. They shall be accessible for inspection and
replacement without disturbing any part of the installation.
Bearing
Two bearing assemblies shall be provided, one within the frame to carry radial load only and
the other to carry both radial and axial thrust. Bearings shall be of manufacturer’s standard
design, antifriction type, oil / grease lubricated. Suitable thrust bearings shall be provided in
the pump to take total thrust of the pump including hydraulic thrust. Thrust bearings shall be
of oil lubricated type with suitable cooling arrangement. Motor thrust bearing shall be
designed without water cooling arrangement. Suitable tapped holes shall be provided for
refilling of oil in the bearing housing.
All the vertical pumps shall be provided with separate thrust bearings with proper lubrication
and cooling facilities as required so that the thrust and other vertical loads due to the moving
parts are not transferred to the prime mover.
Base plate
All horizontal pumps shall be supplied with sturdy base plates as per manufacturer’s
standard, common to pump and drive. Base plates and pump supports shall be constructed
so rigidly and the unit so mounted as to minimize misalignment due to piping strain, internal
differential thermal expansion, etc. Base plates shall be fabricated from MS channels.
Companion flanges, bolts, nuts & gaskets
Plate flanges having raised face shall be provided at suction and delivery side of pumps and
they shall be of mild steel and conform to table 17 of IS: 6392-1971 (R.A.1988). Slip on
raised face flanges to 150 Lbs. class conforming to ANSI B16.5 shall also be acceptable.
Black bolts and nuts conforming to IS 1362-1992 shall be provided for the companion
flanges.
CAF gaskets of 1.5 mm thickness conforming to IS: 2712-1979 (R.A. 1994) shall be
provided for the companion flanges.

03. Data to be furnished by the Tenderer along with offer :-
1. Make and model no.

2. Type of pump
3. Capacity in m3/hr.
4. Total head in m WC
5. Quantity
6. Material of Construction of Shaft, Impeller and Casing
7. Pump speed (rpm)
8. Shaft power
9. Drive details – Motor make, kW, Class of insulation and Frame size
10. Bearing type & make
11. Type of coupling
12. Vibration level
13. Noise level at 1 m distance
14. Duty
15. Weight of pump & motor separately
16. Characteristic curves for pumps
17. Type of liquid to be handled

10.0 ES6 – VAPOUR ABSORPTION M/C (VAM) BASED CHILLER PLANT
01. General
manufacture, test and supply of Vapour Absorption Machine (VAM) based Chilled Water
Plant with all accessories required to be installed for HVAC and process cooling purpose to
achieve desired performance. Specific technical requirement of VAM if any, shall be
mentioned in the job specification/data sheet as furnished along with the Technical
Specification.
Brief description of VAM is given below under clause No. 02. The point wise list of data to
be furnished by the tenderer along with offer is mentioned below under clause No. 03.
02. Description
VAM shall be completely factory assembled and wired in a single package complete with
evaporator, absorber, two stage generator, condenser, heat exchangers, solution pump,
refrigerant pump, vacuum pump for purging, starter panel (starting control), micro processor
control panel (safety & operating controls), all necessary sensors/ instruments, internal
cabling and piping work.
VAM shall be supplied with full operating charge of refrigerant (water), lithium bromide
solution (with non toxic inhibitor) and octyl alcohol for purging. Lithium Bromide and Octyl
Alcohol shall also be supplied for for one year consumption. The machine shall be factory
tested under operating conditions.
The absorption machine shall be horizontal shell and tube with unit shell which shall be
horizontally divided into two parts. The upper part of VAM shall contain the condenser and
the low temperature generator. The evaporator and the absorber shall be housed in the lower
part. The high temperature generator shall be provided either on the side of the machine or at
the top depending upon the type of the machine. The heat exchangers shall be horizontal
shell and tube type and fitted beneath the unit shell.
Material of construction of different components of the vapour absorption machine shall be

as follows.
Shell & Tube sheet: MS (IS 2062)

Tubes - evaporator; absorber; condenser: high quality seamless grade Cu (70%) -Ni
(30%) or SS 316 L
Tubes - low temperature generator: Copper or Stainless Steel
Tubes in high temperature generator: Stainless Steel
HTG Tube sheet: SS316 L
Impeller for Refrigerant & Solution Pumps: Stainless Steel
Casing for pump: CS
The vapour absorption units shall be complete with the following units and features

Hot well pumps (1w +1s)

Cold well pumps (1w +1s)
Condenser water pumps (1w+1s)
Induced draft counter / cross flow FRP cooling tower with FRP / RCC basin & PVC
fills. Cooling tower basin shall be at higher elevation than the condenser water
pump.
Chilled water/ condenser water piping.
Valves/ strainers etc in pipe lines.
RCC hot well tank & cold well tank and insulation of tanks.
Captive Soft water plant for treating make up water.
Evaporator with finned tubes.
The evaporator portion and support structure should be painted with chloro-rubber
paint
Absorber
High Temperature Generator with ‘U’ tube configuration for better thermal
expansion arrangement having.
Unless otherwise specified in the job specifications, the VAM shall be double effect
steam fired type with HTG having SS straight tubes.
Low Temperature Generator
High temperature and low temperature heat exchanger for improving cycle
efficiency.
Sight glasses shall be fused type.
Drain cooler to effectively cool steam condensate & improve energy efficiency.
Solution & Refrigerant pump with necessary isolation valves.
Vacuum pump with motor and complete assembly
All necessary electrics, controls and instrumentation
PLC based control panel.
Pneumatically operated steam control valve complete with air set, regulator, valve
positioner, I/P converter, solenoid valve on air line complete in all respects.
Compressed air lines shall be provided by the Contractor as required for AC system.
The compressed air line shall be drawn from the existing header.
Imported high quality floats/relays for HTG & evaporator levels.
First charge of Lithium Bromide with inhibitors and for one-year consumption.
First charge of refrigerant (water)
First charge of Octyl Alcohol and for one-year consumption.
The unit will be complete with all necessary valves, mountings, instruments,
thermometers, etc. for normal and satisfactory operation.
All pressure and temperature gauges should be glycerin filled with shatter proof
glass and isolation valves for maintenance, calibration and replacement
The unit will also be complete with necessary MS pipes, pipe fittings, valves,
interconnecting pipes, internal piping, etc. as per requirement.

Insulation of chilled water pipelines, steam / water pipelines, valves, fittings, etc.
Painting.
All necessary safety & control switches shall be provided for normal and
satisfactory operation of chiller unit.
MCC, starter panel, electrics, instrumentation etc.
The steam system shall have Auto PRDS System comprising of pressure reducing &
de-superheating station with metering pumps.
Necessary interconnection of the vapour absorption units shall be provided for
flexibility of operation.
The vapour absorption machine shall be designed in such a manner to avoid
crystallization. In the rare chances of crystallization, the machine shall have de-
crystallization protection and auto de-crystallization operation control.
Steam piping (from battery limit onwards) along with all necessary valves (shut off
valve, flow control valve etc.), instruments & safety devices. IBR approval shall be
in the scope of Contractor.
Steam pressure & temperature control system.
Steam condensate disposal arrangement. Steam condensate line shall be of SS
Following safety and controls will be provided with the vapour absorption machines:
Motor overload relay for solution, refrigerant and purge pump

Motor coil temperature cutout for solution and refrigerant pump
Low refrigerant temperature cutout
Chilled water flow failure cutout
First stage generator pressure cutout switch
First stage generator solution temperature cutout
Automatic start/stop temperature cutout
Solution dilution control
Decrystalization operation control
Solution pump start condition switch
Automatic start / stop arrangement
Automatic capacity control system consisting of steam control valve and automatic
temperature controller, to control the refrigerating capacity in accordance with the load
requirement. Capacity control should be smooth, stable and step-less from 100% to 20%
load.
The Contractor shall furnish complete details of electrics, control and instrumentation
system.
Mandatory spares for 2 years, including spares part list shall be provided by the Contractor.
Necessary instruction manual, P&I diagram, control panel drawing, GA drawing and
foundation drawing shall be furnished.

The steam flow control valve should be installed at a maximum height of 1m from the floor.
The VAM shall be designed in such a manner to avoid crystallization. In the rare chances of
crystallization, the machine shall be provided with de-crystallization protection and auto de-
crystallization operation control.
Automatic control of chilled water outlet temperature shall be provided by controlling steam
flow rate.
VAM shall have connectivity for communication, data logging, history charts, mimics to PC
at remote location.
Solution & refrigerant pump drive shall be hermetically sealed.
Insulation of VAM unit shall be provided.
Fouling factor for condenser & evaporator shall be 0.001 & 0.0005 hr-ft² °F/ Btu
respectively.
Specific technical requirement about type of waste heat energy for the operation of VAM
machines if any shall be mentioned in the job specification/data sheet as furnished along
with the Technical Specification. Vapour absorption m/c shall be chosen to operate normally
with Saturated steam in the pressure range 0.5 to 10 kg/cm2 g. However, in specific cases
operation with Hot Water in the temperature range 90 -135°C may be provided.
Vapour absorption m/c shall be chosen not only to meet the full load design, but also to
perform efficiently at lower loads and at lower condenser water inlet temperature
(particularly during winter season). Necessary condenser water temperature control shall be
provided. Tenderer shall furnish the inlet condenser water temperature range of their
machine.
Evaporator heat exchanger design shall meet the chilled water inlet & outlet temperature
required for air conditioning requirement or for process cooling requirement as mentioned in
the job specification.
In case of multiple units, necessary interconnection of the vapour absorption units shall be
provided for flexibility of operation.
03. Data to be furnished by the Tenderer along with offer :-
General
• Application
• No. of units (working + standby)
• AC plant capacity (TR)
• Refrigerant / Absorbent
• Type of VAM machine ( single effect/double effect)
• Charge (Refrigerant & Absorbent) of all circuits (kg)

Design & construction features
General
• Make/Type
• Model No.
• Maximum power required (kW)
• Type of capacity regulation
• No. of steps of control
• Type of drive
• Range of load operation
• No. & type of heat exchangers
• Condenser tube
• Chiller tube
• Shell
• HT generator tube /tube sheet
• LTG tube
• Casing / Impeller for pump
• Bolts /Nuts
• Base frame
Auxiliaries
• High /Low pressure gauge (Yes / No)
• High /Low pressure switches (Yes / No)
• Water differential switch (Yes / No)
• RTD (Yes / No)
• Automatic unloading device (Yes / No)
• Solution pump (Yes / No)
• Refrigeration pump (Yes / No)
• Vacuum pump (Yes / No)
• Local control panel (Yes / No)
Performance
• Design hydraulic /pneumatic test pressure (kg/cm2)
• Condenser cooling water side fouling factor
• Water fouling factor for evaporator
• Water fouling factor for absorption
Driver motor details
Condenser
General
• Type /arrangement
• Manufacturer /model no.

Performance
• Fluid flow rate (m³/hr)
• Inlet/outlet temp (Deg. C)
• Fluid velocity (m/s)
• Pressure drop (allowable / calculated)
• Fouling resistance
Construction
• Bundle /Nozzle orientation
• Design (Hydrostatic) test pressure and duration
• No. of passes
• Corrosion allowances
• Connection size (inlet / outlet)
• Thickness (Min/Average)
• Length of tubes
Material of construction and their codes

• Shell
• Tubes
• Tubes sheets
Auxiliaries
• Thermo wells
• Pressure gauge
• Vent connection with valve
• Drain connection with valve
• Relief valve / fusible plug
Absorber
General
• Type arrangement
• Manufacturer / model no.
• Performance / selection chart furnished
Auxiliaries
• Thermo wells
• Pressure gauge (manometer)
• Vent connection with valve
• Drain connection with valve
• Relief valve
• Anti freeze thermostat
Refrigerant piping, valves & fittings (Included / Not included)

Piping details
Valves (included / Not included)
Solenoid valves (Liquid line) - (Included / Not included)
Charging valve (included / Not included)
Sight glass (included / Not included)
All necessary supports for refrigerant piping provided (Yes / No)
Chiller data
• Chilled water inlet temp. (Deg. C)
• Chilled water outlet temp. (Deg. C)
• Chilled water flow (CMH)
• Steam pressure inlet to PRDS
• Steam pressure & temperature inlet to VAM
• Steam consumption

11.0 ES7 – VAPOUR COMPRESSION BASED CHILLER PLANT
01. General
manufacture, test and supply of different types of Direct Expansion (DX) type / Chilled
Water generator equipment with all accessories required to be installed for HVAC and
process cooling purpose to achieve desired performance. Specific technical requirement of
Direct Expansion (DX) type / Chilled water generator type equipment if any, shall be
Specification.
Brief description of different type of Direct Expansion (DX) / Chilled Water generator Type
Equipment is given below under clause No. 02. The point wise list of data to be furnished
by the tenderer along with the offer is mentioned below under clause No. 03.
02. Description
The Vapour Compression based chilled water plant shall include

• Package type chiller unit comprising of water cooled condenser, hermetic/semi hermetic
sealed reciprocating /screw / centrifugal compressor, refrigerant pipe line, instruments
and controls. Chillers shall essentially be ARI certified.
• The chiller shall be supplied with full operating charge of refrigerant R-134a / R407c
R123 / R22 & lubricating oil. Chiller performance shall be ARI certified as per ARI
standard 550-92. Cooler (evaporator) shall be dry expansion type .
• Insulated chilled water piping network with valves (Shutoff, flow control, float, etc),
strainers, instruments and fittings.
• Thermal insulation over condensate drain line to avoid condensation over cold surface
• Chilled water / cold well / hot well pumps
• Condenser water pumps
• RCC hot well tank & cold well tank and their Insulation.
• Thermally insulated expansion tanks located at the top most location of the entire chilled
water piping network.
• Condenser cooling network comprising Induced draft counter / cross flow FRP cooling
tower with FRP / RCC basin & PVC fills, pipes & fittings, valves (Shutoff, flow control,
float, etc), strainers and instruments. Cooling tower basin shall be at higher elevation
than the condenser water pump. Cooling tower shall be rated for 20% higher capacity
than chilled water plant and shall be supplied with one standby cell.

• Multiple air handling units / Fan coil units as applicable, with fan, filter, cooling coil for
different premises.
• Ducting network with damper, diffuser, acoustic and thermal insulation.

• Humidity control arrangement with strip heater, pan humidifier and humidistat.
• Make up air filter with damper in different AHU rooms.
• Temperature / Pressure gauges, Magnetic type flow meters in chilled & condenser water
lines
• MCC, starter panel, electrics, instrumentation etc.
Chemically treated water shall be considered as make-up for condenser cooling system and
also as make up to the chilled water system. Necessary water treatment / softening plant shall
be considered by the successful tenderer.
Technical specification of equipment
The equipment will be normally as per brief description of main equipment given below
unless otherwise specified in the job specifications:
Base Frame:
Water chilling package base frame structure will hold the following :
A. Semi Hermetic Reciprocating / Centrifugal / Screw refrigeration compressor

B. Condenser
C. DX water chiller
D. Associated refrigerant piping, fittings and controls.
Normally Water chilling package shall be of floor mounted two tier type.
Direct Expansion (DX) type frame structure will hold the following :
A. Semi Hermetic Reciprocating / Centrifugal / Screw refrigeration compressor

B. Condenser
C. Associated refrigerant piping, fittings and controls.
Resistoflex neoprene pads shall be used as vibration isolator between common base frame and
floor and spring cup type vibration dampers shall be used between compressor and common
base frame.
Refrigeration compressor
Refrigeration compressor shall be of multi cylinder semi-hermetic reciprocating / centrifugal /

screw type. The compressor shall be driven by TEFC motor through V-belt drive / flexible
coupling direct drive. Compressor design shall conform the required safety measures as per

IS-11461-1985, RA 2001 guide lines and testing of compressor shall confirm to IS-5111-1993
/ ISO 917: 1989, RA 1999.
Compressor housing cylinder head shall be of fine grained cast iron. Valve plates shall be of
cast iron or stainless (ring plate type). The piston shall be made from light metal alloys
preferably Aluminum with one oil groove and two compressor rings. The connecting rod shall
be of forged steel of Aluminum alloys with integral bearing surfaces on crank and piston pin
ends. Crank shaft shall be of forged steel with drill for oil distribution. Crank shaft shall be
statically and dynamically balanced to eliminate vibration. In case of shaft seal, the same shall
be positive acting to prevent the leakage of refrigerant and infiltration of air during compressor
operation and idle periods.
The main bearing shall be of self-alignment, horizontally split and lined with anti-friction
bearing metal.
Compressor shall be lubricated by forced feed lubrication system comprising of reversible,

positive displacement gear type oil pump, interconnecting pipes, filter cartridge, oil strainer,
sight glass, oil drain valve. If required, oil coolers shall be provided. Oil safety switch shall be
provided to stop the compressor in case of excessive or lower oil pressure.
The refrigerant compressor shall be equipped with built-in automatic unloaded starting
arrangement.
Electrically operated crankcase heaters suitable for specified power supply system shall be
provided. Heaters shall be automatically actuated when compressor is stopped.
The compressor shall have automatic capacity control in addition to manual capacity
regulation. Capacity regulation shall permit the operation of the compressor at part load with
reduced power consumption.
The following accessories and instrumentation shall be considered for the refrigerant
compressor:
A. Large suction strainer, muffler.

B. Service stop valves for suction and discharge sides.
C. Pressure and temperature gauges for suction, discharge and lubricating oil.
D. Common base frame for compressor and motor including coupling.
E. Flexible coupling / V-belt drive.
F. Coupling belt guard.
G. Crank case heater.
H. Oil chargers and oil check valves.
I. Electric motor, drive set.
The following controls and safety devices shall be provided for the compressor:
A. Oil safety switch.

B. High and Low pressure cut outs
C. Relief by pass valves.
D. Spring loaded, built-in safety valves for each cylinder.

E. Indicating lamps and alarms.

F. Timer to set time interval between starting and loading the compressor.
Condenser
The condenser shall be of horizontal, shell and tube type construction with water flowing
inside the tubes and the refrigerant gas condensing outside the tubes. Alternatively, as per job
specification requirement air cooled type condenser may be provided. Condenser design shall
confirm to IS-11327- 2007 guide lines.
The condenser shall be equipped with integral finned type, solid drawn, seamless copper tubes.
Multi-pass construction condenser shall be provided. It shall be designed for proper number of
passes to give optimum water velocity, efficient heat transfer and allowable pressure drop.
The condenser tubes shall be rolled into the grooves of tube sheets at either end to ensure a
perfect water and air tight joint.
Adequate baffling arrangement shall be used in the condenser for improved heat transfer.
Condenser tubes shall be adequately supported to prevent sagging and vibration failure.
The joints of water boxes and tube sheets shall be water tight while those of tube sheets and
shell shall be air tight to prevent leakage of refrigerant and infiltration of moisture into the
system.
The condenser shall be equipped with following accessories / safety devices :
A. Purge valve
B. Charging valve
C. Relief valve / fusible plug
D. Hot gas inlet / liquid outlet connections on the shell with flanges.
E. Water inlet / outlet connections with flanges.
F. Hand shut-off valve for water inlet and outlet to condenser and chiller.
G. Pressure & temperature gauges for water inlet & outlet/refrigerant gas inlet &
outlet.
H. Vent valves etc.
I. Charging valve.
Chiller
The chiller will be of direct expansion, horizontal, shell and tube type construction with the
refrigerant flowing inside the tubes and the water outside the tubes.
Chiller shall have MS fabricated shell, copper tubes with internal turbulators and MS tube
sheet and MS fabricated or cast iron shell end boxes. The shell shall be designed for
approximately 10 kg/cm².

The copper tubes shall be rolled into grooves on tube sheets for a water and airtight joint.
Joints between the tube/sheets and the shell should be watertight while those between the shell
and the boxes should be airtight. Adequate sealing gaskets should be used to prevent leakage
of refrigerant and the infiltration of moisture and air into the system.
The chiller shell shall have flanged water inlet and outlet connections welded as an integral
part of it.
The chiller assembly shall be thermally insulated with polyurethane or equivalent material of
adequate thickness and finished as described under 'Insulation'.
Chiller shall be equipped with the following controls/accessories/safety devices:
A. Refrigerant liquid inlet and gas outlet connections with flanges and liquid line
shut-off valve
B. Liquid distributor with proper circulating arrangement
C. Thermostatic expansion valve
D. Solenoid valve on liquid inlet line
E. Cooling and anti-freeze thermostats
F. Water inlet/outlet connections with flanges and shut-off valves, along with
counter flanges
G. Vent connections with valves
H. Pressure and temperature gauges for water inlet/outlet
I. Relief valve, purge valve, drain valve, shut-off valve,
J. DP switch across the chiller.
Interconnecting refrigerant piping, fittings and valves
Refrigerant piping is required to interconnect the compressor, condenser and the chiller into a
closed network.
Expansion valves shall be pilot operated type. Solenoid valve shall be provided for 'Pump
down' operation of the unit.
Moisture indicators, filter/drier unit shall also be provided in the liquid line with isolating
valves.
Strainers shall be of brass, complete with bronze screen and permanent magnet strainers shall
be installed up-stream of refrigerant solenoid valves, as per requirements. Strainers shall be
provided with isolating valves and bypass valves.
Heavy duty seamless steel pipes shall be used for the piping network; while seamless solid
drawn copper tubes shall be used for the refrigerant liquid line.
The piping network shall incorporate loops in the circuit to efficiently separate oil and liquid
refrigerant from the gas and suction vapour respectively.

All horizontal lines shall be pitched to 12m for every 3 meters in the direction of refrigerant
flow. All necessary loops and bends shall be provided to ensure proper return of oil to the
Compressor. All the piping shall be adequately supported and isolated by means of suitable
vibration isolators.
Suction line shall be thermally insulated with polyurethane or equivalent material of adequate
thickness.
The following accessories/controls shall be provided for the refrigerant piping :
A. Liquid line strainer/drier

B. Liquid-suction heat exchanger
C. Hand shut-off valves
D. Sight glass etc.
All the piping network shall be pressure tested, leak tested, dried, evacuated and charged with
the refrigerant after erection.
Controls & Instruments
• Pressure gauges
Pressure gauge shall not be less than 150 mm diameter dial with appropriate working range
and be complete with shut off gauge cocks etc., duly calibrated before installation. Pressure
gauges shall be provided at the following locations.
A. Supply and return of Chillers and Condensers.

B. Discharge of pumps.
C Inlet and outlet of heat exchangers.
D Supply and return chilled water line of A.H.U.
In refrigerant line suction side gauges shall be compound gauges of the range 0-75 mm (0.3")
mercury vacuum and 4 kg/sq. cm positive pressure. Discharge side gauge shall be 0-6 kg/sq
cm pressure. Gauge shall be connected to pipe by 6 mm dia copper tubing through 6 mm dia
shut off cocks.
• Thermometers
Thermometers shall be 150 mm dial type with capillary tube and protective sheets, duly
calibrated before installation .
03. Data to be furnished by the Tenderer along with offer:-
1. Refrigerant Compressor
a) Manufacturer
b) Model No.

c) Refrigerant
d) Capacity at operating conditions
e) Maximum speed/operating speed
f) BHP at operating conditions
g) BHP/TR at operating conditions
h) BHP consumption
100% load
75% load
50% load
i) Types of controls offered and make
j) Motor
Make :
Type :
Rating (kW) and RPM :
Starter : Make & Type
k) Capacity control
l) Lubrication
m) Total weight
n) Noise level at 1 meter distance in dB(A)
o) Vibration level
p) Vibration isolators details
2. Condenser
a) Manufacturer
b) Shell diameter and length (mm)
c) Tube material
d) Fouling factor
e) No. of tubes
f) Tube diameter (mm) and thickness
g) Tube length (mm)
h) Tube surface area inside (m2)
i) Tube surface area outside (m2)
j) No. of passes
k) Water flow (m3/hr)
l) Water velocity (m/sec)
m) Water temperature entering (Deg.C)/leaving (Deg.C)
n) Fin material and No. of fins/inch.
o) Operating charge
p) Pressure drop
q) Refrigerant temp (Deg. C)
r) Maximum cooling capacity (K.Cal/hr.)
s) Operating weight (kg)
3. Chiller
a) Manufacturer
b) Shell diameter and length (mm)
c) Tube material

d) Fouling factor
e) No. of tubes
f) Tube diameter (mm) and thickness
g) Tube length (mm)
h) Tube surface area inside (m2)
i) Tube surface area outside (m2)
j) Water flow (m3/hr)
k) Water velocity (m/sec)
l) Water temperature entering (Deg.C)/leaving (Deg.C)
m) Fin material and No. of fins/inch.
n) Pressure drop
o) Refrigerant temperature inlet /outlet (Deg. C)
p) Maximum cooling capacity (K.Cal/hr.)
q) Operating weight (kg)

12.0 ES8 – CHAIN PULLEY BLOCK
01. General
manufacture, test and supply of Chain Pulley Block with all accessories complete in all
respects. Specific technical requirement of Chain Pulley Block if any shall be mentioned in
the job specification/data sheet as furnished along with the Technical Specification.
Brief description of the Chain Pulley Block is given below under clause No. 02. The
equipment-wise list of data to be furnished by the tenderer along with the offer is shown
02. Description
Hand-operated chain pulley blocks are used extensively for material handling during
construction, erection and maintenance of industrial plants.
Chain pulley block shall be considered conforming to IS:3832 – 2005. This standard lays
down the general requirements and testing of the hand-operated chain pulley blocks, worm
or spur gear type. The minimum requirements of load chains shall be graded to Grade 40.
Further a design test to prove the design of the block to a factor of safety of 4 shall be
included.
Hand-Operated Chain Pulley Blocks - A block riveted with a load chain and operated by a
hand chain so as to give a mechanical advantage.
Design - The blocks shall be so designed that all components shall withstand without failure,
an application to the block of a load equal to at least four times the working load limit.
Rating - The hand-operated chain pulley blocks shall be rated according to the working load
limit which in case of a block with four or fewer falls shall be determined from the safe
working load of the load chain. Where the falls exceed four, or angles are introduced into the
chain run, a chain stronger than that for the corresponding four-fold block is required to
provide for the additional load caused by friction.
Each chain pulley block shall be subjected by the manufacturer to a proof load of 1.5 times
the working load limit through a length of lift which will ensure that every part of the block
will sustain the load test.
1. Make & Model

2. Capacity of handling in ton
3. Quantity
4. Class of duty as per IS:3832-2005
5. Head room, mm
6. Lift room, mm

7. Minimum radius of curvature of the track beam with which this hoist can be
negotiate
8. Weight
9. Specification of each chain
10. Tools & tackles included in the offer
11. Commissioning spares & 2 years operating spares included in offer.
12. Effort
13. Velocity ratio

13.0 ES9 – COOLING TOWER
01. General
manufacture, test and supply of Cooling Tower with all accessories to make operation of
Cooling Tower complete in all respects. Specific technical requirement of Cooling Tower if
any shall be mentioned in the job specification/data sheet as furnished along with the
Brief description of the Cooling Tower is given below under clause No. 02. The equipment-
wise list of data to be furnished by the tenderer along with the offer is shown below under
clause No. 03.
Job specification of the project shall be referred for any specific requirement.
02. Description
Cooling tower shall be power driven or natural draft type and shall be selected to suit the
requirement of HVAC system or as per job specification requirement. Induced draft type, FRP
cooling tower shall be provided for the cooling of condenser water. Accordingly cooling
tower cooling capacity shall be selected with respect to condenser capacity, which shall be
min. 20% more than the chiller capacity.
In General FRP type cooling tower shall be provided for the cooling of condenser recirculating
water for HVAC application.
The capacity of the cooling tower shall be adequate to take care of the entire cooling water
required for the air-conditioning plant. Only make up water will be made available from the
plant network.
The cooling tower shall be mounted on masonry pillars on the roof of the AC Plant building
or on the ground level near the AC Plant room as per the site conditions.
Normally natural draft cooling tower shall have RCC basin construction. Cooling tower
capacity shall be adequate to cool water basin temperature up to maximum 32oC as per
prevailing ambient condition.
Cooling towers shall be provided with the following items and accessories unless otherwise
specified in the job specifications:
• Type : Induced draft counter flow / cross flow

• Casing/ Basin : RCC ( for chilled water plant), FRP (for air conditioning systems)
• Frame Work : MS hot dip galvanized (for air conditioning systems)

• All the fasteners (Bolts, nuts, miscellaneous hardware) shall be of stainless steel or
hotdip galvanised steel. Rubber/Neoprene gaskets must be used on all bolted joints
as a seal against water leakage.
• Fills : PVC
• Nozzles : Brass
• Fan hub & blades : Cast Aluminium
• Fan type : Axial flow, direct drive
• Fan speed : 720 rpm
• Motor of induced draft fan shall be of weatherproof construction. Degree of

protection of motor : IP 55 (temperature rise limited to class B) unless otherwise
specified in the electrical specifications.
• Ladder : Galvanised steel ladder with safety cage & hand railing up to the top of
tower. Inclined to 300 to the vertical
• Eliminators shall be provided in removable sections and installed in the cell of the
tower. The number of deflections in the eliminators shall be so arranged as to limit
the drift loss to within 0.01% of the circulated water.
• Level switch at cooling tower basin (to be interlocked with pump)
• Make up connection with float valve (float made of copper), back up ball valve
• Quick fill connection with ball valve
• Overflow connection
• Drain connection with ball valve
• GI wire mesh 18 gauge strainer
• Equalizing line of cooling towers with isolation valves
• Cooling tower basin (for chilled water plant) shall have minimum 5 minute water
holding capacity (of circulation water volume)
1. Make & Model

2. Type
3. Quantity
4. Overall size of cooling tower
5. Capacity of cooling in TR.
6. Water flow m³/h
7. Air flow
8. Design water inlet temperature, outlet temperature
9. Material of construction and its thickness
10. Speed in RPM.
11. Drive details.

12. Shaft Power consumption.

13. Wheel diameter.
14. Efficiency.
15. Size of fan
16. Static & Dynamic weight of fan & motor assembly
17. Bare weight and operating weight of cooling tower
18. Noise level at 1m distance in dB(A)
19. Fixing details.
20. Vibration level.
21. Water spray nozzle type

14.0 ES10 – CYCLONES, MULTI-CLONES & PRE-COLLECTOR
01. General
manufacture, test and supply/fabrication of Cyclone / Multi-clone/Pre-collector System with all
accessories required to be installed for dust extraction / process application to achieve desired
performance in all respects. Specific technical requirement of Cyclone /Multi-clone/Pre-
collector System if any shall be mentioned in the job specification/data sheet as furnished along
with the Technical Specification.
Brief description of Cyclone /Multi-clone/Pre-collector is given below under clause No. 02.
The point wise list of data to be furnished by the tenderer along with the offer is mentioned
02. Description
02.1 Single cyclone/group of cyclones
This shall consist of a vertical cylindrical body, in which dust-laden gas is introduced at the
top through horizontal tangential inlet. The cylinder shall have a truncated cone as the lower
section. As the gas moves down the cyclone body, it forms a peripheral vortex. This gives
rise to centrifugal force, which throws the dust particles in the gas stream towards the walls
which then separate from the gas stream and fall down and are taken out through a dust pipe.
As the gas reaches the conical portion, the gas stream reverses direction and moves upwards
towards the exhaust pipe forming an inner vortex. Cyclones shall be constructed of suitably
stiffened mild steel casing of not less than 6 mm thickness. For variable flow application
compartmentalized cyclone chamber shall be constructed to maintain required minimum
velocity to achieve desired performance .
02.2 Multi-clone
This shall consist of a number of small diameter cyclones operating in parallel. Multi-cell
cyclones shall be enclosed in suitably stiffened mild steel casing of not less than 6 mm
thickness. The cyclone elements shall in general have diameters of 150 mm and below and
shall have smooth finished surfaces. Each unit shall include, but not be limited to the
following: gas inlet chamber, cyclone elements with casing, clean gas exhaust chamber,
bottom hopper for dust collection, rotary valve for each hopper, a differential pressure gauge
to measure pressure drop across the unit and leak proof access openings. For variable flow
application compartmentalized cyclone chamber shall be constructed to maintain required
minimum velocity to achieve desired performance .
02.3 Pre-Collector
The collector shall be used as a preliminary dust catcher and a common header for different
incoming ducts from various suction hoods. The collector shall comprise of cylindrical
casing with service doors of quickly clamped type, incoming and exhaust manifold
connected to collector, rotary air lock / double flap valve at the bottom. The dust
accumulated at the bottom of collector shall be disposed off through rotary air lock / double
flap valve to the conveyor. The velocity of air inside the collector shall be around 4-5 m/s.

The Tenderer shall compute the diameter of the collectors to achieve this velocity. The
length of the collector shall depend on the convenience of connecting various ducts to it.
Duct connections should not be bunched in a particular area and shall be evenly distributed
on the cylindrical surface of the collector. The mode of connecting incoming ducts with
collector body shall be of flanged type. The air shall enter the collector tangentially and not
radially. The exhaust duct shall be fitted to the exhaust manifold by flanged connection. The
body and support of the collector shall be designed to withstand its self weight along with
the weight of water and dust considering worst conditions.
a) Pre-collector
1. Make & Model.

2. Capacity in m3/h.
3. Pressure drop in mmWC.
4. Overall size of pre-collector
5. Velocity through collector body in m/sec.
6. Material of construction
7. Cleaning efficiency Vs particle size
8. Methods of dust disposal.
9. Supporting frame details.
10. Total weight of pre-collector
b) Cyclone
1. Make & Model.

4. Overall size of cyclone
5. Velocity through cyclone body in m/sec.
10. Total weight of cyclone
c) Multi-clone
1. Make & Model.
4. Overall size of multi-clone
5. Smaller cyclone diameter of multi-clone
6. Velocity through multi-clone body in m/sec.
11. Total weight of multi-clone

15.0 ES11 – DAMPERS FOR AIR FLOW CONTROL
01 General
manufacture, test and supply of different type of air dampers required to be installed in the
Air Flow Path with all accessories for HVAC and Air Pollution Control Systems. Specific
technical requirement of air dampers if any shall be mentioned in the job specification / data
sheet as furnished along with the Technical Specification.
Brief description of dry air dampers is given below under clause No. 02. The point wise list
of data to be furnished by the tenderer along with the offer is mentioned below under clause
No. 03.
02. Description
02.01 Wall mounted dampers
a) Self acting damper (Gravity damper)
Self acting dampers are provided to maintain pressurisation inside the premises. The
damper shall be multiblade type made of Aluminium flaps of not less than 24G
thickness and MS frame. These shall be designed to operate when the positive
pressure inside the premises exceeds 2-3 mm WC. It can operate in fully open or
partial open positions.
b) Fusible link fire damper
Fusible link fire dampers are provided to stop the flow of air through the exhaust
opening when fire breaks out in the premises. This damper shall be provided on the
inside face of wall openings for outlet/exhaust of air from the premises. This
damper shall essentially consist of multi-leaf blades, MS frame, fusible link with
spring / gravity arrangement for auto closing of the damper. The fusible link shall
be made of low melting alloy which can fuse at a temperature of about 70/80oC.
The damper shall be normally in open position; it shall close on melting of the
fusible link caused by temperature rise due to fire etc. in the premises.
02.02 Duct line dampers
a) Hand operated damper (Geared hand wheel)
The hand operated damper shall be multileaf opposite acting aerofoil blade type
damper with external operating links provided at the outlet of the fan for controlling
air flow. The damper shall be made of GI sheet with MS frame unless otherwise
specified in the job specifications. The fully close/ open/ partial closing position
shall be marked on the damper casing.
b) Electrically operated / pneumatic damper

The electrically operated damper shall be provided as a regulating device for control
of air flow through duct as per job specification requirement. Provisions shall be
kept for interlocking the damper with fire protection system. The fully closed / open
/ partial closing position shall be marked on the damper casing.
c) Solenoid operated fire proof damper
This damper shall be provided in supply air duct. It shall be operated by solenoid
which is to be interlocked with the fire detection system of the served premises. In
case of fire in the premises the fire detection system shall activate the solenoid and
the solenoid in turn shall close the damper to stop air flow in the duct line. The fully
close/open position of the damper shall be marked on damper casing.
02.03 Dampers for dedusting systems and process applications
a) Dampers for fan inlet / outlet, suction hoods and duct lines
Pneumatic operated, all position, variable inlet vane (VIV) type dampers shall be
provided for fan inlet for regulation of air flow. In case standby fans or multiple
working fans are connected to the same duct line, fan outlet dampers shall also be
provided in addition to VIVs. Further, all fan inlet and outlet dampers shall be
motorized or pneumatically operated in case of dedusting, process and hot
applications.
BF Stock house dedusting system: Pneumatic dampers, open/close type, shall be

provided in the suction hoods of each of the coke screens, sinter screens and iron ore
screens and their respective discharge chutes, the suction hoods on the fines
conveyors receiving the respective screen under-sizes and the suction hoods on
conveyors receiving from the respective weigh hoppers of coke, sinter and iron ore.
Interlock with the operation of the respective screens and weigh hoppers shall be
done to ensure the opening and closing of the above dampers as per the operation
and the job specification requirement. For each suction hood, manual butterfly type
dampers shall be provided.
BF Cast house dedusting system: Pneumatic dampers, all position regulating type,
shall be provided in the suction hoods of tap hole and tilting runner and pneumatic
dampers, open / close type, shall be provided for duct line and all other suction
hoods like slag skimmer, slag runner, iron pool, etc.
BOF/LF Secondary dedusting system: All dampers for suction hoods shall be
pneumatic, all position, regulating type and duct line dampers shall be pneumatic,
open / close type.
For dedusting systems of general material handling systems in junction houses, etc.,
manual dampers shall be provided at suction hoods and duct lines unless otherwise
specified in the job specifications.
All duct line dampers shall be butterfly type with bearings to be outboard with an air
gap between its seal and shaft seal. Bearings shall be pre-packaged with lubricant

but shall have means of providing additional lubricant and bearing shall be out of air
stream. The drive of damper shall be through linear actuator. All actuators shall be
provided with manual over-ride.
b) Volume Control Orifice Plate
Single leaf orifice plate shall be provided, if required, in the duct routing after each
suction hood for minor adjustment of air flow as per the site performance testing
results. However, this shall be used only as a last option and as far as possible,
ducting network shall be designed as self balanced type.
c) Design Requirements
All damper components will be weatherproof construction, mounted between flat

face flanges.
Lifting lugs will be provided.
Flow direction shall be clearly identified on each damper, to ensure correct

installation.
The dampers shall be suitable for installation in both horizontal and vertical ducting.
All dampers shall be located with suitable approaches. The approaches shall also be
included in the scope of work of the Tenderer.
d) Actuators
Spring return pneumatic actuator shall be provided for dampers. They shall be
operated with compressed air to close and spring to open. Actuators shall be
provided with electro-pneumatic positioner, direct mounted to spring return, fail-
open actuator. Necessary limit switches shall be provided for position control and
indication for all dampers. The number of limit switches, position control and
indication shall be governed by the operating philosophy of the dedusting system.
Motorized dampers may be provided as per job specification requirements. General
requirements of pneumatic / motorized actuators will be as per specifications of
electrical / instrumentation.
e) Construction and Fabrication
1. General
The design and material selection of damper assemblies will be capable of meeting
the process requirements.
2. Damper Valves
All damper valves will be clearance or ribbed type butterfly dampers, shaft mounted
on frictionless bearing, with flat face flanges.

Damper valves will be complete with spring return pneumatic actuator, limit
switches for position indication, electro-pneumatic positioner and de-clutchable
manual over-ride. All components will be integrally mounted on the valve.
System will fail in the open position at loss of pneumatic or electrical signal.
Each limit switch will be supplied with open and closed contacts.
Fan inlet dampers and dampers for suction hoods of tap hole, tilting runner,
secondary dedusting systems and other specialised applications will be all position
regulating type.
Rate of damper leakage in the fully closed position is to be given as a percentage of

the normal flow with the damper open, and shall not exceed 1%.
3. Actuators, Limit switches, and Positioners
Actuator will be spring return, single acting, pneumatically operated, for 0 to 90

degree travel. The entire train will be totally enclosed within single cavity housing.
Actuator will have external manual indication of valve and output shaft position.
Indicator shall be of corrosion resistant materials, in contrasting colour to actuator
body. Indicator shall be the sole external moving part.
Actuator will be capable of being mounted directly to the damper valve.
Actuator will be complete with external de-clutchable manual over-ride, which will
have safety interlock to exhaust air from actuator when manual mode is selected. All
moving parts must be totally enclosed.
Actuator will be operable with valve installed in any position without loss of
performance and will be mounted parallel to the pipe.
Actuators are to be sized to operate with compressed air supply 5 to 7 kg/cm²

pressure.
Actuator will be complete with position indicating switches. Switches will be totally
enclosed, in approved IP-65 enclosure, for corrosive environments. Switches will be
CAM operated and cams will be independently adjustable throughout the full
actuator travel range. Switches will have external position indicator to the same
specification as the basic actuator.
Actuator will also be complete with electro-pneumatic valve positioner, suitable for
spring return, fail-open operation.
Motorized dampers may be provided as per job specification requirements.

4. Manual Over-ride
The de-clutchable manual over-ride mounted on the damper valve will be of a

worm and segment actuator, in which the worm-drive shaft can be rotated
eccentrically by the worm-drive lever to disengage the worm from the segment. The
segment is then free to rotate when driven by the actuator.
The drive-shaft will have an internal locking device to lock it into the selected mode
of operation.
Normal operation is with the worm-drive lever in the "auto" position. In this position
the worm-drive will be disengaged from the segment gear, and the actuator will be
free to rotate the valve shaft.
To engage the de-clutchable manual over-ride, the worm-drive locking button,

mounted on the unit, will be released allowing the worm-drive to rotate to the
"manual" position.
5. Control Equipment Enclosure
A covering will be supplied for each damper to protect the actuator control
equipment from the local environment, such as dust, and sprayed water during
routine clean-ups. Enclosure shall be IP-65 rated.
6. Materials
Damper valve body, disc, and shaft and de-clutchable manual over-ride will be
carbon steel construction, suitable for the rugged service demands encountered
during blast furnace cast house operation.
Actuator housing will be hard anodized, extruded aluminum. End caps and pistons
will be pressure die-cast aluminum. Output shaft will be heat treated steel. All
actuator seals will be of Nitrile material and will be of O-ring construction
7. Valves
The broad specification for the different categories of valves pertaining to

compressed air and water line are as follows:
Isolation valves - for size 50 NB and below, screwed end ball valve with SS ball
& cast steel casing shall be supplied.
- for size above 50 NB butterfly valve with SS disc & cast

steel casing shall be supplied.
8. Pipelines
Compressed air & water pipelines along with accessories and supports are in the
scope contractor up to design limit. Pipelines will be GI (as per IS 1239, part I) and
heavy class.

The following data shall be furnished by the tenderer along with the offer.
03.01 Wall Mounted Dampers
a) General data applicable for all types of dampers
1. Size
2. Quantity offered
i) Frame
ii) Blade
iii) Flange
4. Provision of horizontal & vertical direction control
5. Weight
6. Velocity of air
b) Self acting damper
1. Operate on differential pressure requirement mm WG –
c) Fusible link fire damper
1. Material of fuse link

2. Melting temperature of the fuse link
03.02 Duct line Dampers
a) Hand operated damper (Geared hand wheel)

1. Operating device
b) Electrically operated / Pneumatic damper

1. Type of actuator
2. Motor kW /Pole (in case of electrically operated damper)
3. Pneumatic piston (for pneumatic operated damper): make, type and weight
4. Compressed air requirement with pressure for pneumatic operated damper
c) Solenoid operated fire proof damper
1. Type of actuator
2. Supply voltage and solenoid power supply rating

16.0 ES12 – DUCTING NETWORK FOR DUST EXTRACTION SYSTEM
01. General
manufacture, test and supply/fabrication of Ducting Network with all accessories required to
be installed for Dedusting System application to achieve desired performance in all respects.
Specific technical requirement of Ducting Network of Dust Extraction System if any shall be
Specification.
Brief description of Ducting Network of Dedusting System is given below under clause No.
02. The point wise list of data to be furnished by the tenderer along with the offer is
mentioned below under clause No. 03.
02. Description
Ducting Network shall comprise of suction hood, ducting, duct support, measuring hatch,
cleaning hatch and duct line dampers as required.
The suction hoods and enclosures shall be constructed of 5 mm MS plate unless otherwise
specified in the job specification with necessary external stiffeners, flanges, counter flanges,
fasteners, gaskets and other accessories for fixing with technological equipment and duct
line. Dust collection hoods and enclosures shall be fitted with conveniently placed hinged
access doors (top hinged type) to enable internal access to the equipment for maintenance as
required. The air velocity at hood inlet shall be 1.5m/s (max). Suitable refractory lining shall
be provided for ducting, suction hoods and dust collection enclosures in high temperature
zones.
Duct work details shall have following minimum features :
1) Construction
The duct sizing shall be so selected to maintain proper conveying velocity throughout the
system. Man holes/hand holes and dust outlets shall be provided at intervals to facilitate
cleaning of dusts and for disposal of dust. The successful tenderer shall design the dedusting
system ductwork connecting the dust collection hoods, to the dust collector, fans and stack.
The ducting shall be fabricated from M.S.(IS 2062: 2006) having thickness as follows unless
otherwise specified in the job specification :
Duct diameter Straight line duct thickness Bend Thickness

Upto 500 mm 3.15 mm 4 mm
Upto φ 900mm 4 mm 6 mm
φ 900mm to φ 1500mm 6 mm 8 mm

φ1500mm to φ 2000 mm 8 mm 10 mm
above φ 2000mm 10 mm 10 mm
At all duct bends (carrying abrasive dust such as sinter dust etc.) above 900 mm diameter
shall have abrasion resistant liners with caster wood / rock basalt / FRP in line with job
specification requirement .
Thickness of flanges shall be 12 mm. Necessary stiffeners shall be provided in the duct,
depending on size. The ducts shall be laid vertical as far as practicable for dedusting
installations and horizontal ducts should be avoided.
For special application corrosion / abrasion resistant duct liner material of construction of
FRP / Liner material may be required to be installed in line with job specification
requirement.
2) Conveying velocity
A conveying velocity of 18-22 m/s shall be maintained at all points in the ductwork between
dust collection hood and dust collection plant to ensure flow of air without settling of dust .
Expansion joints shall also be provided in the ducting network to reduce thermal stress as
required.
3) Provision for Slide Gates/ Dampers

All extraction points shall have slide gates (single leaf inclined plate type) / dampers
provisions for flow balancing during commissioning if required. These gates/dampers shall
be bolted by the successful tenderer in position after commissioning to prevent inadvertent
operation and consequent un-balancing of flow of the dedusting system.
4) Provision of Flow Testing Points

Main duct and all major branch ducts shall have two 100mm diameter capped sockets
installed at 90° to one another at least 8D away from flow disturbance (bends, hood inlets)
for insertion of pitot tubes for flow measurement and system balancing during
commissioning. Test points are to be located in a readily accessible position in the duct.
However in any suction hood if flow appears to be on the lower then necessary flow
measurement and correcting device shall be made by the successful tenderer to suit site.
5) Straight Duct Runs

Interconnecting duct work shall be circular in cross section. The duct work shall be
fabricated from mild steel plate, IS 2062:2006 or be seam welded spiral wound duct work as
per job specification requirement.

6) Branches
Branch connections should be oriented to the top or side of the main with no two branches
entering at opposite sides.
7) Joints
Matching flanges are to be bolted together with asbestos rope gasket or rubber gaskets. All
bolts and gaskets for jointing shall be included in the scope of work of the successful
tenderer. All duct joints are to be air tight to minimise air leakage.
8) Duct Cleanout Doors

Clean-out doors will be provided on horizontal runs, before elbows and junctions. The
spacing between cleanout doors should not exceed 6 meters. Clean out doors will be
constructed to have a diameter of 600 mm or the duct diameter which ever is less for ducts
upto 1 meter diameter. Larger diameter ducts will have clean out doors sized 600 mm high
by 600 mm wide.
9) Duct system hangers and supports

The ductwork support spacing and hangers will be designed for the weight of settled dust plus a
25% design margin. Following dust load will be considered for designing duct and duct support
and duct stiffeners.
Duct dia (in mm) % Cross section of duct filled up with dust.
500 and below 70 %
Above 500 to 1000 50 %
Above 1000 diameter 30 %
Bulk density of dust will be considered 2.2 t/m³ for iron ore and sinter dust and 0.7 t/m³ for
coal / coke dust, unless otherwise specified in job specification.
All duct inside buildings and duct along main structural building will be supported from
plant building structure for which load data shall be furnished by successful tenderer within
15 days of placement of order. Details of duct supporting members will be decided during
detail engineering. To suit site condition supporting members may have to be modified by
the successful tenderer without any commercial implication to the purchaser. All outside
ducting network shall have independent duct supporting trestles.
10) Ductwork Layout

Ductwork will not interfere with fixed or mobile crane access to the plant. Horizontal run of
the ducting will be avoided to prevent settling of dust.

Minimum horizontal clearance from road center line is 5 meters. It is the responsibility of the
successful tenderer to effect the dedusting system ductwork arrangement in accordance with the
design requirements set down in the specification and to the satisfaction of the purchaser /
consultant.
11) Ductwork integrity

The successful tenderer shall design the ductwork in such a way to ensure that the ductwork will
not collapse at any point, should it be subject to the maximum suction capacity of the fan
system. The design shall accommodate any variation in ambient temperature.
12) It is the responsibility of the Successful tenderer to size all ductwork in detail as per duct
balancing calculation. Duct balancing calculation will be furnished by the successful
tenderer for approval of the purchaser. It is the Successful tenderer’s responsibility to
establish routes both inside and outside building. This is to be done in conjunction with and
to satisfy the Purchaser.
13) The duct work will be self pressure-balanced type. However, during testing and
commissioning if any throttle piece is required for adjustment of flow in any duct branch
same will be carried out by the successful tenderer without any commercial implication.
14) Flexible connection at inlet & outlet of fan and in the ducting network will be provided by
the successful tenderer as required.
The following data shall be furnished by the tenderer along with the offer.
Ducting
1. m2 of duct work
2. Weight of duct work
3. Weight of supports and flanges
4. Material and thickness of duct work
Suction Hood
2. Measuring hatch provided or not
3. Capturing velocity
4. Hoods sizes

17.0 ES13 – DUCTING NETWORK FOR HVAC SYSTEM
01. General
manufacture, test and supply/fabrication of GI/MS Ducting Network with all accessories
required to be installed for HVAC application to achieve desired performance in all respects.
Specific technical requirement of Ducting Network if any shall be mentioned in the job
Brief description of Ducting Network is given below under clause No. 02. The point wise
list of data to be furnished by the tenderer along with the offer is mentioned below under
clause No. 03.
02. Description
The ducting network comprises of ducting work, duct line dampers, down comer & supply
air diffuser with volume control damper for HVAC system, supply air grill/ adjustable
louver grill duct supporting arrangement, flexible connections, etc.
All GI / Aluminium ducting work for airflow shall conform to IS 655: 2006. Galvanised
steel sheet conform to IS 277: 2003. As per job specification requirement ventilation duct
may be fabricated from steel sheet conforming to IS 2062 :2006.
These items are briefly described below:-
a) Ducting work
Ducting work consists of main duct, branch ducts, bends, reducers, joints, access
doors, etc. Duct work shall be complete with flanges, gaskets, stiffeners, fasteners
(nuts, bolts & washers), hangers, etc. as required. Minor modification of ducting
network may be required to suit site condition. GI Ducts shall be fabricated at site to
match with site condition.
All ducting work shall be properly reinforced to prevent sagging, buckling or

vibration.
GI Ducting shall be provided with joints at 2.5 - 3m interval conforming to IS 655:

2006 as and where required. In case of flanged joints, the flanges shall be of angle
iron type riveted with GI sheet on duct perimeter. Flange joints should be made air
tight with use of felt gaskets.
Duct supports shall be provided to keep the ducting in position in aligned condition.
Measuring hatch for measurement of flow / pressure shall be provided in ducting

network at convenient locations.
For proper distribution of air in the premises, supply air grills (adjustable louver
grills) with volume control dampers shall be provided in the ducting work for

ventilation system and supply air diffusers with volume control damper shall be
provided in the ducting work for air conditioning system.
Sizing of the duct shall be done for pressure balancing as well as to maintain the air
velocities in the ducting work as given below: -
Description Air Velocity for Ventilation Air velocity for Air

System conditioning system
Main duct 8 – 10 m/sec. 6 – 8 m/sec.

Branch ducts 6 – 8 m/sec. 4 – 6 m/sec.
Supply air grills 4 – 6 m/sec. -
Branch risers - 4 – 5 m/sec.
Supply air diffuser - 3 – 4 m/sec.
Fresh/Make up Air - 1 – 2 m/sec.
filter
Fine filter - 1 – 1.5 m/sec
Return air duct / - 2 – 3 m/sec.
grill
The following accessories may be fitted in the duct line depending upon the job
specification requirement.
i) High efficiency filter

ii) Strip heater for dehumidification purpose
iii) Pan humidifier for humidification purpose
Joints :
In line with IS 655: 2006 guide lines the type of transverse joints shall be followed
unless otherwise specified in job specification :
Sealing:
All construction joints and duct seams shall be reasonably sealed with bitumastic
cold emulsion or equivalent vapour seal.
Bends :
The interior of all ducts shall be smooth for free flow of air. The radius to bend shall
not be less than 1.5 D. Turning guide vane shall be provided in all large duct bends
and bends with radius less than 1.5 D for proper air flow.
Access door :
All main ductwork shall be accessible throughout using tight fitted hinged access
doors, provided with sponge rubber gaskets. Angle joints shall be provided with felt
or rubber gaskets for leak-tightness of the joints.

Access doors/panels are to be provided at following places :
• Near each fire damper

• Near each Reheat coil
• Near high efficiency filter/absolute filter
Any other place if envisaged by the owner about its essentiality during drawing
approval or construction period.
In case access doors are to be installed in the insulated ducts, the access door panel
should be insulated too with overlapping, such that it can be operated without
damaging the duct insulation and there should be no condensation either on the
access doors or on the duct when the plant is in running condition.
Duct line dampers :
Refer equipment specification no. ES-11.
c) Adjustable louvers grill (Supply air grill) with volume control

damper for ventilation system
1.25mm MS sheet shall be used for the manufacture of grill. All grills shall be true
to shape and shall be checked with a level gauge before being secured in position.
No distortion or warping is permitted.
All duct mounted grill shall be complete with rubber gaskets and flanged holding
frames of suitable design for the intended installation. They shall be mounted on
collar extending from the duct. No part of grilles shall project into the main duct.
The adjustable louver grill shall be provided with volume control damper as well as
double deflection flap/ grill for direction control.
d) Supply air diffuser with volume control damper for AC System only
Thickness of Grills, Diffuser, Damper shall be as follows:
(a) Frame 16 gauge

(b) Louvers 18 gauge
Supply air diffusers shall be circular/rectangular in shape as per detailed engineering

requirement. The throat of a diffuser shall be connected with collar piece provided at
the duct bottom for holding the diffuser as well as for supply of air. Each diffuser shall
be provided with volume control damper. Each diffuser shall comprise of fixed plate,
damper blade, damper blade operating knob, spindle, connecting rod etc. The diffuser
should flush with the false ceiling. False ceiling shall not bear the load of any diffuser.
The load of diffuser shall be borne by the duct and collar. Each diffuser shall be
painted with appropriate colour to match with the colour of the false ceiling. Diffuser
shall be placed considering light fittings position and false ceiling runner position.
Diffusers/grills shall be of extruded aluminum powder coated / Anodized aluminum.

e) Return air grill
In general the return air opening shall be provided above false ceiling in the wall
between served premises and A.C. plant room. The return air grill of suitable size
shall be provided at the A.C. plant room side face of the said opening for smooth
flow of return air. The air supplied in the served premises shall return above false
ceiling through the return air slit of 50~100 mm all around false ceiling along the
walls of the served premises. From there it shall pass into the A.C. plant room
through the return air passage. The return grill shall comprise of horizontal fixed
louvers made of 2 mm thick MS sheet, 50x6 thick MS flat shall be placed vertically
at middle of the louvers with 50x50x6 size angle frame all around. Spacing of the
fixed louvers in the grill shall be 25 mm.
f) Insulation
Sheet metal duct shall be acoustically and thermally insulated as per requirement.
For details of insulation refer respective equipment specification.
g) Flexible connections
Flexible material shall be used for fabrication of flexible connections. These shall be
of at least 100 mm length and shall be provided at each connection between duct
work and fan units and any other places as asked for in the job specification.
Flexible connection material shall be selected considering the temperature and
pressure of the system.
h) Hangers & supports for ducting
All duct work shall be provided with adequate supports as required to ensure rigid
support and to prevent vibration.
The fixing and supports interval shall not exceed 3 meters. Hanger rods having U-
bend at one end and threading at other end shall be hung from the ceiling by anchor
fasteners / expansion bolts. Duct angle supports from brick wall/RCC wall/
structural wall shall be grouted / welded to suite site.
i) Make up air filter with damper
Make up air for packaged air conditioner and AHU will be drawn from ambient
through filter and volume control damper.
a) Ducting
1. m2 of duct work
2. Weight of duct work
3. Weight of support and flanges

4. Material and thickness of duct work

5. Duct support type and material
6. Velocity of air.
b) Supply Air Grills / Diffuser with volume control facility
1. Size
2. Quantity offered
3. Material of construction & thickness
4. Provision of horizontal & vertical direction control
5. Weight
6. Velocity of air
7. Methods of volume control
c) Return air grills / intake air louvers
1. Size
2. Quantity offered
4. Weight
5. Velocity of air

18.0 ES14 – ELECTROSTATIC PRECIPITATOR
01. General
manufacture, test and supply/fabrication of Electrostatic Precipitator (ESP) System with all
accessories required to be installed dust extraction / process application to achieve desired
performance in all respects. Specific technical requirement of Electrostatic Precipitator
(ESP) System if any shall be mentioned in the job specification/data sheet as furnished along
Brief description of Electrostatic Precipitator (ESP) System is given below under clause No.
02. The point wise list of data to be furnished by the tenderer along with the offer is
mentioned below under clause No. 03.
02. Description
Electrostatic Precipitator and Accessories will include the following:
- Housing assembly of fabricated plate work.

- Gas distributor plate at inlet and outlet of ESP.
- Dust hopper assembly of fabricated plate work.
- Mixing chamber / Static mixer before ESP
- Discharge electrodes.
- Dust collecting electrodes.
- Rapping units for both discharge, collecting electrodes and gas distributors.
- ESP supporting structure complete with service platforms (minimum width 1.2 m)
and walkways, stairs, hoisting facilities, overhead canopy, etc.
- Thermal insulation of ESP casing and hoppers along with hopper heating
arrangement to avoid condensation.
- Flexible connection with matching flanges at ESP inlet and outlet.
- The number of electric fields shall be considered suitably to achieve required stack
emission standards unless otherwise specified in the job specifications.
- Two nos. rapping system (for collecting electrodes) shall be provided at the last two
fields to control puffing of dust.
- Specific collection area shall be considered based on tenderer’s experience on past
project. However required specific collection area shall not be less than the
minimum as defined in the job specifications.
- Electrics as given below:
- High voltage power supply package.
- Power supply to all drives with interlocks and controls.
- TR controller with feedback control optimization of current voltage from on
line continuous stack monitoring instruments .
- For details refer job specification requirement.
- Temperature and pressure transmitter, CO gas analyser as required.
- ESP system will comprise of multiple fields, unit/multiple cells Electrostatic
Precipitator (ESP) and its accessories such as Dust disposal system, Electrics and
control, Instrumentation, interlocks, Supports etc.

Design requirement
1. The Electrostatic Precipitator (ESP) will be in general dry, horizontal flow type. It should be
a completely self-supporting unit, ready to be assembled on the foundation.
2. Configuration
The Electrostatic Precipitator will feature one gas pass design with compensator at inlet &
outlet of ESP.
3. Electrostatic Precipitator Casing
a) The precipitator steel casing will be gas tight and of welded construction throughout.
Casing plate thickness will be 6 mm minimum unless otherwise specified in job
specification.
b) ESP casing shall be suitable to withstand cold test commissioning at shut off head of
fan, without suffering structural or mechanical damage. For gas cleaning system,
working pressure will be maintained as per system requirement. The normal
working pressure of suction and temperature will be considered as per system design
unless otherwise specified in job specification.
c) The precipitator will have access openings ladders, stairs, platform etc. necessary for
inspection, cleaning and maintenance. All equipment and the openings will be made
accessible to the maintenance personnel by installation of access ways, stairs,
ladders, platforms etc.
d) Sealing of glands, inspection doors, etc. must be such that air is prevented from
leaking into the electrostatic precipitator to prevent infiltration of ambient air. The
precipitator will be of weatherproof construction.
4. Electrodes
a) The discharge electrodes system should be able to withstand efficient rapping and
temperature changes.
b) Collecting electrodes will have a spacing of approximate 400 mm. The collecting
plates should be 1.5 mm thick CR sheets to ensure an adequate service life.
c) Discharge electrodes and collecting plates will be automatically and sequentially

rapped with heavy duty hammer rappers.
5. Rapping
The electrode rapping system will be capable of maintaining clean electrodes. The supplied
rapping mechanism will feature a microprocessor based adjustable rapping frequency for
each field.
6. Insulator housing

Special attention will be given to the rapping shaft insulators. These will be electrically
heated to avoid condensation and will have efficient seals to avoid dust deposits.
7. Safety
The Electrostatic Precipitator will be provided with a key interlocking system for preventing
access to high voltage internals of the precipitator until the associated high voltage system is
de-energised and grounded. All the access openings will be provided with earthing rods. The
earthing strips will be of GI and it will be firmly bolted to the precipitator casing.
8. Hoppers
Each field of the Electrostatic Precipitator will be fitted with a dust hopper. The hopper will
be constructed of 8 mm plate unless other wise specified in TS. The hoppers will have a
pyramidal / conical configuration with 65°valley angle minimum.
Inspection doors, poke holes and electric heaters will be provided in the hoppers. Motorised
double cone valves / RAVs will be provided at the hopper discharge. High and intermediate
level switches will be installed in each ESP hopper. With the help of intermediate level
switch dust in hopper can be discharged into the chain conveyor by double cone valve /
RAV. High level switch in ESP hopper will be provided for safety interlocks. Stainless steel
liner of 1.6 mm thick up to a height of 1.2 m from the bottom flange of ESP hoppers and
storage hopper will be provided for smooth flow of dust.
Separate dust-dumping outlets with flange provision, necessary chutes, gates etc. will be
provided by Successful Tenderer with ESP hoppers of last two fields for dumping of dust in
case of increase in alkali content to prevent recycling of dust under emergency situations as
per technological requirement. Therefore, Truck / dumper entry provision below each ESP
hopper will be provided by Successful Tenderer for dust disposal.
9. Insulation
ESP walls, roof panels, and hoppers will be provided with thermal insulation of resin bonded
mineral wool of density 100 kg/m³ as per IS 8183 :1993 (RA 2004) having 50~100mm
thickness for hot gas application as per technological requirement. The thermal insulation will
be covered with 0.8 mm CGI sheet cladding.
10. Platforms and access ladders
The minimum platform width will be 1.2m. The platforms will be located at the top of
hoppers level and at the top of the gas cleaning equipment. Safe guard rails will be provided
around all the platforms. Angular rather than round members will be used, as far as possible.
Safe and easy access to the platforms will be provided by providing stairways to chain
conveyor platform level, ESP chamber access door level, ESP top and transformer house etc.
Maintenance platforms all over ESP area, at dust disposal conveyor level will be provided.
Access door to ESP chamber will be provided from both sides. Access doors to distributor
grid will also be provided. Maintenance platforms at access door level all around ESP will

be provided. Ladder approach with platform will be provided for hopper level switches,
access doors, hopper heater and for any other equipment or access above man height.
11. Material of construction:
Sl. No. Item Material Thickness (min)

1. Collecting IS 513 : 1994 (RA 1.5 mm
Electrodes 1998) CR sheet
2. Discharge IS 513 : 1994 (RA spiral SS coil / rigid
Electrodes 1998) member
3. ESP casing IS 2062 : 2006 Gr. A 6.0 mm thick
4. G.D. screen IS 2062 : 2006 Gr. A 3.15 mm
5. Hopper wall IS 2062 : 2006 Gr. A 8.0 mm thick
6. Pent house roof IS 2062 : 2006 Gr. A 5.0 mm thick
(insulator hamber)
7. Side wall of IS 2062 : 2006 Gr. A 3.15 thick
insulator chamber
8. ESP inlet and IS 2062 : 2006 Gr. A 8.0 mm
outlet connection
piece
9. Handrail IS 1239 : Part 1 : 2004 Minimum 32 NB
10. Post IS 1239 : Part 1 : 2004 Minimum 40 NB
11. Access grating, IS 2062 : 2006 45 depth – 6 mm
stair treads thick, 40 centre to
centre
12. Insulation of ESP Resin bonded mineral 50~100mm thick
casing (for hot gas wool IS 8183 :1993 with 0.8 mm CGI
application) (RA 2004) density 100 sheet cladding as per
kg/m3 specific application
13. Insulation of Resin bonded mineral 50~100mm thick
hopper (for hot gas wool IS 8183 :1993 with 0.8 mm CGI
application) (RA 2004) density 100 sheet cladding
kg/m3
Keeping in view the properties of the dust, the Successful Tenderer will make selection of
material and thickness of plates and supporting structure. However, minimum material of
construction specification shall be as mentioned above.
12. Air tightness of ESP housing
The construction of the ESP housing and design of dust disposal gates, insulator boxes and
discharge electrodes will be such that air infiltration inside ESP housing is negligible to
prevent corrosion problem and idle suction.
Design Criteria
1. Process Parameters

Following technical input parameters will be considered as a general guide line only for
designing the ESP since the actual gas & dust composition and condition of gases changes
based on operation / process condition of technological plant. Based on the job specification
technological data as well as past experience of successful tenderer and their collaborator on
design of ESP for technological process, successful tenderer will demonstrate and establish
performance guarantee parameters under varying process parameters.
i) Type : cells, fields, dry / wet, horizontal / vertical

ii) Gas handled : Dusty gas from process application
iii) Design flow : m3/hr (avg.). at operating temp.
iv) Temperature : -- °C Normal -- °C maximum
v) Bulk density of dust : - t/m3.
vi) Dust content at ESP inlet : - gm/Nm3.
vii) Dust content at ESP outlet : - mg/Nm3.
viii) Gas velocity through ESP : - m/s
ix) ESP duty condition : 24 hrs continuous operation
x) Chemical : Oxygen -
composition Carbon dioxide -
of flue gases / dirty air / Carbon monoxide -
gases (% vol.) Nitrogen -
Sulphur dioxide-
Moisture-
Other constituents-
xi) Chemical : CaO -
composition of SiO2 -
dust (% weight) Fe2O3 -
Fe –
FeO –
Al2O3 -
MgO –
MnO -
P-
S-
C-
Na2O & K2O -
Other constituents-
xii) Particle size of dust (% distribution );
< 5micron :
5-10 micron :
10-20 micron :
20-30 micron :
30-40 micron :
> 40 micron :
xiii) Expected cleaning efficiency under normal design condition:

(moisture content -v/v, Temperature : Deg C ,
Inlet dust content - gm/Nm3, Gas flow volume – m³/hr)

xiv) Basicity Ratio –

xv) Migration velocity – cm/sec
xvi) Casing design condition - mmWC suction / ---°C
xvii) Permissible noise level - 85 dB (A)
2. Guaranteed Emission value
The efficiency of the ESP will be such that the guaranteed emission of dust from stack will
not be more than 50 mg/Nm3 or as per job specification requirement.
Correction curves for calculating revised efficiency will be applicable for change in
following input parameters:
a) Temperature : Design temperature will be considered as defined

in the TS.
b) Moisture content : Correction factor will be not be applicable
c) Dust load : Correction factor will be not applicable as this is a

technological parameter of process designer.
d) Gas flow : Positive factor or negative correction factor will

be applicable for decrease or increase in gas flow
respectively.
e) Dust composition, gas : No correction factor will be applicable for change

composition and particle in said parameters. Successful tenderer will select
size analysis the ESP which will be suitable for dust generated
by the specific process.
3. The Successful Tenderer will adopt the following criteria while designing dust disposal
system.
i) Easy maintenance of dust disposal equipment.

ii) Minimisation of outside infiltration to the ESP casing.
iii) Moisture regulation facilities to control dry dust disposal nuisance as well as too much
wet dust handling problem.
4. The equipment will be suitable to operate satisfactorily under such variations of load,
pressure and climatic conditions as may occur during working.
5. Working parts of all equipment will be suitably located for convenient operation and will
allow access to facilitate easy replacement, connecting up, inspection, lubrication,
maintenance and repair, without dismantling other equipment/ components/ structures.
6. The Successful Tenderer will carry out Computational Fluid Dynamics (CFD) based
computerized model testing for gas flow distribution inside ESP for the project. The results
of the CFD model study shall be submitted to the purchaser and consultant for their perusal
and comments, if any before proceeding with the manufacture.

7. Design calculation of ESP main supports, weather enclosure, structures, platform will be
based on IS 875 : 1987 Part 1, 2 & 3 (RA 2003) and IS 800 : 1984 (RA 1998). Service load
of 4 KN/m2 and 2 KN/m2 will be considered for maintenance platform and walk ways
respectively.
8. Compensator between rotary feeder and the chain conveyors, between two conveyors and
between dust moistener and rotary feeder will be provided to facilitate maintenance. Slide
gates will be provided before all the double cone dust valves / rotary feeders. For calculation
and design of structural members, accidental fill up of dust up to top of ESP hoppers in
worst case will be considered by Contractor.
9. To ensure safe and reliable operation of ESP, the Successful Tenderer will provide the
following minimum safety measures.
i) Prevention of condensation inside ESP chamber.

ii) Prevention of damage to rapping system.
iii) Prevention of insulator creeping and damage.
iv) Prevention of air leakage and corrosion.
v) Provision of heat expansion accommodation.
vi) Prevention of personal injury.
Lightning resistance and grounding
Explosion protection arrangement.
03. Data to be furnished by the Tenderer along with offer:
Sl.No. Item Description Technical Data
A. ESP design data

1. Model No.
2. Treatment velocity
3. Treatment time sec / Treatment length m
4. Aspect ratio
5. Press, drop mm WC
6. Migration velocity cm/sec
7. Guaranteed outlet emission at design conditions
8. Wt. of ESP with dust, ton
9. Overall size, Approx. WxLxH m
10. Cross sectional Area m²
11. Collaborator
12. Casing Design condition
13. TR set rating
14. SCA m²/m³/sec.
B. Collecting Electrode
1. Material
2. Height m
3. Spacing mm
4. Area m²

Sl.No. Item Description Technical Data

5. Rapper type
C. Discharge Electrode
1. Type
2. Material
D. ESP – Proper
1. Gas distributor
2. Insulator heating
3. Bearing
4. ESP, inlet and outlet cones
5. Enclosure sheeting & fixing hardware for TR set
6. Monorail with electrical operated trolley and hoist for lifting
TR sets
7. Insulation of casing and hopper
8. TR Rating and Drive Rating in kW
9. TR sets for different fields with quantity
10. Rappers :
Gas distributor
Collecting Electrode
Discharge Electrode
E. ESP Hopper
1. Quantity
2. Hopper volume each
3. Valley Angle in deg.
4. Hopper heater
5. RAL Valve
F. Safety Interlock System
1. Mechanical Key interlock safety system for each access door
2. Lightning arrestor and grounding

19.0 ES15 - FILTER DRY TYPE
01. General
manufacture, test and supply of different types of dry air filters required to be installed in the
Air Flow Path with all accessories for HVAC system to achieve desired efficiency of
cleaning. Specific technical requirement of air filter if any shall be mentioned in the job
Brief description of dry air filter is given below under clause 02. The point wise list of data
to be furnished by the tenderer along with the offer is mentioned below under clause 03.
02. Description
Dry panel type air filter shall be of high efficiency cleanable type, constructed out of HDPE
(6 ply) supported by layers of GI wire gauge. It shall be corrugated to the depth of filter
casing in order to increase the ratio of filtration area to frontal area. It shall be covered by
strong GI/MS frame and shall have space to ensure uniform distribution of air. Filtering
panel shall be of standard size which can be mounted on angle frame in multiple number as
per capacity of the fan. Face velocity of air shall not exceed 1.5 m/sec. The resistance of air
filter shall not exceed 10 mmWC when dirty. Efficiency of the normal air filter shall not be
less than 90% down to 10 microns unless otherwise specified in the job specifications.
Cleaning efficiency of the high efficiency air filter shall not be less than 99% down to 5
microns unless otherwise specified in the job specifications. Absolute filter as required shall
be considered in line with job specification requirement. Panel type air Filters testing shall
conform to IS 7613 : 1975 (RA 2001). A compressed air tapping with isolation valve and
hose shall be provided near to the filter installation for periodical cleaning of the filter.
a) Dry Panel type filter
1. Make & Model.

i) When clean
When dirty
4. Effective cross sectional free and face area in m2
5. Velocity through filter free and face area in m/s.
6. Material of filtering panel and construction details.
8. Methods of surface regeneration.
9. Filter box construction details.
10. Overall dimensions & no. of filters.
11. Fixing frame details.
12. Total weight
13. Module size and no. of modules.

20.0 ES16 – VOID

ES17 – THERMAL & ACOUSTIC INSULATION FOR HVAC (INSULATION

FOR COLD APPLICATION )
01. General
manufacture, test and supply of Insulation with all accessories for HVAC application.
Specific technical requirement of Insulation if any shall be mentioned in the job
Brief description of the Insulation is given below under clause No. 02. The equipment-wise
list of data to be furnished by the tenderer along with the offer is shown below under clause
No. 03.
02. Description
The insulation of water piping, air-handling units, ducting, chillers etc. shall be carried out as
per following specifications (a) to maintain proper temperature of fluid / vapour in the
conduits (b) to prevent surface condensation on cold surfaces.
Insulation Materials :
The materials to be used for insulation shall be as follows, unless some other material is
specifically mentioned elsewhere or in the job specifications.
Closed cell Nitrile rubber/Polythene (CFC/HCFC free)
The thermal conductivity of the material shall not exceed 0.04 W/m deg. C. at 10 deg. C
mean temperature and density should not be less than 60 kg/ m3. Thickness of the insulation
shall be as specified below for the individual applications. The insulation material can be
readymade pipe section or precut sheets.
Polyurethane Foam (PUF)
The thermal conductivity of the material shall not exceed 0.04 W/m deg. C. at 10 deg. C
mean temperature and density should not be less than 40 kg/ m3. Thickness of the insulation
shall be as specified below for the individual applications. The insulation material can be
readymade pipe section or precut sheets as per application. The PUF shall be CFC/HCFC
free.
Sl. Surface Insulation material Type of Thk. Finish

No. Material Section (mm)
1. Chilled water PUF PIPE 50 Sand cement Plaster
piping (100 NB Closed cell Nitrile Plain/Pipe 25 Al cladding
and less) rubber/Polythene section
pipe insulation Closed cell Nitrile Plain/Pipe 31 Al cladding
(125 NB & rubber/Polythene section

above)
pumps, valves, Closed cell Nitrile Plain section 31 Al cladding
flanges etc. rubber/Polythene
4. Expansion tank PUF Plain section 50 Sand cement Plaster
Closed cell Nitrile Plain section 25 Al cladding
rubber/Polythene
5. AHU drain pipe PUF PIPE 25 Sand cement Plaster
Closed cell Nitrile Plain/Pipe 19 Al cladding
rubber/Polythene section
6. Acoustic Resin bonded glass Slab 12 Fiber glass tissue &
insulation wool board perforated Al sheet
26G
7. Under deck PUF Slab 50 --
thermal
insulation
Ducting :
Closed cell Nitrile rubber/Polythene
The air handling ducts shall be insulated with closed cell Nitrile rubber / Polythene with density
60±2 kg/m3. Duct insulation thickness shall be as follows :
AC Duct in conditioned space - 13 mm thickness

AC Duct in unconditioned space - 25 mm thickness
Cold adhesive or equivalent can be used for setting the insulation on the pipe/duct.
Resin bonded glass/mineral wool:
The air handling ducts shall be insulated with resin bonded glass/mineral wool with density not
below 48 Kg/m3 with polythene back hessian on outer side. Duct insulation thickness shall be
as follows :
AC Duct in conditioned space - 25 mm thickness

AC Duct in unconditioned space - 50 mm thickness
Application Procedure (Resin bonded glass/mineral wool):
Clean the surface with wire brush to make it free from rust etc. Apply two coats of hot
bitumen 85/25 to the surface @ 1.0 Kg/m2 for first coat & in patches for second coat. Wrap
the duct with insulation blankets of the specified thickness. Apply PBH layer on the outside
and reinforce it by tying GI wire of 0.5 mm at interval of 450 mm.
Duct in outdoor areas exposed to weather shall be covered with 24 SWG Aluminum sheet
bent true to shape and secured with self-tapping screws and over lapped joints sealed with
Loidseal – 94.

Acoustic Lining :
The first 5 meter length of duct starting from each fan outlet shall be provided with
insulation for acoustic purposes. The insulation material shall be as specified under
“Insulation materials” above. Then it shall be covered with 0.56 mm perforated Aluminium
sheets.
Application Procedure :
The duct surface shall first be cleaned from inside. The insulation boards shall be wrapped
in Glass Cloth of 7 mil thick with ends stitched. The boards shall be fixed inside the duct.
The insulation shall then be covered with 0.56 (24 SWG) perforated Aluminum sheets.
The sheet and the insulation, shall be secured to the duct by means of cadmium plated bolts,
nuts and washers and the ends should be completely sealed off so that no insulation material
is exposed.
Walls and Ceiling – Acoustic Treatment of equipment rooms :
Insulation material shall be resin bonded glass wool/mineral wool of density 48 Kg/m3 of 50
mm thickness.
Application Procedure :
Fix 40 mm x 50 mm Deodar / Kail wood battens at 500 mm intervals longitudinally. Then

fix cross battens at 1.0 meter C – C using suitable gutties and brass / SS Screws.
Fill each rectangle with 50 mm resin bonded glass/mineral wool wrapped in glass cloth.
Then tie with 24 SWG GI wires at 300 mm intervals. Then cover with 24 SWG (0.56 mm)
perforated Aluminum sheet having 3 mm perforations at 6 mm C – C. Overlap all the joints
and provide beads of 25 mm by 1.5 mm MS flat.
Extent of Acoustic Treatment :
Walls : Two of the walls enclosing the room starting from 1 ft. above the
floor up to the ceiling.
Ceiling : The entire ceiling covering the room.
Measurement :
The measurement of insulation of vessels, piping and ducts shall be made over the insulated
surface area as per IS 14164: 1994 (RA 2001).
1. Make & Type

2. Quantity
3. Density in kg/m³

4. Thermal conductivity
5. Sound absorption co-efficient
7. Application procedure reference standard.
8. Vapour barrier material
9. Fire resistance property
10. Cladding material

22.0 ES18 – INSULATION FOR HOT APPLICATION
01. General
manufacture, test and supply of Insulation with all accessories for hot surface application.
Specific technical requirement of Insulation if any, shall be mentioned in the job
Brief description of the Insulation is given below under clause No. 02. The equipment-wise
list of data to be furnished by the tenderer along with the offer is shown below under clause
No. 03.
02. Description
02.1 General Requirements:
Thermal insulation shall be provided for all vessels, equipment, pipe fittings, heat
exchangers etc. containing fluid or vapour for which it is necessary to (a) Conserve heat (b)
Maintain temperature for process control (c) provide for personnel protection.
Thermal insulation system shall be selected so as not to result in a residual heat loss
exceeding 150 Watts/m2 under plant operating conditions measured over insulated surfaces.
For design, the following data are specified:
Ambient air temperature : 45oC (Max.)

Wind velocity : 1 m/sec.
Surface temperature : Not to exceed 15oC above ambient
Design should include de-rating factors of direct conduction paths e.g. spacer rings and
stitching wires normally associated with blanket type insulation material.
02.2 Reference Standards:
IS 8183: 1993 (RA 2004) Specification for Bonded Mineral Wool, Group – III & IV
IS 9842: 1994 (RA 2006) Specification for pre-formed Fibrous Pipe Insulation, Group–
III
IS 737: 1986 (RA 2006) Wrought aluminium and aluminium alloy sheet and strip for
general engineering purposes
IS 14164 : 1994 (RA 2001) Industrial application and finishing of thermal insulation
material at temperature above -80 deg C and up to 700 deg C -
Code of practice
02.3 Application procedure - Piping:
• For surface preparation wire brush shall be used to remove rust, dust or oil etc. thoroughly.
• Fix the pre-formed pipe-section insulation of required thickness against each diameter of
pipe as per the thickness requirement for temperature class and pipe diameter. Construction

(upto 75mm thick – 1 layer thereafter 2 or 3 multi layer) joints should be staggered so that
complete breaks are minimum on single layer insulation and no through joints occur in multi
layout work. The insulation must be held in position by strapping with 20mm x 24 SWG
Aluminium Straps.
• When lightly bonded rock wool mattresses are used, they shall be wrapped around the pipes
without any under layer. On top of each layer, the wire netting already on top of mattresses
should be tightly butted against each other so that the fibers interlock both along the
longitudinal and circumferential joints. The pipe joints shall be stitched with 22 SWG soft
GI lacing wire for pipes upto 400mm O.D. For pipes over 400mm O.D., the mattresses
should be further secured by strapping with 20 mm x 24 SWG Al. straps at 500mm intervals.
All un-insulated flanges, pipeline insulation shall be stopped off at a suitable distance from
the flange for facilitating withdrawal of bolts without disturbing insulation.
• When supporting insulation of vertical pipelines it is essential that all the pipe insulation
(above 200 NB pipe) should be supported at minimum of 3.0 meters distance by applying
insulation support spider clamps. These clamps are fitted around the pipeline bare surface
with projecting legs whose length should not be more than 70% of insulation thickness.
• Flanges and Valves: Removable covers shall be provided over all flanges and valves
whenever they are insulated with preformed materials. These covers over valves and flanges
shall have provision for quick – release clips.
• Sheet Metal Cladding: All pipes shall be covered with Aluminum sheet (24 SWG/0.56mm
upto 325mm O.D. inclusive of insulation thickness and 22 SWG/0.71mm beyond 325mm
O.D.) conforming to IS 737: 1986 (RA 2006), to the outside of the insulation with minimum
25mm circumferential and longitudinal over laps. The overlapping should be grooved so as
to prevent ingress of water into the insulation. In horizontal piping, joints shall be arranged
at an angle of 30 to 40o from the horizontal so as to shed rain water.
When lightly bonded rock wool mattresses have been used as the insulation material, spacer
rings shall be required screwing the Aluminum sheet. The sheet metal shall be secured to
themselves by self-tapping screws at a pitch not exceeding 150mm.
After securing the Aluminum sheet, the overlapped joints of the sheet metal shall be sealed
with metal sealant to make joints perfectly waterproof.
02.4 Application Procedure – Vessels & Equipment:
• The surface to be insulated shall be thoroughly cleaned by wire brushing to remove dirt,
loose scales, dust etc.
• Where welding is permissible, weld 10 SWG GI spokes at 300 – 400mm diamond pitch.
• `L’ shaped lugs to be fixed to the spacer rings made of 25mm x 3mm MS flats at 450mm C –
C with 25mm x 25mm x 3mm asbestos mill board washers and 4mm MS rivets.

• The spacer rings shall be fixed around the tank at 900mm C – C by welding `L’ shaped lugs
to tank body.
• Impale Rock wool lightly bonded machine stitched mattresses with one side wire netting of
required density (upto 400o – 100 Kg/m3, above 400oC – 120 Kg/m3) and thickness, with the
ends of mattresses butted closely together with lacing wire of 22 SWG. In addition,
mattresses shall be secured with tightly tensioned circumferential Aluminium bands at
approx. 450mm pitch.
• The ends of GI spokes shall be bent on the insulation.
• The Aluminium metal cladding (22 SWG/0.71mm) is to be fixed on the spacer rings with
self-tapping screws at 150mm C – C.
• All over lapped joints of Aluminum sheet metal shall be sealed with loidseal-94 to make
joints waterproof.
02.5 Expansion Joints:
Expansion joints shall be provided in the insulation to allow for movement and expansion of the
pipe or vessel without producing random cracks. At the expansion joints, there shall be complete
cut and the cutout portion shall be 25mm wide and dry filled with loose insulation material the
density of which shall be equal to that of the basic insulation. The expansion joints wherever
necessary shall be installed by overlapping the cladding material.
Pipe temp. oC Spacing of Expn. Joints in meters
Upto 200oC No Expn. Joint.

201 to 300oC 3.5
301 to 400oC 3.0
Above 400oC 2.0
02.6 Design Criteria :
Ambient air temperature 35oC or 45oC

Design surface temperature Not to exceed 15oC above ambient air temperature
Wind velocity 1 meter/second
Cladding over insulation Aluminium (Emissivity : 0.2)
Insulation material Rock wool density 144 Kg/m3 upto 350 mm NB, Rock wool
mattresses above 350mm NB pipes density 100 Kg/m3 upto
400oC and 150 Kg./m3 above 400oC
02.7 General Guidelines for insulation thickness :
Temperature: 100oC 200oC 300oC 400oC 500oC

Pipe NB Thickness of Insulation
100 25 40 70 100 140
200 25 45 80 115 160

300 25 45 85 125 170

400 25 55 95 145 190
500 25 55 95 150 195
600 25 55 100 150 200
Flat 25 60 115 140 255
Note: For piping upto 325 mm OD (including insulation thickness) aluminum sheet
thickness – 24 SWG (0.56mm) and beyond 325 mm OD (including insulation
thickness) aluminum sheet thickness – 22 SWG (0.71mm).
1. Make & Type

2. Quantity
3. Density in kg/m³
4. Thermal conductivity
6. Application procedure reference standard.
7. Vapour barrier material
8. Fire resistance property
9. Cladding material

23.0 ES19 – PACKAGED AIR CONDITIONER
01. General
manufacture, test and supply of Packaged Air Conditioner with all accessories to make
operation of Packaged Air Conditioner complete in all respects. Specific technical requirement
of Packaged Air Conditioner if any, shall be mentioned in the job specification/data sheet as
furnished along with the Technical Specification.
Brief description of the Package Air Conditioner is given below under clause No. 02. The
02. Description
Each package air-conditioner will essentially comprise of compressor, cooling coil, refrigerant
circuit, condenser, blowers, air filter, electric drives, instruments and controls and other standard
accessories assembled in steel cabinet. The air-conditioner will be designed for continuous duty
and mean time between failures will be considered minimum 2 years. The equipment shall be
designed, manufactured and tested as per IS 8148 : 2003. All electrical connections shall be
built in, Purchaser will provide the power supply load.
The compressor will be semi-hermetically/ hermetically sealed, mounted on anti-vibration pads

& dynamically balanced.
The condenser will be water cooled shell and tube type with effective surface area for heat
transfer taking into consideration the scale factor of 0.0006 for water side and optimum number
of passes to achieve desired duty conditions. Provision will be made in the steel cabinet for tube
side cleaning during maintenance. The condenser will also serve as refrigerant receiver of
refrigerant circuit with fusible relief plug.
Alternatively as per job specification requirement condenser may be air cooled with fins and
tube type with effective heat transfer area taking into consideration high ambient temperature of
site selected. A refrigerant receiver shall be provided in the refrigerant circuit. Air cooled
condenser along with the fan shall be installed in the free area for movement of outside air
through condenser tube for effective cooling of refrigerant.
Cooling coil will be direct expansion type with integrally finned copper tubes and fitted with
equalizing distributors to ensure equal amount of refrigerant in each circuit. Condensate drip
pan will be provided below the cooling coil for collecting the condensate.
The refrigerant circuit will be completely piped at factory and charged with required amount of
refrigerant. The circuit will comprise of thermostatic expansion valve, distributor, liquid
strainer, liquid line shut off valve, dehydrator etc. The circuit will be protected with safety
devices such as high and low pressure cutouts, fusible plug, water flow/differential pressure
switch, oil safety switch, time delay relay etc. to protect the unit from damage due to sudden
and serious fluctuations in operating conditions. The refrigerant will be R22 / R134a/ R407c/
R123.

For control of temperature and humidity of the conditioned premises, thermostat and
humidistat will be provided in the package A.C. plant room as per job specification
requirement.
The centrifugal blower will be designed for distribution of the conditioned air through the
network of duct and supply air diffusers. The impeller will be of forward curved, dynamically
balanced for low noise and vibration free operation. The fan will be coupled with motor by
V-belt and mounted on anti vibration mounting.
The necessary control and instruments include thermostatic expansion valve, sight glass,
strainer, cooling thermostat, heating thermostat, humidistat, strip heater, shut off purge valve
and drain valve, dial type pressure and temperature gauges etc. Cooling thermostat and
humidistat will be provided in the return air circuit (in A.C. plant room) as per job specification
requirement.
Dial type 150mm dia pressure gauge will be provided with isolating cocks/ valves. Flow switch
/ water differential pressure switch will be installed in condenser water inlet line to stop the
compressor when water supply stops. High efficiency filter & strip heater will be installed in the
supply air duct at the discharge end of packaged unit and the strip heater will be interlocked
with the blower of the packaged unit to prevent independent control/ switching of heaters as per
job specification requirement.
The blower and the evaporative coil sections of the packaged unit will be thermally insulated to
minimize thermal leakage. The unit will be supplied with rubber pad for installation on PCC
pedestals.
Circulating condenser water cooling pipeline will be provided with strainer and by pass line.
Make & Model

Quantity
Capacity in TR
Overall dimension of Packaged AC Unit
Air flow capacity of blower m³/h
Total Pressure, mmWC
Fan Motor kW
Fan RPM
Compressor type, model
Compressor motor kW
Refrigerant type
Condenser type
Condenser material of construction
Overall size of condenser
Material of construction and its thickness of casing
Insulating material of casing
Total Power consumption.
Noise level at 1m distance in dB(A)

Vibration isolation pad

Performance curve.
Fixing details.
Refrigerant drier and strainer

24.0 ES20 – PROPELLER FAN
01. General
manufacture, test and supply of Propeller Fan with all accessories to make operation of
Propeller Fan complete in all respects. Specific technical requirement of Propeller Fan if
any shall be mentioned in the job specification/data sheet as furnished along with the
Brief description of the Propeller Fan is given below under clause No. 02. The equipment-
wise list of data to be furnished by the tenderer along with the offer is shown below under
clause No. 03.
02. Description
Propeller type axial flow fanis used for general air exchange of the served premises. The fan
shall be heavy duty and wall mounted type propeller fan design and shall conform to IS
2312: 1967 (RA 2000). Fan impeller blade shall be of aerofoil section and mounted directly
at the motor shaft. The RPM of the fan preferably shall be restricted to 900 RPM and should
always be less than 1500 RPM. Noise level should not exceed 85 dB(A) at 1 m distance.
Air entry shall be from motor side. Louver shutter/non-return damper shall be provided at
the outlet side of fan to prevent back draft. The fan shall be provided with fixing frame,
supporting lugs and other standard accessories.
1. Make & Model

2. Capacity in m³/hr
3. Quantity
5. Total pressure in kgf/m²
6. Characteristic curve
7. Speed in RPM
8. Size of fan
9. Drive details (kW & power supply)
10. Efficiency
11. Fixing details
12. Weight of fan & motor
13. Performance curve
14. Details of non-return damper/louver shutter
15. Fixing frame

25.0 ES21 – SCRUBBER DUST EXTRACTION SYSTEMS
01. General
manufacture, test and supply/fabrication of Centrifugal / Venturi Scrubber System with all
accessories required to be installed for dust extraction application to achieve desired
performance in all respects. Specific technical requirement of Centrifugal / Venturi
Scrubber System if any shall be mentioned in the job specification/data sheet as furnished
along with the Technical Specification.
Brief description of Centrifugal / Venturi Scrubber is given below under clause No. 02. The
point wise list of data to be furnished by the tenderer along with the offer is mentioned
02. Description
02.1 Centrifugal scrubber
Centrifugal scrubber is essentially a vertical steel cylinder with conical bottom. Casing and
bottom are made of heavy gauge sheet steel. The top of the casing is connected to exhaust
fan and conical portion of the casing is provided with a hydraulic seal. The rectangular inlet
of the scrubber is welded to the casing tangentially with respect to its inside surface and with
a slant of 10oC toward casing. Dust deposited on the walls of the inlet duct is washed by
water sprayers.
The inside surface of the casing is continuously sprayed by sprayers. The water jet emerges
from sprayers in the same direction as the swirling air, and at the same time, tangentially to
the inside surface of the casing and thus washes it without producing any droplets. The
operation of nozzles is checked through inspection holes located just above them.
Dust laden air enters the bottom cylindrical part of the scrubber casing through inlet duct at
an approximate velocity of 20 m/sec. As it enters the scrubber, a portion of the stream is
directed upwards along a helical line, following closely the inside surface of the casing. The
remaining stream revolves and descends, rebounds from the scrubber bottom and rises along
a helical line but closer to cyclone axis. Both streams merge at the outlet.
A centrifugal force arising on rotation of the air stream ejects dust particles towards the
sprayed surface of the scrubber. The majority of the particles reaches the film of water and
are captured by it.
Water containing captured dust particles trickles down the casing wall and is removed via
the hydraulic seal. The protective baffle provided above the sprayers is intended to minimize
entertainment of droplets. The mean air velocity for the full cross section of the cylindrical
portion of the scrubber is taken to be 5.5 m/s.
The efficiency of the scrubber should be sufficiently high so that the dust concentration in
the exhaust ducting shall not exceed 50 mg/Nm³.

02.2 Venturi Scrubber
The venturi scrubber consists of high speed atomizer and centrifugal separator. High speed
atomizer consists of converging cone, throat and diverging cone. Air stream is accelerated in
converging cone and the velocity of the stream rises. Water is introduced at the throat, where
it is atomised due to high pressure.
Dust laden air and water enter the throat, where they are mixed at high energy and extreme
turbulence. The throat with its length provides an extended period of thorough mixing. The
scrubbed air and entrained droplets (with contaminants entrapped) then enters the diverging
cone where further collisions and agglomeration takes place creating larger droplets. The air
stream then proceeds to centrifugal separator where liquid droplets due to their coarse size
are easily removed from the air stream. The working of the centrifugal separator is similar to
that of centrifugal scrubber except that the water sprayers are not required.
The efficiency of the venturi scrubber shall be sufficiently high so that the dust concentration
in the chimney does not exceed 50 mg/Nm3 or as per job specification requirement.
a) Centrifugal Scrubber
Make & Model.

Capacity in m3/h.
Pressure drop in mmWC.
Overall size of centrifugal scrubber
Air velocity through scrubber body in m/sec.
Water quantity and pressure required for scrubbing
Spray nozzle quantity, diameter and material of construction
Material of construction of scrubber body
Cleaning efficiency Vs particle size
Water sealing arrangement at bottom of scrubber
Methods of slurry disposal.
Supporting frame details.
Total weight of scrubber
b) Venturi Scrubber
Make & Model

Capacity in m3/h.
Pressure drop in mmWC.
Overall size of venturi scrubber and centrifugal collector
Air velocity at inlet, throat & outlet of scrubber in m/sec.
Water quantity and pressure required for scrubbing at throat & slurry disposal at
centrifugal collector
Spray nozzle quantity, diameter and material of construction
Material of construction of scrubber body
Material construction of throat
Cleaning efficiency Vs particle size

Water sealing arrangement at bottom of centrifugal collector

Methods of slurry disposal.
Supporting frame details.
Total weight of venturi scrubber

26.0 ES22 – STACK
01. General
manufacture, test and supply/fabrication of Stack with all accessories required to be installed
for exhaust of air to achieve desired performance in all respects. Specific technical
requirement of Stack if any shall be mentioned in the job specification/data sheet as
furnished along with the Technical Specification.
Brief description of Stack is given below under clause No. 02. The point wise list of data to
be furnished by the tenderer along with the offer is mentioned below under clause No. 03.
02. Description
1. Construction
Self-supported stack made of M.S. Plates (IS 2062 : 2006) shall be provided to discharge the
cleaned air to atmosphere. The height of the stack shall be 2 to 3m above the nearest highest
building or minimum 45m. Higher stack heights will be required for high volume
applications like secondary dedusting system of BOF, sinter waste gas cleaning, etc. or as
specified in the job specifications. Stack shall be fabricated as per IS 6533 : Part 1 : 1989
(RA 2006) for design and construction of steel chimneys - Mechanical aspects & IS 6533 :
Part 2 :1989 (RA 1998) for design and construction of steel chimneys - Structural aspects.
2. Lightning Protection
Protection against lightning shall be made in accordance with IS 2309:1989 (RA 2005).
Lightning Protection shall be provided by creating a path of minimum electrical impedance
from the stack top to an earthing strip on the ground. At about 1500 mm from the stack top, a
circumferential conductor (coronal band) shall be provided which is lead-covered, stranded and
of tinned copper. This is connected to air-terminal rods (which shall project about 750 mm
above the top of the earthing strip. During construction, temporary lightning protection shall be
provided and this should be in the form of a single conductor connected to a temporary
air-terminal at the top and to the earthing system on the ground. Vertical reinforcing bars near
the stack base shall be electrically connected to a down conductor. Similarly all steel parts and
footing reinforcement should be connected to a down conductor. At the top of the stack the
lightning conductors shall be adequately protected from chemical corrosion by applying a lead
coating or by other suitable means.
3. Aviation Warning Lights
Aviation warning lights shall be provided even during construction once the stack reaches a
height of about 40m above ground. Both temporary as well as permanent provisions shall be of
neon type. These lights shall have sufficient intensity (about 100 lux) so that they are
conspicuous considering the back-ground illumination level against which they are viewed. Day
marking shall be provided by painting the stack in contrast colour bands for at least the top
one-third of its height. Such bands shall range from 0.75 to 3 m in width with the outer bands in

darker colour. The paint used for the bands shall be acid-resistant and shall safely withstand the
temperature of the gases handled.
4. Staircase
The stack shall be provided with staircase, landing / resting platform at every 10m, handrails,
painter's trolley, structures etc. Ring platform around stack shall be provided at location of
aviation lamps.
5. Clean-out and Access Door
A suitable access door shall be provided at the bottom of the stack.
6. Sampling Ports
The sampling ports shall be provided as per Emission Regulation Part-III or its latest
amendments. A single phase, 15A power point shall be provided near the ports for operating the
stack monitoring kit.
7. Partition plates
When bottom of the stack is used as a suction chamber for fans, vertical and horizontal partition
plates shall be provided to isolate the suction chamber and to ensure equal distribution of air to
multiple fans. Similarly, partition plates shall also be provided in the discharge chamber of the
stack to avoid turbulence from multiple discharges. The no. of such partition plates shall depend
on the no. of ID fans. Suitable stiffeners shall be provided for these partition plates in stack.
8. Work Platform
a) Construction
Size and extent of platform : If two ports are required at 90 degrees, the work
platform should serve that half of the stack circumference between the ports and
extend at least 1.2 meters beyond each port. If four ports are required at 90 degrees,
the work platform should serve the entire circumference of the stack. The minimum
platform width shall always be 1.2 meters regardless of diameter of stack and
number of sampling ports.
b) Platform Access
Safe and easy access to the platform shall be provided via stairway or other suitable
means. A safe guard rail should be provided on the platform. Angular rather than
round rails members should be used, wherever possible. No stairwell or any other
opening shall be located within 1 meter of any port.
c) Platform loading
The work platform should be able to support atleast three men (average 80 kg each)
and 91 kg of test equipment (stack monitoring kit etc.). If the stack exists through a
building roof, the roof may suffice as the work platform, provided the minimum test
site conditions are still met.

d) Clearance Zone
A three dimensional, obstruction free clearance zone should be provided around
each port. The zone should extend 0.6 m above, below, to either side of the port. The
zone should extend outward from the exterior wall of the stack to a distance of at
least 3 meters.
03. Data to be furnished by the Tenderer along with offer:
a) Diameter in mm
b) Material & thickness
c) Height in m
d) Level of sampling port holes
e) Level of platforms
f) Support & structure with stairs
g) Weather Cowl / telescopic duct connection

27.0 ES23 – TUBE AXIAL FLOW FAN
01. General
manufacture, test and supply of Tube Axial Flow Fan with all accessories to make operation
of Tube Axial Flow Fan complete in all respects. Specific technical requirement of Axial
Flow Fan if any shall be mentioned in the job specification/data sheet as furnished along
Brief description of the Tube Axial Flow Fan is given below under clause No. 02. The
02. Description
Tube axial flow fans shall be of heavy duty type and of four kinds, as per service
requirement, as follows: a) Roof exhauster, b) Roof mounted supply air fan, c) Wall
exhauster, d) wall mounted supply air fan.
Axial fan design shall confirm to IS 3588: 1987(RA 1999).
The roof exhauster / roof mounted supply air fan shall have multi-bladed impeller with short
duct casing while the wall exhauster/ wall mounted supply air fan shall have cone inlet
suitable for free discharge of air. The fans shall be capable of withstanding the stresses
which may be experienced during normal operation under the condition which it is required
for and during over speed test. The noise level shall not exceed 85dB(A) at 1m distance.
The first critical speed of the rotating assembly shall be at least 25% above the operating
speed. The speed of the fan shall preferably be limited to 1500RPM for fan with diameter
600mm or less and 960RPM for fans with diameter more than 600mm to limit the noise
generation.
Impeller:
The impeller shall be of cast aluminium alloy construction of high efficiency aerofoil section
blades. The fan impellers shall be cast in one piece, finished all over and carefully balanced
both statically and dynamically as per ISO - 1940. Finally the assembled rotor shall be
dynamically balanced.
Casing:
Axial flow fan casings for wall mounted/roof mounted fans and their components shall be
suitable for outdoor installation. The casing shall be minimum 2 mm thick. The casings
shall be provided with flanges at inlet and outlet. All nuts & bolts associated with it shall be
of zinc or cadmium plated. Easily removable inspection cover having galvanised fly nut
shall be provided. The covers shall be located such that the grease nipple for all bearings,
and also motor terminals are easily accessible through the cover.
Hood and Cowl

Roof exhauster/supply air fans shall be provided with hood for protection against rain and

other contingencies. It must ensure no dripping of rain water under any circumstances and
will have low pressure drop of air. The hoods shall be provided with a heavy gauge
expanded metal bird screen.
Rain protection cowls shall be designed to suit wall exhausters for protecting fans from rain.
The cowls shall be provided with bird screen of heavy gauge expanded metal netting. The
rain protection hood & cowl shall be fabricated from minimum 14G thick MS sheet (Hot dip
galvanised).
Coned Inlet
Wall exhausters shall be provided with coned inlet made of MS 2 mm thick or 16G, GI
sheet.
Inlet Screen
Inlet screen shall be manufactured with minimum 14 SWG galvanised wire knitted in 25 mm
square mesh. Suitable flanges to protect the edges of the screen shall be provided.
Fans for Special Applications
These fans & motors when used in explosive / inflammable fume extraction system shall be
of spark proof construction. Fan impeller and inside surface of the casing shall be epoxy
painted. In case of exposure to acid fumes, the fan along with drive motor, accessories &
supports etc. shall have acid proof painting.
Fan Drive
All direct drive axial flow fan impellers shall be directly mounted on extended motor shafts.
Alternatively as per job specification requirement bifurcated type V-belt drive may be
considered. Flame proof motors shall be provided in explosive / inflammable zones.
Materials of Construction
a) Impeller : Cast Aluminium Alloy

b) Shaft : EN-8 as per BS-900 or its equivalent
c) Fan Scroll : Heavy gauge M.S.
d) Fan Supports, Frames : M.S.
e) Coned inlet : M.S. 2mm thick
f) Dampers : M.S. of heavy gauge
g) Connection pieces : Galvanised M.S.
h) Bolts and Nuts : Galvanised M.S.
i) Rain protection cowls, : GI sheet
hoods and casing
Make & Model

Quantity

Capacity in m3/h.
Total Pressure, mmWC
Material of construction and its thickness
Speed in RPM.
Drive details like make, kW rating, type, insulation & protection class etc.
Shaft Power consumption.
Wheel diameter.
Efficiency.
Size of fan
Static & Dynamic weight of fan & motor assembly
Critical speed of fan
Performance curve.
Air flow direction.
Fixing details.
Vibration level.

28.0 ES24 – WATER LINE VALVES
01. General
manufacture, test and supply/fabrication of Valves with all accessories required to be
installed for HVAC systems & Air pollution control systems to achieve desired performance
in all respects. Specific technical requirement of Valves if any shall be mentioned in the job
Brief description of Valves is given below under clause No. 02. The point wise list of data
to be furnished by the tenderer along with the offer is mentioned below under clause No. 03.
02. Description
Depending on the layout, the Tenderer will provide valves wherever required for HVAC &
Air pollution control systems.
All valves shall conform to applicable Indian Standards.
All flanged valves and pipe fittings will be supplied with matching flanges, bolts, nuts and
gaskets.
All valves will be suitable for required working pressure of the system served.
Pot strainers will be provided in the condenser water supply / inlet line, washed air systems,
etc. Y-strainers may be provided only in vertical lines. Bypass line with valves will be
included to facilitate cleaning the strainer without affecting the functioning of the unit.
Gate / Butterfly valves will be provided at pump outlets, inlets & at tank outlets. Non return
valves shall be provided at pump outlets.
For dust suppression systems, pressure relief valves shall be provided at pump outlet to
divert water back to the tank in case downstream usage of water is reduced. Butterfly valves
shall be provided in branch headers to operate a particular group of sprinklers. Globe valves
shall be provided on sprinkler headers to control the flow through each sprinkler.
Butterfly valve
Butterfly Valves shall be provided in water line of size 65 NB and above and ball valve be
provided for pipe size below 65 NB
Type : Wafer design

Body : SG iron with nitrile rubber/ EPDM lining
Disc : SG Iron with teflon (PTFE) coating
Stem : High tensile stainless steel
The valves shall be provided with integrally moulded & bonded body liner to provide perfect
seating and complete isolation of body material from fluid. The body liner shall provide the
seating to valve disc, primary seal to the stem & gasket joint with matching pipe flanges.
Valves shall be provided with self locking lever operation from open to fully closed position

with intermediate positions marked on the indicator plate mounted on the top flange. The
valves shall conform to BS 5155 / IS 13095: 1991, RA 2003. Extended valve shaft shall be
provided so that the lever can be operated without any obstruction on the insulated pipes.
Gear operated valves shall be provided for sizes more than 150 NB.
Ball Valve
Body : Cast steel

Body liner : Nitrile rubber/ EPDM
Ball : ASTM A351 Gr CF8
The ball valve shall be of 3 piece design, socket welded type and be supplied with 200mm
length of pipe on both sides
Gate Valve
1. Type Gate valve with non-rising spindle & bolted bonnet

2. Body Below 50 mm Bronze. 50mm & above Cast iron as
per IS: 210-1993 (RA 1999),GR.200
3. Bonnet Bolted
4. Spindle SS as per AISI 410
5. Disc Cast iron as per IS:210-1993 (RA 1999),GR 200
6. Body seat ring & SS as per AISI 410
Disc facing ring
7. End connections Below 50 mm - Screwed. 50 mm & above flanged
end, to be drilled as per ANSI B.16.5
8. Pressure rating As per system requirement
9. Flange facing Flat Face
10. Manufacturing std. IS:778, 1984, RA 2007
11. Bolts & nuts Black Hexagonal bolt with nut as per ASTMA 307
Gr B.
12. Gaskets Compressed Asbestos Fibers to IS 2712: 1998 (RA
1999), 1.5 mm thick
13. Hand wheel CI Gr 200 as per IS : 210 – 1993 (RA 1999)
14. Packing Asbestos
15. Companion Flanges ANSI B16.5 Class 150
16. Hydrostatic testing As per relevant IS & Pressure rating of PN 1.6
17. Test certificates For Physical/chemical analysis & metallurgical
tests for body parts , Hydro testing
18. Service Re-circulation water/ Make up water/chilled water
Globe Valves
1. Type Globe valve for water supply pipelines

2. Body/Bonnet Bronze As per IS 318: 1981 (RA 2001) Gr 2
3. Stem Brass as per FHTB 1 of IS 6912: 2005
4. Hand wheel CI FG 200 as per IS : 210 – 1993 (RA 1999)
5. Gland, Gland nut, As per IS 318 (RA 2001) Gr 2

spindle nut
6. Gland Packing Asbestos
8. Manufacturing std. IS : 778 : 1984 (RA 2007)
9. Max. Optg. temp 50 0 C
10. Operation Manually operated hand wheel with open and close
direction indication.
11. End connection Screwed as per IS-554 upto 40 mm unless
otherwise mentioned in job specifications. Flanged
end for 50 mm and above.
12. Special features 1) Arrow indicating flow direction
2) Embossed nameplate-giving details of tag nos.,
type and size.
13. Service Re-circulation water/ Make up water/chilled water
14. Hydrostatic Testing As per relevant IS and pressure rating of PN 1.6
Non return valves
1. Type Dual plate check valve with two springs hinged on

a central hinge rod / Swing check type
2. Body SG iron / Cast iron as per IS: 210-1993 (RA 1999),
GR. 200.
3. Body liner Nitrile rubber/ EPDM
4. Cover SG iron / Cast iron as per IS: 210-1993 (RA 1999),
GR. 200.
5. Hinge Cast iron as per IS: 210-1993 (RA 1999), GR.220.
6. Hinge pin HT brass IS 320: 1980 (RA 2006) HT-2
7. Body Seat Ring & IS 318: 1981 (RA 2001) Gr 2
Disc ring
8. Disc ASTM A351 Gr CF8 / CI as per IS: 210-1993 (RA
1999), Gr.200
9. Gasket CAF gasket as per IS 2712: 1998 (RA 1999) of
thickness 1.5 mm
10. End connections Flanged end, drilling as per ANSI B16.5
12. Manufacturing Std IS:5312(Part-1)-2004 / BS-5153 1991
13. Bolts & Nuts Hexagonal type as per IS:1367-1967 Cl.-4.614.4
14. Companion Flanges ANSI B 16.5 class 150
15. Hydro static testing As per IS : 5312 Part-1 -2004 / BS 5153 (1991) and
pressure rating of PN-1.6
16. Test certificates For Physical/chemical analysis & metallurgical
tests for body parts , Hydro testing
17. Service Water / chilled water
Make & Model -

Type -
Quantity -
Size -
Pressure rating -
Material of construction -
Operating system -
Drive details. -
Gland packing -
End connections -
Service -
Test pressure -

29.0 ES25 - WINDOW / SPLIT / DUCTABLE SPLIT TYPE AIR CONDITIONER
01. General
manufacture, test and supply of Window Type Air Conditioner / Ductable type split air
conditioner /Split Type Air Conditioner with all accessories to make operation of Air
Conditioners complete in all respects. Specific technical requirement of Air Conditioners if
any, shall be mentioned in the job specification / data sheet as furnished along with the
Brief description of the Air Conditioners is given below under clause No. 02. The
02. Description
1. Window Type Air Conditioners
Window air conditioners shall comprise of hermetically sealed compressors, air cooled
condenser, refrigerant piping, blower, instruments and controls, supply air grill with direction
deflector etc. enclosed in a insulated steel cabinet. 3 meter long power cable along with plug
and socket unit shall be provided for each air conditioner. Necessary installation fittings like
condensate drain pan and fixing attachments shall be provided by the successful tenderer. Any
additional services required shall be included in line with job specification requirement.
Window air conditioner unit shall conform to IS 1391 : Part 1 : 1992 (RA 1999).
2. Ductable Split Type Air Conditioner
Air cooled Ductable Split Air Conditioners shall comprise of ceiling suspended ductable
Indoor Unit and Outdoor Unit with Hermetically Sealed Scroll Compressors. Nominal
Evaporator Air quantity should be 400 CFM / TR. The Indoor Unit should have air duct outlet
at the front. The Ductable Split Air Conditioners shall be suitable for operation on 415 V +/-
10%, 3 Phase, 4 Wire, 50 Hz electrical power supply. The ductable split type air conditioners
shall be complete including refrigerant piping, valves, accessories, power & control cables and
insulated drain piping.
The Outdoor Units shall be located outside the air-conditioned space and shall be
interconnected through hard drawn copper refrigerant pipes to the indoor unit located inside
the air-conditioned space with Liquid Line & Suction line.
The Outdoor Unit shall be Air cooled Condensing Unit. The Condensers shall have suitable
diameter copper tubing with extended aluminum fins. The tube shall be arranged in a staggered
fashion for better efficiency. Ambient air will be used for cooling of refrigerant in the copper
tubes. The air will be sucked by one or more propeller type direct driven fan. The fan shall be
adequately sized for circulating enough quantity of air from ambient for giving the rated
output. The fan shall be of speed less than 1000 RPM so that the noise level of the equipment

is low. The casing shall be made from corrosion resistant 0.9 mm (min.) galvanized steel sheet
with polyester powder coating to withstand the effect of nature.
The Indoor Unit shall have necessary number rows of Cooling Coil of copper tubing with
extended aluminum fins for higher heat transmission efficiency. The fins shall be bonded on to
the tube by hydraulic expansion of copper tubing. The Cooling Coil shall be designed in a
staggered manner for maximum contact between air and tube surface with low bypass. The
cooling circuits are fed with liquid refrigerant through Thermostatic Expansion Valve and
liquid distributor. The surface area of the cooling coil shall be adequate to give required
refrigeration capacity.
Scroll Compressors in each Outdoor Unit shall be mounted on rubber grommets with metal
sleeves so that no vibration is transmitted to the body of the Outdoor Units or to its base. The
Compressor shall be Hermetically Sealed Scroll Type Compressor.
The air circulation from the indoor unit shall be maintained through centrifugal forward curved
DIDW fans, statically and dynamically balanced to give sufficient static pressure and the
required air quantity of not less than 400 CFM/ TR.
The blower fan shall be selected for minimum three-speed operation with a maximum speed
upto 1000 RPM.
The Indoor Unit shall have washable non-woven polyester media enclosed by HDPE mesh Air
Prefilter. The filter shall be mounted in a filter frame so that it is held in position during
operation of the unit. The casing of Indoor Unit shall be made from corrosion resistant 1.6 mm
(min.) galvanized steel sheet on the side panels and 0.9 mm (min.) galvanized steel sheet for
front, back and top panel with polyester powder coating. The supply air side of the Indoor Unit
shall be insulated with 12 mm Fiberglass bonded by non-water soluble fire retardant
thermosetting resin.
The Split type Air Conditioners shall be accompanied with remote micro-controller having the
following features :
(i) Two Speed Selection

(ii) Automatic Selection of Compressor to ensure energy efficiency.
(iii) Run time equalization between Compressors
(iv) Accurate temperature sensing through Electronic Thermostat.
(v) Memory backup in case of power failure
(vi) Digital control of temperature.
(vii) Auto restart after power failure.
(viii) Built in time delay protecting compressors from instant Stop / Start.
(ix) Single and Reverse Phase protection.
(x) Fault diagnostics, facilitating safety trips and fast corrective action.

The Unit shall have type accessories like HP/LP Cutout for safety protection of the
Compressor, liquid line valve and catch all dryers.
3. Split Type Air Conditioner
Split air conditioning unit shall comprise of two sections - Indoor and Outdoor. Indoor section
shall comprise of cooling coil, fan, supply air grill, filter. Outdoor section shall comprise of air
cooled condenser, condensing fan, hermetically sealed compressor. Sealed refrigerant piping
shall inter connect indoor and outdoor sections. Outdoor unit shall be installed in open space
for easy heat dissipation from condenser. Indoor section shall be ceiling suspended or wall
mounted type as per job specification requirement. Remote control unit, thermostat and other
standard accessories for successful installation of split type air conditioner shall be included in
the scope of successful tenderer. Any additional services as required, shall be included in line
with job specification requirement. Split air conditioner unit shall conform to IS 1391 : Part 2 :
1992 (RA 1999).
Make & Model

Quantity
Capacity in TR
Air Flow m³/h
Flow direction and volume control grill
Compressor type
Drive details and total power consumption
Overall dimensions
Refrigerant type
Filter efficiency
Weight of unit
Fixing details.
Vibration level.
Accessories included

ABBREVIATION
Sl. Abbreviation Description

No.
1. VAM Vapor Absorption Machine
2. A/C Air Conditioning
3. HVAC Heating, Ventilation & Air Conditioning
4. ISHARE Indian Society of Heating and Refrigeration Engineers
5. DBT Dry Bulb Temperature
6. RH Relative Humidity
7. RPM Revolutions per Minute
8. AHU Air Handling Unit
9. SWG Standard Wire Gauge
10. MS Mild Steel
11. NB Nominal Bore
12. RA Re-Affirmed
13. HP/ LP High Pressure / Low Pressure
14. SPM Suspended Particulate Matter
15. RPM Respirable Particulate Matter
16. DE SYSTEMS Dedusting Systems
17. ACGIH American Conference of Governmental Industrial Hygienists
18. CPCB Central Pollution Control Board
19. HRC Hardness measured on Rockwell Scale
20. IS Indian Standard
21. BHN Brinell Harness Number (Hardness measured on Brinell Scale)
22. ESP Electrostatic Precipitator
23. RAV Rotary Air Lock Valve
24. RAL Valve Rotary Air Lock Valve
25. DFDS Dry Fog / Dual Fluid Dust Suppression System
26. AISI American Iron and Steel Institute
27. SS Stainless Steel
28. DS Dust Suppression
29. P & ID Piping and Instrumentation Diagram
30. PVC Polyvinyl chloride
31. FCU Fan coil unit
32. PUF Polyurethane Foam
33. EU-3 Europa Universalis III
34. G.I. Galvanized Iron
35. ISO International Organization For Standardization
36. S / AIR DUCT Supply air duct
37. ADP Apparatus Dew Point
38. HDPE High Density Polyethylene
39. GSS Galvanised Sheet Steel
40. DIDW Fan Double Inlet Double Width Fan
41. AMCA Air Movement and Control Association
42. TIG Tungsten inert gas
43. MOC Material of Construction

Sl. Abbreviation Description

No.
44. PTFE Polytetrafluoroethylene
45. CRCA Cold Rolled Closed Annealed
46. MCB Miniature Circuit Breaker
47. HRC High rupture capacity
48. LED Light emitting diode
49. DP Switch Differential Pressure Switch
50. VIV Variable inlet vanes
51. RTD Resistance temperature detector
52. H-Q Enthalpy -Flow characteristics
characteristics
53. NPSH Net Positive Suction Head
54. ANSI American National Standards Institute
55. CAF Compressed Asbestos Fibre
56. HTG High Temperature Generator
57. RCC Reinforced Cement Concrete
58. PRDS Pressure Reducing and De-superheating Station
59. IBR Indian Boiler Regulations
60. GA General arrangement
61. TR Tones of refrigeration
62. LTG Low Temperature Generator
63. DX Direct expansion type
64. ARI Air-Conditioning and Refrigeration Institute
65. FRP Fiberglass Reinforced Plastic
66. TEFC Totally Enclosed Fan Cooled
67. CR Sheets Cold Rolled Sheets
68. SCA Specific Collection Area
69. CFC/HCFC Chloro Fluoro Carbon / Hydro Fluoro Carbon
70. EPDM Ethylene propylene diene Monomer
71. ASTM American Society for Testing and Materials

NMDC LIMITED

FOR
PAINTING
(GS – 09)
MECON LIMITED
RANCHI - 834002


Sl . D e scr i pt i o n Pa g e No .
N o.
01 G ENE RA L 2
02 S UR FA CE PR EP AR A TIO N 3-4
03 P AI NT AP P LICA T IO N 4-7
04 P AI NTI N G S CH E ME S 7-8
05 G UA R AN T EE 8
A NN E XU R E-0 1 – SU RF ACE PREP ARAT IO N G RA DE 9
A NN E XU R E-0 2 – PA I N T MA TER IA LS 10 -15
A NN E XU R E-0 3 – PA I N TIN G S CH E ME 16 -18
A NN E XU R E-0 4 – CO LO U R COD E 19 -19
Chapter 09 Painting Page 1 of 19

01 GEN ER A L
0 1. 01 Th i s sp e ci f i cat i on covers t h e m at eri al s, t o o l s, f a ci l i ti es an d q u al i ty

r equ i r em en t f o r su r f a c e p r ep ar a ti o n and p ai n t i ng o f st e el st r uc t u r es,
eq ui p m en t , p i pi n g, d u ct s, chu t e s, w o od w or k et c .
0 1. 02 Th i s i s o n l y a g en eral gu i d el i n e o f t h e p ai nt i n g sch em e t o b e f ol l o wed

b y t h e T en d er er . Ho we v er , i n c a se a sp e ci f ic p ai nt i n g p r o c ed u re i s
st i p u la te d i n an y t en d er i ng sp e ci f ic ati o n , t hen t h is gen er al gu i d el in e
sh al l b e su p er c ed ed. A n y sp ec i al c a s e wh i ch m a y ar i se f r om t im e to
t i me sh al l b e d eal t wi t h i nd i vid u al l y on t h e mer it o f e a ch c ase
0 1. 03 Th e t erm “ p ai n t i n g” r ef err ed h er ei n co v er s r ust p r e v en ti v e,

f un gu s/ i ns ect s p r e ven t i ve an d d eco r at i v e co at i n g al on g w i t h su r fac e
p ro t ect i o n of th e fo l lo wi n g are a b ut no t lim i ted t o t he ar e a s i n d i cat e d
b el ow .
i) St r u ct ur al st eel w or k s
ii) M ech an i c al eq ui p m en t
iii) El e ct r ic al equ i p m ent
i v) In st ru men t at i on an d c on t ro l eq u ip men t .
v) Pi p e w or k
vi ) O xy g en p l an t , et c.
0 1. 04 Su r fac e s mad e of a sb e st os, al u mi n um , b ra s s, br o n ze , gal v an i zed st e el ,

st ai n l e ss st e e l, c a st i r on an d o t he r co r r osi on r e si st an t al l o y s an d
r ub b er/ s yn t h et i c p o l y mer / f ib er r ei n fo r c em e nt p l ast i c a nd bu r ie d p ip e
w or k ar e n o t r eq ui r ed t o b e p ai n t ed u nl es s sp e c if i ed e x c e p t f or
a e st h et i c p ur p o s e s o r f o r i d en t i fi cat i o n b an d s, w h er e v er r el e vant .
0 1. 05 Th e co mp l e te p ai n t sy st e m f o r an y i t em i n cl u de s t h e f o l l ow i ng b asi c
a ct i vi ti e s:
i) Pr o per sur f ac e pr ep ar at i o n
ii) A pp l i cat i on o f pr i mer co at s
iii) A pp l i cat i on o f i n t er m ed ia t e co at s
i v) A pp l i cat i on o f fi n i sh e d c o at s
A ll t h e ab o ve co at s sh al l b e o f q u al i t y p ai n t pr o du ct s an d o f ap pr o ved
mak e. Th e sc op e of wo rk sh al l al so i n cl ud e su pp l y o f al l p ai nt
mat er i al s a s p er sp e ci fi cat i o n de s cri b ed h er ei n .
0 1. 06 If th e c on t ra ct o r d e si re s t o ad op t al t er n a t i ve p ai n t sy st em fo r an y
sp e ci f ic i t em f or an i mp r ov e men t or equ i v al ent t o t h e sy st em sp e ci f ied
h ere -i n or a s per r e c omm end at i o ns of p ai nt m anu f a ct ur er , m a y do so
su b j e ct t o p u rch a ser ’ s ap p ro va l i n ad v an ce .

02 SU RF A CE P REP AR AT IO N
0 2. 01 Su r fac e p r ep ar ati o n r eq ui r ed f or p ai n t ap p l i cat i o n , sh al l b e su c h a s to

cl e an t h e su r f ac e t ho r ou gh l y o f an y m at er i al wh i ch w il l be con d u ci ve
t o pr em at u re f ai l u re of t h e pai n t su b st r at e s .
0 2. 02 A ll sur f a c es sh al l be cl e an ed of l o os e su b st an c e s, and f or ei g n
mat er i al s, su ch a s d i rt , r ust , sc al e, o i l , gr ea se, w el di n g fl u x, et c. i n
o rd er t hat t h e p ri m e co at i s r i gid l y anc h o re d t o t h e vi r gin met al
su r fa c e. Th e su rf a c e pr ep arat i o n sh a l l con f i rm t o pi ct o ri al
r epr e sen t at i o n o f su r fac e q u a li t y gr ad e of Sw e di sh St a n d ard s
In st it u t i o n SIS – 0 5 59 0 0 o r eq u i va l en t st an d ar d s su ch a s S SP C – VIS
– 1. 67 o r D I N 5 5 92 8 (P art 4 ) or BS 4 2 32 o r IS 14 7 7 – 1 9 71 ( P ar t I)
0 2. 03 Th e a c c e pt ab l e sur f ac e p r ep ar at i o n q u al i t y / gr ad e are d e scr ib ed u n d er

e a ch p ai n t syst em . Th e pr o c edu r e s i n cl u d e so l v ent cl e ani n g, h an d t ool
cl e an i n g, p o w er t o ol cl e an i n g, bl a st cl e ani n g, wo o d su rf a c e cl e an i n g,
f l am e cl e an i n g a nd p i ck l in g. Th i s wi l l en su re su r fa c e qu a l i t y a s
r equ i r ed b y t h e sp ec i fi c p r i mer pai n t . F or r ead y r ef er en c e su r fac e
p rep ar at i on q u al i ty gr ad e t o b e ad op t ed i n re sp e ct o f S IS 0 5 59 0 0 and
D IN 55 9 2 8 ( p art -4) i s gi v en in A nn e xu re -0 1 .
0 2. 03 .0 1 So l v ent Cl ea ni n g
Th e su rf a c e sh al l b e c l ean ed b y w i pi n g , i m mer si o n, sp r a yi n g or vap o u r

co nt a ct i n g o f a sui t ab l e so l ven t or w a s hi n g w i t h an emu l si on o r
al k al i ne so l u t io n t o remo ve o i l , gr e a se, d i rt , o ld p ai nt , et c. So l v ent
cl e an i n g sh al l n o t remo v e r u st , sc al e s, mi l l sc al e s o r w el d f l ux.
Th er ef o re, b efo r e a p pl i cat i o n of p ai n t , sol v en t cl e an in g sh al l b e
f ol l o wed b y ot h er cl e ani n g pr o c edu r es a s st at ed in sub seq u ent cl a u se s.
0 2. 03 .0 2 Ha nd Too l Cl ea ni n g
Th e su r fa c e sh al l b e c l ean ed m an u al l y b y vi go ro u s w ir e b ru sh i n g a s p er
gr ad e S t -2 qu al i t y of Sw edi sh S t and ar d In st i t ut i o n SIS 0 55 9 0 0 an d DIN
5 55 9 2 8. Th i s me th o d ef f e ct i vel y re m o v e s l o o sel y adh er ent mat er i al s,
b ut wo u l d no t aff ect r esi d u e s o f r ust o r mi l l sc al e s t h at ar e in t a ct ar e
f i rml y ad h er en t . Fi n a l l y t h e sur f a ce i s t o b e cl e an e d w i th a v a cuu m
cl e an er o r w it h cl ea n co mp r es sed ai r or wi t h cl ean br u sh . Af t er
p rep ar at i on t he su r fa c e sh al l h a ve a f ai n t m e tal l i c sh i n e. Th e
ap p e ar an c e sh al l co rr e sp o nd t o t he pr i nt s d e si gn at ed St – 2 .
0 2. 03 .0 3 Po w er To o l Cl ea ni ng
Th e su rf a c e sh al l b e cl e an ed b y el e ct r i c o r p n eum at ic t o o l s, su ch a s
b ru sh e s, san d i ng m a c h in es, d i sc ab ra si v e gr i n der , ro t ar y di s c s c al er
et c. t o S t – 3 q ual i ty. Th e t o ol s sh a ll b e u se d c ar efu l l y t o p r e vent
e x c essi v e ro u gh en i n g of su rf ac e an d f o rm ati o n o f r i dge s an d b ur r s.
Th i s m et ho d w il l re mo v e l o o sel y ad her e n t mat er i al s b u t wo u l d n ot
af fe ct r e si d u es o f r u st o r m il l sc al e s t h at ar e f i r ml y ad h ere nt an d i nt act .

0 2. 03 .0 4 Bl ast C l ea ni ng
Th e su rf a c e sh a ll b e c le an ed b y i mpi n g e men t o f ab r a si ve m a t er i al s,
su ch a s grad ed sa n d at hi gh v el o cit y cre at ed b y cl ean an d d ry
co mp r e s sed ai r b l a st a s p er t h e gr ad e a c c o r di n g t o S wed i sh S t an d ard
In st it u t i o n S IS 0 55 9 00 .Th i s me th o d wi l l rem ov e l o os el y a d h er ent
mat er i al s a s w el l a s adh er ent sc al e s a nd mi l l scal e s. P ri o r to
ap pl i c at i o n of b l a st , h e a vy d ep o si t of o i l and gr e ase ar e r em o v ed b y
so l v ent cl e an i ng e xc e ssi v e su rf a ce scal e s a r e r emo v ed b y h an d t o o l s o r
p ow er t oo l cl e an i n g. The e xt en t s of r em o val of ad h er en t sc a l es i s
v ari ed , d ep en d i ng o n t h e app l i c at i on an d ar e d ef i n ed b y t h e su rf ac e
q ual i t y gr ad e s Sa1 , Sa2 , S a2 .5 an d S a 3 in t h e o r de r o f i n cre a si ng
cl e an l i ne s s. Th e b l a st cl e an i n g i s no t rec o mm en d ed f or sh e et met al
w or k .
0 2. 03 .0 5 Fl a me Cl ea ni n g
Th e sur fa c e i s c le a n ed b y r api d h e at i n g by m e an s o f o x y ac et yle n e

f l am e t o l o os en t h e ad h er en t sc al e s, f ol l o wed im m ed iat el y b y w i r e
b ru sh i n g. Th i s m e th o d wi l l r emo v e l o o s el y ad h er en t m at er ia ls a s wel l
a s mo st o f t h e ad h er e n t sc al e s an d m il l sc a l es. In or d e r t o mi n i m i ze o r
p re ven t d i st o rt i o n fl am e cu t t in g shal l n o t b e u sed o n m e mb er s h a vi n g
t h i ckn e ss of 6 m m an d l ow er.
0 2. 03 .0 6 Pi c kl i n g
In t h i s m et ho d t he su r fac e i s cl e an ed o f mi l l sc al e s, r u st o r r u st sc al e s
b y ch emi c al r e a ct i o n o r el e ct ro l ysi s o r bo t h .
0 3. PA INT A PPL IC A T ION
0 3. 01 Pa i nt s
0 3. 01 .0 1 Pai n t sh al l b e ap p l i ed i n a c c or d an c e w i th p ai nt m an u f a ct u r er’ s
r eco m m end at i o ns. Th e w o rk sh al l gen er al l y fo l l o w IS 1 47 7 – 1 9 71
( Par t II) f or jo b s c ar ri ed ou t in Ind i a and S S PC-P A -1 o r D IN 55 9 28 o r
eq ui val en t fo r j ob s ca r r i ed o u t ou t si d e In d i a .
0 3. 01 .0 2 G en er al co mp at i bi l i t y b et we en p r im er and f i ni sh i ng p ai n t s sh a l l b e
e st ab l i sh ed b y t h e p a in t man u f act u r er sup p l yi n g t he p ai n t s.
0 3. 01 .0 3 In t h e e ven t o f co n fl i ct b e tw e en th i s g en er al p ro c ed u r e o n p ai n ti n g and
t h e p ai nt m anu f a ct ur e r ’s sp e ci fi c at i o n , t h e sam e sh al l b e i mm ed i at el y
b ro u gh t t o t he n ot i c e of t h e Pu r ch aser . G en er al l y i n c a s es o f su ch
co nf l i ct s, m a nu f a ctu r e r’ s sp e ci f i c at i on s/ r e co mm en d at i o n s sh al l p re v ai l .
0 3. 01 .0 4 Befo r e bu yi n g t h e p ai n t in b ul k , i t i s r e co m m end ed to o bt ai n sa m p l e o f
p ai nt an d e st ab l ish “ Co n t ro l Ar ea o f P a in t i n g”. On Co n t ro l Ar e a,
su r fa c e p r ep ar at i o n an d p ai nt i n g sh a ll b e c ar ri ed o u t .
0 3. 01 .0 5 If r eq ui r ed, s amp l e s o f p ai nt sh al l b e t e ste d i n la bo r a to r i es t o est abl i sh

q ual i t y o f p ai n t wi t h re sp ec t to :

(i) V is co si t y
( i i) A dh e si o n /Bo n d o f p ai n t i n st e el su r fa c e s
( i ii) A dh e si o n /S i mu l at e d s al t sp r a y t e st .
( i v) Ch e mi c al anal y si s (p e r cent a g e o f sol i d s b y wei gh t )
( v) N or mal w e ar r e si st a n c e a s en c ou n t er ed d ur i n g h an d l in g &
er e ct i on .
( vi ) Re si st an c e a g ai nst e xp o su re t o a ci d f um e s, et c.
0 3. 01 .0 6 Wh o l e qu an t i t y of p ai nt f o r a p ar t i cul ar sy st em of p ai nt sh a ll b e
o bt ai n ed fr o m t h e sa m e m an u f a ct u r er.
0 3. 01 .0 7 Th e m ai n Con t r a ct or sh all b e r e sp o n si bl e f or su pp l y o f p ai nt s a n d t h i s
r esp on si b i l i t y sh a ll n o t be p as sed on t o t h e su b- co nt r a ct or .
0 3. 01 .0 8 Th e p ain t i n g m at e ri al a s d el i v er ed t o t h e Co nt r act or , mu st b e i n th e
man u f a ct u re r’ s o ri gi n al co n ta in er be ar i ng t h ereo n m anu f a ct ur er ’s n a m e
b ran d an d d e scr i p ti o n . P ai nt / P ai nt i n g mat er i al i n co n t ai ner s w i t h out
l ab el s or wi t h i l l egi b le l ab el s sh al l b e rej e c t ed , re m o v ed f r om t h e are a
an d sh all n o t b e u sed .
0 3. 01 .0 9 Th i nn er s w h er e v er u sed sh al l be th o se r e com m en ded b y t h e p ai nt
man u f a ct u re rs an d sh al l b e ob t ai n ed i n co n tai n er s wi t h man u fa ct u r er’ s
n am e an d b r and n am e o f th i n ne r l e gi b l y p ri n t ed, f ai li n g w h ic h th e
t h i nn er i s l i ab le t o b e r ej e ct ed an d sh al l no t b e u sed .
0 3. 01 .1 0 A ll pai n t co n t ain er s sh al l b e cl e arl y l ab el ed t o sh ow t h e p ai nt

i d ent i f i cat i on , d at e of man u f a ct u r e, b at ch n um ber , sp e ci al i n str u ct i on ,
sh el f l if e et c. Th e co n ta in er sh al l b e op en ed o n l y a t th e t i m e o f us e.
0 3. 01 .1 1 A ll pa in t s sh al l b e st o r ed i n ac co rd an c e w i th th e req u i reme nt s of l aid

d ow n pr o c edu r e b y t h e p ai nt m a nu f a ct ur er.
0 3.0 1 .1 2 A ll i n gred i en t s i n a p ai n t co nt ai n er sh al l b e t h or o ugh l y m ix ed t o br eak -

u p l ump s and d i sp er s e p i gm e nt s b ef o re u se and d u ri n g ap pl i c at i o n to
mai n t ai n ho mo gen ei t y .
0 3. 01 .1 3 Th e p r op o sed m ak e , q u al it y a nd sh ad e o f t h e p ai nt sh all ha v e th e
ap pr o va l of t h e cl i en t .
0 3. 01 .1 4 Th e co l ou r cod e o f t h e f i ni sh i n g p ai n t t o b e f ol l o we d sh al l b e i n tim at e d
t o th e su c c essfu l Ten der er aft er fi n al i sai t o n o f or de r. Th e u nd e r coat
sh al l h a ve di f fer en t t i nt t o d ist i ngu i sh t he sam e f ro m t h e f i ni sh i n g co at .
0 3. 01 .1 5 Th e Co nt r act or shal l f u rn i sh p ai nt m an u f act ur er ’s t e st r epo r t o r

t ech ni c al d at a sh e et p er t ain i n g t o t he p ai n t sel e c te d. Th e d at a sh eet
sh al l in d i cat e am on g o t h er t hi n gs t he r el e van t st an d ar d s, if an y,
co mp o si ti o n i n wei gh t p erc en t of p i gmen t s, veh i cl es, ad di t i v e s, d ryi ng
t i me, vi sco si t y, sp r e adi n g r ate , fl a sh p o i nt , met ho d o f app l i cat i on ,
q ual i t y of su rf a ce pr e p arat i o n r equ i r ed, co rr o si o n r esi st an c e pr o per t i e s
an d col o u r sh ad e s a va i l ab l e.
0 3. 01 .1 6 Fo r d eta il s of p ai nt m at eri al s r ef er A n n e xu r e - 0 2

0 3. 02 Gen e ral
0 3. 02 .0 1 Ea ch co at of p ai n t shal l be co nt i n u ou s, f re e o f po r es and of e ve n fi l m
t h i ckn e ss wi t h ou t t h i n sp ot s.
0 3. 02 .0 2 Ea ch co at o f p ai n t sh al l b e su ff i ci ent l y d r y b efo re ap pl i c at i o n o f ne xt
co at .
0 3. 02 .0 3 Pai n t sh al l b e a pp l i ed at m an uf a ct u rer ’ s r eco m m en d ed rat e s. Th e

n um ber of co at s sh al l b e su ch t h at t h e m i n i mum d r y f i l m th i ck n e ss
sp e ci f ie d i s a chi e v ed . Th e dr y f i l m th i ck ne s s of p ai n t ed sur fa c e s sh al l
b e ch eck ed wi t h ELC O METER o f m e a sur i ng gau g e s t o en su re
ap pl i c at i o n of sp e ci f ie d D FT.
0 3. 02 .0 4 Zi n c ri ch p ri m er p ai nt s wh i ch h a v e b e en e x p os ed s e ver al mo n t h s bef o re
f i ni sh i n g coa t i s ap p l i ed shal l b e w a sh ed do w n th o ro u ghl y t o r emo v e
so l u bl e zi n c sal t d ep o si t s.
0 3. 02 .0 5 Th e m a chi n e f i n i sh e d su rf a c es sh al l b e co at ed w i t h w hi t e le a d and
t al l ow b efo r e sh i pm en t o r bef o re b ei n g pu t o ut i n t o th e o p en a ir .
0 3. 02 .0 6 A re a s wh i ch b eco m e i n a c ce ssi b l e af t er a s se mb l e sh al l be p ai n t ed b ef o re
a sse mb l y ( af t er o b t a i ni n g p ai nt i n g cl e ar an c e f ro m t h e i n sp e ct i ng
au t ho r i ty) af te r r eq ui si t e sur f a c e cl e ani n g a s sp e ci f i ed.
0 3. 02 .0 7 Pai n t sh al l no t b e app l i ed wh en t h e amb i ent t emp er at ur e i s 5 d e g C and

b el ow o r 4 5 d e g C an d ab o ve. A lso p ai nt sh al l n o t b e ap p l ie d i n rai n ,
w in d , fo g o r at r el ati v e h u m i di t y o f 8 0 % an d abo ve un l e ss th e
man u f a ct u re r’ s r e co m m end at i o ns p er mi t . Ap p li cat i o n s o f p ai nt shal l
b e o nl y b e sp r a yi n g o r br u sh i ng a s p er IS 4 86 – 1 98 3 and IS 4 8 7 –
1 98 5 .
0 3. 02 .0 8 Pr i mer p ai n t sh al l b e ap p l i ed no t lat er t h an 2 – 3 ho u r s af te r
p rep ar at i on o f sur f a c e , u nl e ss sp e ci fi ed o t he r w ise.
0 3. 02 .0 9 Ed g e s, co rn er s, cr e vi c e s, d ep r e ssi o n s, j o i n t s and w el d s sh al l re c eiv e

sp e ci al at t en t i on t o en su re t h at t h e y re c ei ve p ai n ti n g co at s o f th e
r equ i r ed t h i ck n e s s.
0 3. 02 .1 0 Su r fac e s w h i ch can no t be p ai n te d b ut r equ i re p r ot e ct i o n sh al l b e gi ve n

a coat of r u st in h i bi t iv e gr e a se ac cor d i n g t o IS 9 58 – 19 7 5 o r so l ve nt
d epo si t ed co mp ou n d a c cor d i ng t o IS 1 15 3 – 1 9 7 5 o r IS 1 67 4 – 1 9 6 0.
0 3. 02 .1 1 Su r fac e s i n co n t a ct du r i ng sh o p a s semb l y sh all n o t be p ai n t ed. Su rf ac e s

w hi ch w i ll be in a c c e ssi bl e aft er a ss emb l y sh al l r ec ei ve mi n i m u m t wo
co at s o f sp e cif i ed p ri mer .
0 3. 02 .1 2 Su r fac e s t o b e i n co n t act w i t h wo o d, br i ck o r ot h er ma so n r y sh al l b e
gi ven o n e sh op - co at o f t he sp e c if i ed pr i m er .
0 3. 03 Si t e/ Fi el d Pa i nt i ng

0 3. 03 .0 1 Wh er e ver sho p p ri m e r p ai n ti n g i s scr at c h e d , ab r ad ed o r d am a ge d , th e

su r fa c e sh al l b e t h o r o ugh l y cl e a n ed u si n g e m er y p ap e r an d po w er
d ri ven wi r e b r ush w her e v er w arr an t e d, an d t o u ch ed u p w i th
co rr e sp o nd i n g p r im er. To u chi n g u p pai n t sh al l b e m at ch ed an d b l en d ed
t o el i mi nat e co n sp i cu o u s m ar k s.
0 3. 03 .0 2 If mo r e t h an 5 0 % of th e p ai nt ed su rf a c e o f an i t e m r eq ui r e s r ep ai r , th e
en t i re i t em shal l b e m e ch an i c al ly cl e an ed a nd n ew p r i mer c o at s sh all b e
ap pl i ed f ol l o wed b y i n t erm edi at e an d fi n ish i ng co at s as p er pai n t i ng
sp e ci f ic at io n .
0 3. 03 .0 3 A ll f i eld wel d ed a re a s o n sho p p ai n t ed i t em s sh al l be me ch a n i cal l y

cl e an ed (i n cl ud i n g t h e w el d ar e a p r op er , a d ja c ent ar e a s co n t ami n ate d
b y w el d sp att er o r fu me s and ar e a s wh er e e xi st i n g pr i m er p a i n t i s
b ur n t ).
Su b seq u ent l y, n ew pr i mer an d f i n i sh in g co a t s o f p ai n t sh al l be ap p li ed

a s p er p ai nt i n g sp e c if i c at i o n.
0 3. 03 .0 4 Th e f i r st co at of fi n i sh p ai n t at si t e sh al l b e ap p li ed pr ef er ab l e w i t hin
t h ree m on t h s o f t h e sh o p pai n t .
0 3. 04 St ru ct ur al
0 3. 04 .0 1 A ll fab r i cat ed st e el st r u ct ur e, f ab ri c at ed ste el pi p e s, et c. sh al l h a v e a

mi n i mu m o f t w o co at s o f p ri mer p ai nt b ef or e d i sp at ch t o si t e.
0 3. 04 .0 2 Par t s o f st e el st ru ct ur es e mb e d ded i n c on cr et e sh al l b e gi v en a
p ro t ect i v e co at of Po r tl an d c em en t slu r ry i mm ed i at el y af t er f abr i cat i o n
an d af t er su r fa c e s o f t h i s par t is t h o ro u gh l y cl ean ed f r om gre a s e , ru st ,
mi l l sc al es, et c. No p a i nt sha ll b e ap p l ie d o n t hi s par t .
0 3. 04 .0 3 A ll str u ct ur e s sh al l re c ei v e ap pr o pr i at e nu m b er o f pr i mer an d fi n i sh i ng
co at s in o r der to a ch i e ve o v eral l DF T as p er d e si g n
d raw i n gs/ sp e ci f i cat i o n .
0 3. 05 Ho t Surf a c e s
0 3. 05 .0 1 To t al D FT fo r h e at re sist ant p ai n t s sh o ul d n o t e xc e ed 1 0 0 – 1 2 0
mi cr on s, o t her wi s e f l aki n g o c cu r s ( a s p er p ai n t man u f a ct u r er’ s
r eco m m end at i o ns).
0 3. 05 .0 2 H e at re si st ant p ai n t s sh o ul d b e ap pl i ed b y b r ush.
0 3. 05 .0 3 Pr i mer co at sho u l d n o t b e ap p l i ed on t h e sur f a c e s h a vi n g te m p er at u r e

co nd i t i o n m or e t h at 12 0 de g C.
04 PA INT IN G S C HE ME S
Fo r a co mp l et e p ai n t i ng sch e me of an y i t e m bei n g p r i nt ed , al l typ e s of

p ai nt s ar e t o b e p r o c u re d fr o m t h e sam e man u f a ct u re r a s ap p r o v ed b y
t h e pu r ch a s er.

0 4. 01 Leg end
SP - Su rf ac e p r ep ar at io n q ual i t y a s p er SIS st an d ard

2 P1 - Two ( 2) co at s o f P ri m er p ai nt t yp e P1
1 I1 - On e (1 ) co a ts o f In te r med i at e p ai nt t yp e I1
2 F1 - Two ( 2) co at s o f Fi ni s h p ai n t t yp e F1
D FT - Dr y Fi l m Th i ckn e ss i n m i cro n s d e vel o p ed
CRT- Cl e an an d Ret o u ch
Typ e o f p ai n t p r od u ct s l i ke P 1 t o P9 , I1 t o I4 an d F1 t o F1 0 h a v e been
sp e ci f ie d u n der A nn e x ur e-02 .
0 4. 02 Th e p ai n t i ng sch em e t o b e fo l l ow ed f o r v ari o u s st ru ct u re/ eq u i pm ent

e xpo sed t o d i ffer en t co nd i t i on i s b ri ef l y gi v en i n An n e xur e- 03 f o r
gui d an c e t o t h e t en d er er .
0 4. 03 Th e co l ou r co d e fo r d i ff er ent a pp l i c at i on s are i nd i cat ed i n An n e xu r e -

0 4. Wh ere v er col o u r co d es ar e no t sp e ci f i ed, t h e sam e i s t o b e
mu t u all y a gr e e d b et w e en t h e Pu r ch a s er an d Con t ra ct or .
0 5. GU A R AN TEE
0 5. 01 Th e Co n t ra ct o r sh al l gu ar ant e e t h at t h e p h y si c al an d ch e mi c al
p ro p ert i es o f th e pai n t mat er i al s c on f or m w i t h t he sp eci fi c at i o n o f
p ai nt p r od u ct s.
0 5. 02 Th e Con t r act o r sha l l su b mi t i nt er n al t est r ep or t s f ro m p ai nt

man u f a ct u re rs r e g ard i ng t h e q u al it y o f p ai nt wh en e ve r a sk ed b y th e
Pu r ch as er/ Co n su lt an t .
0 5. 03 G uar an te e p er i od sh al l co mm en c e fr o m t he d at e o f co mp l et io n o f
f i ni sh i n g co at o f p ai nt . T he gu aran t e e p er io d wi l l b e i nd ic at ed
d ep en d i ng o n t h e t yp e of su r fa c e pr ep ar at i o n and s yst e m o f p ai n t i ng.
To f u l fil l t hi s o b l igat i o ns t h e Con t r ac to r m a y o bt ai n fr om t h e p a i n t i ng
man u f a ct u re r, gu aran t e e f or t h e p er f or man c e o f p ai n t /p ai n t ed su rf a c es.

Annexure-01
Surface Preparation Grade
Sl. Swedish Std DIN Std. Din

Surface Preparation
No. SIS 055900 55928 (Part 4)
1 Blast cleaning to white metal
Removal of all visible rusts, mill-scales, paint and Sa 3 Sa 3
foreign matters.
2 Blast cleaning to near white metal:
95% of any section of surface area is free from all Sa 2.5 Sa 2.5
rusts, mill-scales and visible residues.
3 Blast cleaning to commercial quality:
At least 2/3 of any section of the surface area is Sa 2 Sa 2
free from all rusts, mill-scales and visible
residues.
4 Brush-off blast cleaning:
Removal of all loose mill-scales, rust and foreign Sa 1 Sa 1
matters etc.
5 Power tool cleaning:
Very thorough scrapping and wire brushing to St 3 St 3
remove loose mill-scale, rust and foreign matters
to have pronounced metallic shine.
6 Hand tool cleaning:
Removal by hand brushing of loose mill-scale, St 2 St 2
loose rust and foreign matters.

Annexure - 02
PA INT MA TER IA LS
0 1. PR IME R PA IN TS ( P )
Pr i mer p ai nt p r od u ct s sh al l b e app l i ed on l y on d r y an d cl e an su rf a c e s.
0 1. 01 Pri me r Pa i nt – P1 (P h eno l i c – A l ky d Ba se d)
A si n gl e p a ck ai r dr yi n g ph en ol i c mo di f i ed al k yd co mpo si t i o n w i th
zi n c p ho sp h at e as a p r i me r p ai n t c on f or mi n g g en er all y t o IS : 2 07 4 .
Air drying time - About 60 minutes (touch dry)
- Overnight (hard dry)
Dry film thickness (DFT)/Coat - 40 microns (min)
Temperature resistance - Upto 1000C dry heat
01.02 Primer Paint – P2 (Chlororubber Based)
A si n gl e p a ck ai r d ryi n g h i gh b u il d ch l o ri n at ed ru b b er b as e d zin c
p ho sp h at e p ri m er .
Percent chlororubber - 20 to 22 (% Chlorine above 65% in

chlororubber)

- Overnight (hard dry)
DFT/ Coat - 50 microns (min)
Temperature resistance - Up to 650 C dry heat
01.03 Primer Paint – P3 (PVC Copolymer Alkyd Based)
Polyvinyl chloride (PVC) - Alkyd zinc phosphate – redoxide

based primer
Ratio : PVC copolymer + alkyd resin (1:1)
Pigments : Zinc phosphate & Fillers
Air drying time - 24 hours
DFT/Coat - 80 microns

01.04 Primer Paint – P4 (Epoxy Based)
A t w o p ack ai r d r yi n g Ep o xy p ol y ami d e r esi n ba s ed r ed o xi d e -zi n c

p ho sp h at e p ri m er .
Epoxy content (% wt.) - 15 to 18

- overnight (hard dry)
DFT/Coat - 30 microns (min)
01.05 Primer Paint – P5 (Epoxy Based)
A t w o p a ck ai r dr yin g Epo x y p o l ya mi d e wi t h z in c d u st o f at l ea st 9 2%
zi n c d u st on t h e dr y fi l m
Epoxy content (% wt.) - 8 to 10
Air drying time - Less than 10 minutes (touch dry)

Less than 2 hours (hard dry)
01.06 Primer Paint – P6 (Poly – Vinyl Butyral Resin Based)
A t wo pa ck ai r dr yi ng po l y vi n yl b u t yr al r e si n b a sed wa sh pr i m er w i th
r ust i nh i b iti ve p i gm en t s.
Air drying time - 5 to 7 minutes (touch dry)

- 2 hours (hard dry)
Application for - Galvanised iron, aluminium, light

alloys etc. on which the adhesion of
conventional paints are poor.
01.07 Primer Paint – P7 (Ethyl Zinc Silicate, EZS Based).
A t w o pack h e a vy d ut y zi n c du st r i ch si l i ca t e pr i mer wh i ch p r ot e ct s th e
su r fa c e w i t h ju st a si ngl e co at .

Total solids (3 wt) - 84 +/- 2

D ensit y ( g / cc ) - 3.07 +/ - 0.05
Air dr yin g time - To top coat 16 ho urs
D FT / co at - 60 mi cron s
Temper ature resi st an ce - Upto 450 deg C dr y h eat
01.08 Pri mer P aint – P8 ( High Build Coal Ta r Epoxy)
A two p ack cold cured H.B. epoxy co al tar co ating – no pri m er i s

requir ed.
Mi xin g r atio - Base: Hard en er (4:1by vol.)

Air dr yin g time - 48 hour s (h ard dr y)
Full cure 7 d ays
D FT / Co at - 100 mi crons
01.09 Woo d V arni sh-P9
Treat ed oil based pri mer pi gment ed with suit abl e pi gm ents :
Air dr yin g time - 16 hour s for applicati on of

top coat.
Co ver age - 10 to 14 sq. m/litre
02. INTERMED IA TE P AINTS (I)
Th ese p aints sh all be appli ed o ver pri mer coats as an int ermedi at e l ayer
to pro vide weath er pro of seal of primer co at s.
02.01 Int er mediate Paint-II ( Phenolic alkyd based)
A sin gl e p ack hi gh b uild phenolic based pain t with mi caceous iron oxid e
(M10) .
Air Dr yin g Time - 4 to 6h our s (touc h dr y)

- 2 d ays (h ard dr y)
D FT / Co at - 75 mi cron s ( min )
Temper ature resi st an ce - Upto 100 d eg C dry h eat
Comp atibl e with - Primer P1
02.02 Int er mediate Paint-I2 (Chlo ro rubber based)
A sin gle pack air dr yi ng hi gh b uild chloro ba sed p aint with MIO.
Air Dr yin g Time - 15 minut es (tou ch dr y)

- 24 hours (h ard dry)
D FT/Co at - 70 mi cron s ( min )
Temper ature resi st an ce - Upto 65 d eg C d ry h eat
Comp atibl e with - Primer P2,P3 & P4
02.03 Int er mediate Paint-I3 (PV C – Al ky d Ba sed)

PVC Co plo ymer - Resin 1 : 1

Pigment s - Mi caceous iron o xide (MIO)
D FT/Co at - 80 mi cron s (min)
Temper ature resi st an ce - Upto 80 d eg C dr y hea t
Comp atibl e with - Primer P2 & P3
02.04 Int er mediate paint- I4
A two p ack air dr yin g high build epo xy r esin based p aint with MIO.
Air dr yin g time - 6 to 8 ho urs (tou ch dr y)

- 7 d ays (full cur e)
D FT / co at - 100 mi cron s
Temper ature resi st an ce - Up to 1 80 0 C dr y heat
Comp atibl e with - Primer P4 & P5
0 3. FIN IS H PA I NTS (F)
Fi n i sh p ai n t co st s sh a l l b e a pp l i ed o ver p r i mer co at s an d i n t erm edi at e

co at s af t er p r op er cl e a ni n g and t o u ch u p o f p r im ed sur f a c e.
0 3. 01 Fi ni sh Pa i nt – F1
A si n gl e p a ck ai r d ry i n g h i gh gl o ss p h en o l i c al k yd mo di f i ed syn t het i c
en am el p ai nt sui t ab l y p i gm en t ed .
Air drying time - 3 to 4 hours (touch dry)

Compatible with - Primer P1

Intermediate I1
Colour - Generally all shades
03.02 Finish Paint – F2
A si n gl e pa ck ai r d r y i n g po l yur et h a ne e n a mel of h i gh gl o ss a n d h ard

f i ni sh sui t ab l y pi g m en t ed.
Air drying time - 2 to 2 ½ hours (touch dry)

Compatible with - Primer P1 & P8 and

Intermediate I1

A t wo pa c k ai r d ryi n g b i t um i no u s al u mi n u m p ai n t .

Compatible with - Primer P1 and Intermediate I1
Colour - Bright metallic
A re ad y mi xed o i l -al k yd b a sed syn t h e ti c en am el p ai n t o f hi gh glo ss an d

h ard w e ari n g pr o p er t i e s.
Air drying time - 6 to 8 hours
Coverage - 14 to 16 Sq. m /litre
Compatible with - P8
A si n gl e p a ck ai r d ryi n g pl a sti ci z ed c h l or o ru b be r p ai n t su i t abl y

p i gm ent ed .
Air drying time - 30 minutes (touch dry)

Compatible with - Primer P2 & P3,

Intermediate I2 & I3
Colour - Nearly all shades except few.

A PV C – Co po l y m er a l k yd b as ed en a mel .
Density - 1.17 U+U 0.05
Total solids (1 wt) - 55 U+U 2
Compatible with - P2 and P3
A t wo pa c k ai r d ryi n g ep o xy p o l y ami d e en a mel su i t ab l y p i g m en te d .

- 7 days (full cure)
Temperature resistance - Up to 1300C dry heat
Compatible with - Primer P4 & P5,

Intermediate I4
Colour - Generally all shades.
A si n gl e p a ck synt h et i c r ub b er b a sed al u mi n iu m p ai n t .
Air drying time - 2 hours (touch dry)

Compatible with - No Primer paint except primer P6 is

applicable in case of non-ferrous
substrate.
Colour - Smooth aluminium.

Annexure - 03
PAINTING SCHEME
Sl. Description Painting Scheme Total

No. At Shop At Site DFT
1.0 Steel Structures (Refer
(Temp. not exceeding 800C) Note-1)
1.1 Technological steel structures for plant and

equipment
Indoor SP – Sa 2.5 CRT

2P1 2F1 130
Outdoor SP – Sa 2.5 CRT

2P1 1I1 2F1 205
1.2 Fabricated steel structures at site for rung

ladders, cat-ladders, gates, rolling shutters,
etc. (Springs/rubbing surfaces excluded)
- Indoor / Outdoor SP – St-2 and/ CRT

or St-3
2P1 2F1 130
1.3 Walkways, stairs, platforms etc. which are of

wearing surface
- Indoor SP – St-2 and/ CRT

or St-3
2P1 2F1 130
- Outdoor SP- St2 and/ CRT

or St-3
2P1 1I1 2F1 205
1.4 Steel doors and windows
- Indoor / outdoor SP–St-2 and / or CRT

St-3
2P1 1I1 2F2 215
Sl. Painting Scheme Total

Description
2.0 MECHANICAL EQUIPMENT
2.1 Mechanical equipment

(Temp. not exceeding 800C)


Description
2.1.1 Static equipment like storage tanks,
vessels, bins, bunkers, heat exchangers,
coolers, cyclones, scrubbers, etc.
- Indoor SP – Sa 2.5 CRT

2P2/2P3 2F5/2F6 170/240
- Outdoor SP – Sa 2.5 CRT

2P2/2P3+1I2/1I3 2F5/2F6 240/320
2.1.2 Rotary/moving equipment and machineries

like crushers, mills, vibratory screens, bin
activators, blowers, fan, air/gas
compressors, pumps, gear boxes, machine
housings etc.
- Indoor SP – Sa 2.5 CRT

2P3/2P4 2F6/2F7 240/140
- Outdoor SP-Sa 2.5 CRT

2P3 + 1I3/1I4 2F6/2F7 320/340

Description
3.0 Pipe / Duct work
(Overground)
3.1 Non – insulated

(temperature up to 800C)
- Indoor SP – St2 and CRT

or St3
2P1 2F1 130
- Outdoor SP – St2 and / CRT
or St3
2P1 + 1I1 2F1 205
3.2 Insulated (hot)
- Indoor/Outdoor SP- St2 and/ Remove

or St3 paint and
insulate
1P1

Description
4.0 Oxygen Plant
4.1 Outdoor steel SP – St2 and / CRT


Description
structures or St3
2P1 + 1I1 2F3 205
4.2 Rotary equipment like air compressors Sa 2.5 CRT
2P4 2F7 140
5.0 Others
5.1 Standard mobile equipment like chasis of As per manufacturer’s standards

trucks, dumpers, crawler cranes bulldozers,
railway rakes, chasis of slag cars, ladle cars,
etc.
5.2 Laboratory equipment like ovens, screens, Stove enamelling CRT 110
magnetic stirrers, samplers, etc.
5.3 Steel structures partly immersed in water SP – Sa 2.5 CRT
2P8 200
0B N o te s: -
1. Pai n t i n g s ch em e of al l fab r i c at ed st e el st ru ct u re s, f ab r i c at e d p i pe wo rk ,
b ui l d i n g str u ct ur e, co n ve yo r g al l eri e s, pi p e t re st l e s et c. i s i n di c at ed i n th e
Te ch n ic a l Sp e ci fi c at i o n o f st e el st r u ct ur e s.
2. Pr i mer P ai n t
Pr i mer c o at sh al l b e su i t abl e f or in t en d e d t emp er at u r e ap p l i c at io n s a s p er

man u f a ct u re r’ s r eco m m end at i o n. Th e p ri m er sel ect i o n sh al l b e g en er al l y i n
l i n e wi t h t he sp e cif i c a t i on l ai d d ow n in A nn e xu re -0 2.
3. Fi n i sh Pa in t
In c as e o f A l u m in i u m cl ad di n g fi n al p ai nt i n g wi l l n ot b e r equ i r ed.

ANNEXURE - 04
COLOUR CODE
The colour codes are mentioned for all the items including pipe work. Shades of finish coat of paint
applied over respective item indicated below are tentative and subject to alteration as per Purchaser’s
request or due to compatible paint system adopted. The service for which colour code/bands are not
specified are to be mutully agreed for by the Purchaser & the Contractor.
Sl. Colour No. of

Items Painted 1BColour
No. IS:5
1. Structures
Building frames including bracings, Aircraft grey 693
side girts, louvers etc.
Crane girders Azure blue 104
Crane stops Post office red 538
Gutters Black bituminous -
aluminium
Fire escape platforms ladders, etc. Signal red 537
General hand railing, top runners Lemon yellow 355
Rung ladders Lemon yellow 355
All members blocking passages for Lemon yellow 355
movement
Trestles, towers and pipe bridges Dark admiralty grey 632
Conveyor gallery structures Aircraft grey 693
Steel chimneys Aluminium -
2. Equipment and Machinery
General indoor equipment Light grey 631
General outdoor equipment Dark admiralty 632
Crane bridges, trolleys, hooks etc. and Base : Lemon yellow 355
other mobile equipment Stripes : Black (100 mm
wide)
Furnaces Aluminium
Tanks Base : Same as for general
equipment
Strips : Same shade as for
piping around the tnk at
half the tank height
Fire-fighting equipment Signal red 537
3. Pipe work
Pipeline shall be painted as per the IPSS No. 1-07-064-03 code of practice for painting in steel plant.

NMDC LIMITED

FOR
FIRE FIGHTING
(GS – 10)
MECON LIMITED
RANCHI - 834002


Sl. No. Description Page No.
A PORTABLE FIRE EXTINGUISHERS 2-6
B PASSIVE FIRE PROTECTION 7-9
C GENERAL SPECIFICATION FOR HIGH VELOCITY WATER 9-20

SPRAY SYSTEM (HVWS/WATER MIST SYSTEM) / WATER
MIST SYSTEM AND MEDIUM VELOCITY WATER SPRAY
SYSTEM (MVWS)
D GENERAL SPECIFICATION FOR CLEAN AGENT SYSTEM( 20-25

Inert Gas)
E LOW EXPANSION FOAM SYSTEM 26
F WATER AND WATER CUM FOAM MONITOR 26-29
G DRAWINGS AND DOCUMENTS 30
Chapter 10 Fire Fighting Page 1 of 30

A. GENERAL SPECIFICATIONS FOR PORTABLE FIRE EXTINGUISHERS
01. SPECIAL INSTRUCTION TO TENDERER
Portable fire extinguishers bearing IS marking shall only be supplied.
The following information shall be furnished with the tender.
(i) GA and cross-sectional drawings of the equipment covered in the

specification.
(ii) Catalogues for the above.
(iii) Name and address of manufacturer for various equipment.
(iv) Test pressure.
(v) Materials of construction of various components.
(vi) Weight of each item/ assembly.
(vii) Copies of ISI approval/TAC approval/or other statutory authority certificates

& Test Certificates
(viii) Reference list.
(ix) List of 2 years operation and maintenance spares as well as fast wearing item
along with unit rates.
Necessary tools, spanners etc. required for regular operation/ maintenance of the
equipment shall be supplied along with the equipment and shall be mentioned in the
offer.
All equipment shall be so packed to avoid any damage during transit.
The tenderer shall guarantee satisfactory performance of all the equipment supplied
by him.
No deviations or exceptions from this Specification shall be permitted without the

written approval of the Purchaser/consultant. Intended deviations if any, shall be
listed by the vendor on a separate sheet of paper at the time of bids submission and
supported by reasons for consideration by the Purchaser/consultant.
Compliance with this Specification shall not relieve the contractor of his
responsibility of furnishing equipment and auxiliaries of proper design, materials and
workmanship to meet the specific operating condition.
All the equipment shall be provided with test certificates. A certificate shall be
produced from Chief Inspector of Explosives in case of Carbon dioxide
extinguishers. IS/TAC approval shall be required for all types of extinguishers.
All portable extinguishers shall be supplied with mountings, accessories and installed

along the column/walls near entry/exits and at height of approximately 1200 mm

from the finished floor level. Wherever extinguishers are required to be installed on
the steel columns of the building, the welding of the supporting fixture to columns
shall be done by the successful tenderer. Necessary welding set for this job shall be
arranged by the tenderer. The tenderer shall mark / provide border around the fore
extinguisher installing point / fire point describing details as specified by fire officer
in florescent paint.
Approval of drawings
The following drawings and document shall be submitted by the successful tenderer:
(i) GA and cross-sectional drawings showing all dimensions and materials of

construction of various components.
(ii) Distribution of extinguishers with respect to their type, capacity and numbers
in various premises will be decided in accordance with IS – 2190-1992. A
drawing/table showing such distribution shall be submitted for approval.
(iii) Quality Assurance Plan (QAP) in MECON’s format
Performance Guarantee and Warranty
The Equipments supplied shall be guaranteed for satisfactory performance as per

General Condition of Contract (GCC).
All equipment supplied shall be subject to WARRANTY for a period of 12 months

from the date of commissioning of the plant. The warranty shall cover defect, defect
in material or workmanship for sub-assemblies as well as the total assembled
equipment Initial fill of gas and other fire extinguishing media (including quantity
required for PG test) shall be under the scope of tenderer and quantity/item used for
testing/PG shall be replenished by the tenderer free of cost.
Scope of Inspection
• Verify and certify the material (equipment) offered meets all the details
mentioned in the specifications.
• Welding materials/ rods shall be checked for meeting specifications/

standards. Wherever radiography welding is required, the same has to be
inspected (only for welding applications).
• Extinguisher is as per relevant IS codes mentioned in the specifications.
• Checking performance of extinguisher on random basis.
• Check the fire extinguisher as per the design calculations.
02.01 4.5Kg, 5 Kg ,10 kg & 25 kg(Trolley mounted) DCP Fire Extinguishers :

Portable fire extinguisher dry chemical powder gas cartridge type, 5 kg & 10 kg
Capacity with initial charge (monex) confirming to IS:2171-1999 and ISI marked.
The body is cylindrical in shape fabricated by mild steel sheet of 2 mm thickness
treated internally with plastic lining of 0.5 mm and externally with epoxy powder
anticorrosive coating, fitted with nozzle. The cartridge is manufactured as per IS:
4197:1985 and ISI marked. The material of cap, neck ring are of gunmetal and
siphon tub e shall be of brass construction. The extinguishers are painted with fire
red colour provided with wall mounting breakers and screws complete.
Specifications:
a) All components, design and performance should be as per IS-2171-1999 and with
anti corrosive treatment.
b) Hose shall be of braided plastic (high pressure) having one metre length with
nozzle of ABS Plastic.
c) Cap shall be of gunmetal and siphon tube shall be of brass construction suitable to
fit extinguisher neck ring of 3” straight pipe thread (SPT) and 11 threads per inch
(TPI). Major, minor & pitch dia of the thread 87.887, 84.93 & 86.409 mm
respectively.
d) Certification that every extinguisher has undergone radiography, quality welding

and fabrication and design of vessel as per IS: 2825-1969.
e) In addition to markings stipulated in IS-2171-1999 the following permanent

punching at the bottom ring is required.
i) Manufacturer’s name
ii) Year of manufacturing
iii) Manufacturer’s serial
iv) Purchase order number and date
v) Inspector’s Stamp
vi) The date of hydraulic test along with the dates of subsequent hydraulic
tests.
vii) Dry Chemical Power filling height should be marked on the extinguisher.
NOTE: - 25 KG DCP type extinguisher shall conform to IS-10658-1999
02.02 4.5kg, 6.5 Kg & 22.5 Kg CO2 Fire Extinguisher
CO2 type (6.5 Kg & 22.5 Kg capacity) fire extinguisher assembled out of cold drawn
seamless steel cylinder having CCE approval and conforming to IS: 2878-1986 shall
be provided. It shall be complete with ISI marked wheel type valve, one metre hose
and discharge horn, complete with fittings. For 22.5 Kg extinguisher hose shall be 2.0

m long. The cylinder shall be fully charged with CO2 gas. In addition to markings
stipulated in IS: 2878 (1986) the following permanent punching shall be provided.
i. Manufacturer’s name
ii. Year of manufacturing
iii. Manufacturers serial number
iv. Purchase Order Number and date
v. Inspector Stamp.
02.03 9 lt Water type fire extinguisher
Portable fire extinguisher water gas cartridge type 9 ltrs. capacity upright operation
with initial charge manufactured as per IS:940 – 2003 and ISI mark. The body is
cylindrical in shape fabricated with mild steel sheet of 2 mm thickness and treated
internally with plastic lining of 0.5 mm and externally with epoxy powder anti
corrosive coating. A high pressure hose of length 600 mm is to be fitted to the body.
The material of neck ring and cap shall be of gunmetal and siphon tube of brass
construction. The cartridge is manufactured as per IS:4977-1985 and ISI marked. The
extinguisher is painted with fire red colour and provided with wall mounting brackets
and screws complete. Extra 2 nos. of 60 gms. CO2 gas cartridge shall be provided
with each extinguisher.
i) Manufacturer’s name
ii) Year of manufacturing
iii) Manufacturers serial number
iv) Purchase Order Number and date
v) Inspector Stamp.
02.04 Fire Bucket
Galvanised mild steel fire bucket capacity 10 litres as per IS:2546-1974 shall be
provided for Class A fire in various premises. The requirement with respect to
shape, design, material and finish shall be strictly according to above mentioned IS.
The bucket shall be fabricated of MS black sheets conforming to IS:1079 - 1968
(Grade 57 34 or grade 57 42). After fabrication bucket shall be galvanized. The body
shall be in two valves joined together by butt welding. The top rim of body shall be
wired and uniformly beaded. Thickness of body shall be 1 mm and dia of beading
wire shall be 3.55 mm.
Top and bottom handles shall be provided for easy use of buckets.
For keeping buckets in the premises, metallic stands each accommodating 2-6
buckets as required, shall be provided.
02.05 9 lt capacity Mechanical Foam type
Portable fire extinguisher mechanical form (Gas cartridge) type of 9 litres capacity
with initial charge manufactured as per IS:10204-2001 with ISI mark. The body is
cylindrical in shape fabricated by mild steel sheets of 2 mm thickness and treated
internally with plastic lining of 0.5 mm and externally with anticorrosive, epoxy
powder coating. A high pressure hose of length 600 mm is to be fitted to the body.
The material of cap neck ring shall be of gunmetal. The refills are manufactured as

per IS 4989 (Part-II)- 1984 with ISI marked. The cartridge is manufactured as per
IS:4947- 1985 with ISI mark. The extinguisher will be painted with fire red colour
and will be provided with all accessories, wall mounting brackets and screws. The
dimensions of neck thread should be in accordance with size G-21/4 of IS 2643
(part-1). 19 Extra 2 nos. of 60 gms. CO2 Gas cartridge shall be provided with each
extinguisher.
iv. Purchase Order No. and date
vi. Inspector Stamp.
02.06 50 lt capacity Mechanical Foam type(trolley mounted)
Portable fire extinguisher mechanical foam type of 50 litres capacity with initial
charge manufactured as per IS:13386-1992 with ISI mark. The body is cylindrical
in shape and of mild steel. All internal and external surfaces shall have
anticorrosive treatment with completely epoxy powder coated to minimum
0.050mm thickness. Internal surface of the body shall be plastic/rubber coated and
lining shall be of minimum thickness of 0.5mm.. A high pressure hose of length
not less than 3000 mm and minimum bore of 12.5mm is to be fitted to the body.
The material of cap, neck ring shall be of tin bronze. The refills shall be
manufactured as per IS 4989 (Part-2)- 1984 with ISI marked. The extinguisher
shall be painted with fire red colour (shade no 536 or 538 of IS 5-1978) and will
be provided with all accessories and wheeled carriage as per IS 13386.. Testing
shall be done as per the guidelines of IS 13386.Each extinguisher shall bear the
following:
iv. Purchase Order No. and date
v. Inspector Stamp.
vi. IS mark on the body of the extinguisher
02.07 Dry chemical power (ABC – type)
DCP – ABC type shall be dry power type (stored pressure) 2kg, 5 kg and 10kg
capacity fitted with squeeze grip valve. Self indicating pressure gauge with Mono-
Ammonium Phosphate base ABC powder pressurised with nitrogen gas complete
with wall mounting brackets and screws confirming to IS:13849-1993 with ISI
mark shall be provided.
Material of construction shall be Mono-Ammonium phosphate base ABC dry

powder with necessary additives as moisture repellence.

B. GENERAL SPECIFICATION FOR PASSIVE FIRE PROTECTION
01 INTRODUCTION
Passive fire protection is an integral part of a complete fire protection system and
is essential for prevention of spread of fire through openings in walls or floors.
These measures are intended to contain a fire in the fire compartment of origin,
thus limiting the spread of fire, excessive heat and corrosive, re-ignitable and fatal
gases for a limited period of time, as determined by testing, which must bound
installed configuration in all respects in order to comply with the law and
regulations.
02 TECHNICAL SPECIFICATION
02.01 Fire Retardant Coating/Painting
For vertical run of cables & PVC conduits, fire retardant coating will be provided
for the whole length. For horizontal run of cables, 1 m length of fire retardant
coating will be provided at every 20 m interval wherever cables cross any partition
wall, floor or pass through any opening, coating shall be provided for at least 1m
length on either side.
Specification
The Fire retardant coating / painting shall be intumescent / ablative, water based
compound, supplied in a manufacturer seal container indicating manufacturing
and expiry dates. The coating material shall be non-toxic, asbestos free, and
halogen free and shall have good mechanical strength. It shall not affect ampacity
of cables and shall last the life of the cable. It should have more than 95% Oxygen
Index.
Shelf life - 12 months (minimum) from the date of receipt (in original
container). 20 years (minimum) from the date of
application.
Material - Water based intumescent compound resistant to

hydrocarbons, acid, and alkali attacks.
Fire rating - Upto 40 minutes minimum.
Method of Application
Coating shall be applied by ordinary paint brush after cleaning the cables of dust
and oil deposition. A minimum textured finish of 2.5 mm dry film thickness shall
be achieved by applying the material a few times leaving intervals of at least 4
hours between each coat.
Test
Fire coating material should have test certifications for fire survival test, ampacity
test, accelerated ageing test, insulation test etc. as per stipulation of
norm/standards indicated below. The material shall be UL/FM/VDS/LPCB
approved and enlisted.
The coating should be tested to following standards:-
Fire retardancy test - IEEE 383

Flame propagation on coated cables - IEC 332:1992 (Part 3)

Electrical circuit integrity test - IEC 331:1970
(With & without coating applied on cables)
100 LOI (Limited Oxygen Index) - ASTM D 2863
Flame spread - BS 476 Part 20 (UK))
02.02 Fire barrier/Sealing of Cable Openings
Cable fire stops/barriers shall be provided in following cases:
a) Entry/Exit area of cable/cable trays in various compartments of cable

gallery/basement/tunnels having different fire loads.
b) Under control panel/any other panel where cables are entering or going
out.
c) In floor openings.
These barriers shall provide for effective compartmentalization with a fire rating
not less than minimum 3 hrs or fire rating of compartment itself which ever is
more. The sealing system should be smoke and gas tight, mechanically sound
besides being an efficient fire stop. It shall be possible to take out cables and
provide new cables from Fire Stops/barriers at site. System shall not adversely
affect ampacity (current carrying capacity) of the protected cable by more than 2
percent. System material should be non combustible and shall not contain
inflammable material or solvent which are toxic or release toxic gases during
exposure to fire.
Components of Fire Stops/Sealing system
Material shall be such that it will not create too much heat to affect rating of the
cables, heat dissipation and cables performance under barrier condition. The
system shall have minimum 3 hours fire rating. System material shall have no
shrinkage or cracking after prolonged use and shall not contain any material which
is prone to ageing or getting adversely affected by moisture, adverse weather
condition or prone to damage by ants/termites and rodents. System material shall
be non hygroscopic and no asbestos shall be used. System material shall be
weather and water proof and shall retain its integrity and perform satisfactorily
even after remaining in water for a long duration. It shall not be corrosive and
shall be non hazardous. It shall be compatible with FRLS PVC, PVC neoprene,
Silicon rubber sheeting material or similar material used in manufacture of cables.
It shall be resistant to chemicals and shall have high Oxygen Index. System as a
whole including reinforcing elements shall be capable of withstanding mechanical
loads such as foot traffic, drop loads, vibration etc. through out service life of the
system.
2.03 Testing and Evaluation
The relevant specifications in respect of testing and evaluation of fire stop system
are as under. The fire resistance for the door shall be at least 3 hours duration.
Building Material Testing - BS: 476 (Part 8)

Through Penetration Fire Stops - ASTM E 814
Fire Stop Penetration – Fire Test - UL-1479

Fire Tests – elements of building construction - ISO 834

Code of Practice for fire protection of cable runs - IS: 12459
Test as per standard - DIN 4102
System should also meet the requirement of high pressure hose steam test.
Fire Stop materials shall have approval and certification from UL/ FM/ LPCB/
VDS.
02.04 Partitions in Cable Channels/tunnels/galleries
In all cable channels/tunnel/galleries partition walls shall be provided at every 30

m interval. Partition walls shall be constructed of RCC wall and shall have
minimum 3 hrs. fire rating. Any openings left out after construction of partition
wall shall be sealed with fire stops. Steel Fire doors shall be suitably provided in
each partition wall .
Steel fire door shall also be provided at every entry/exit of the cable galleries,
cable tunnel, cable basement and oil cellars. Fire rating of the door shall be
minimum of 3 hrs.
C. GENERAL SPECIFICATION FOR HIGH VELOCITY WATER SPRAY

SYSTEM (HVWS/WATER MIST SYSTEM) / WATER MIST SYSTEM AND
MEDIUM VELOCITY WATER SPRAY SYSTEM (MVWS)
01. SPECIAL INSTRUCTION TO THE TENDERER
It is assumed that the tenderer has studied the specification and satisfied himself
regarding the workability of the proposed system and takes full responsibility for the
proper system design, best quality of material and workmanship, guaranteed
operation and smooth performance of all the equipment and accessories. The tenderer
shall satisfy the Purchaser that he possesses the necessary technical experience for
design and has at his disposal suitable facilities and crew to ensure that his work shall
be of the best quality and workmanship.
Any loss of plant and equipment after receipt at site due to imprudence,
negligence and unsuitable treatment and handling shall have to be replaced by the
tenderer at his cost. Any existing services or other property if damaged or
demolished during the course of execution either willfully or negligently, shall be
re-erected by the tenderer at his own cost.
Existing underground service lines coming in the way of trench excavation etc. have
to be supported adequately by the tenderer to avoid any damage at his own cost. Prior
approval is to be obtained from the purchaser for excavation wherever any
trench/pipe lines are crossing roads. In case of any damage, the same shall be
rectified by the tenderer without any cost implication to the purchaser.
The approval of drawings and/or inspection by Purchaser and/or their authorised

representative shall not absolve or relieve the tenderer from any of his obligation
under this contract and they shall be wholly and solely responsible for the satisfactory
operation and guaranteed performance of the systems and equipment forming part of
the system.

This specification is issued for procurement from indigenous sources. No foreign

exchange or import license for importing equipment, components, raw materials or
spares will be arranged for or provided by the purchaser. In case the equipment
offered involves expenditure in foreign exchange, same shall be arranged by the
tenderer.
All material, dimensional standards, tolerances, process of manufacture and testing

procedures shall be in accordance with the latest revision of the standard codes
specified in this Specification. In case where such suitable standards are not
mentioned, any acceptable Indian/International Standards shall be adopted.
The items described in the specification are indicative and not exhaustive. The
tenderer shall provide all the equipment and material required for the system to
complete in all respects.
At the time of award of contract, or at any date preferred by the purchaser the
detailed Quality Assurance Plan to be followed for execution of the contract will be
mutually discussed and agreed to.
The systems shall be designed & engineered, manufactured, assembled, tested and
commissioned as per the standards laid down in this specification. Detailed
instructions on such aspects if not indicated shall be as per the latest standards, codes
and recommendations of the TAC/NFPA. Where TAC standards are not specific,
NFPA or other equivalent international standards shall be used with the approval of
Purchaser/ Consultant.
The safety posters/regulation for prevention of accidents shall be displayed by the

Tenderer at appropriate places. Notices and warning signs shall be displayed for all
sources of dangers. All electrical drives and equipment must be equipped with safety
devices. The safety provisions shall conform to the recognised standards, safety
codes and statutory regulations. All safety measures as required to be adopted as per
the statutory regulations and the safety rules of the plant shall be strictly followed by
the Tenderer during the execution of the Contract. Adequate number of first aid
boxes as defined in the State Factory Rules shall be provided and maintained at all
work sites.
The tenderer shall possess a valid and competent tenderer' s license issued by the
Licencing authorities of the State Government for carrying out the type, nature and
magnitude of work covered in this specification. Copy of the tenderer’s license shall
be made available to the owner/consultant for verification during execution of
contract if required.
All linemen, wiremen, electricians, welders, supervisors and engineers engaged by

the tenderer or his sub-tenderer shall possess necessary valid licence issued by the
statutory authority and the same shall be submitted for verification, if called for.
02. INSPECTION
The tenderer has to submit an inspection procedure for all items to be supplied by
him within 4 weeks of placement of order. The inspection procedure shall be
finalised and approved by the purchaser.
No equipment or part item shall be dispatched without provisional acceptance

certificate and dispatch instructions issued by the purchaser.
All equipments, assemblies and subassemblies shall be shop tested as per relevant
standards and test certificates to be submitted by the tenderer. Purchaser' s
representatives/personnel from fire department shall have the option to visit the place
of manufacture for stage inspection. All equipments shall be inspected by the
purchaser before despatch of the equipment. The tenderer has to make all
arrangements for providing the necessary tools, tackles and instruments free of cost
to carry out the inspection.
03. DESCRIPTION OF THE SYSTEM
HVWS/WATER MIST SYSTEM & MVWS envisaged is a special fixed pipe

system connected to a reliable supply of adequate quantity of water and equipped
with spray nozzles (projectors) for specific water discharge and impingement over
the surface or area to be protected. The piping system is to be connected to the
water supply through an automatically actuated valve (deluge valve) which can
initiate flow of water. Deluge valves for the spray system are to be actuated by an
automatic detection system which in the case of transformers and oil premises
consists of quartzoid bulb detectors mounted around the protected area and for
cable galleries these are part of fire detection & alarm system. Multisensors (fixed
temperature cum rate of rise cum smoke) shall also be provided in addition to Q.B
detectors for oil premises. HVWS/WATER MIST SYSTEM / Water Mist system
shall be installed for protection of transformer and oil premises such as oil cellar,
lubricant stations, oil and lubricants storage and handling premises/ areas and oil/
oil pipe tunnel. Cable galleries/basements shall be protected by MVWS system.
For all HVWS and MVWS, systems shall have bypass arrangement for the deluge
valve. All instrumentation points actuated by the FDA system shall be addressable
and controlled by FDA panel.
04. MAIN COMPONENTS OF THE SYSTEM
The HVWS/WATER MIST SYSTEM/MVWS System shall be provided with the

following major components:
a/ Water Supply at high Pressure

b/ Arrangement of Spray Nozzles
c/ Arrangement of Quartzoid Bulb Detectors (for HVWS/WATER MIST
SYS.)
d/ Deluge Valve assembly including water motor gong and valves etc.
e/ Y-type Strainers just before deluge valve
f/ Pipes, fittings and fixtures
g/ Basket strainers in HVWS/WATER MIST SYSTEM header
h/ Pressure gauges, pressure switches and solenoid valves
i/ Fire detectors
j/ De-watering pumps
k/ By pass manually operated Butterfly valve.
l/ Local deluge valve panel.
m/ Pressure switches
n/ solenoid valves
05. OPERATION OF THE SYSTEM
Initially, delivery line should be pressurized up to deluge valve with the help of

electrically driven Main Pump/Jockey pump and the water line pressure upto deluge
valve should be maintained at delivery pressure of the main pump. The Q.B. detector
line should be pressurized to a pressure of 4 Kg/cm2 with help of water which should
be tapped from the header itself. Deluge valve clack is kept in horizontal position in
normal condition due to balanced hydraulic pressure on two sides of the clack.
In case of transformer and oil premises fire, temperature will rise all around the
transformer/ oil premises. On reaching a predetermined temperature (generally 30oC
above ambient temperature) quartzoid bulb detectors, which are installed on
pressurized water line (water for which is tapped from the main header itself), will
shatter. As the bulb shatters, water in the detector line gets released through the
detector openings and water pressure in detection line drops rapidly. Pressure switch
mounted on the detection line detects the fire and shall give signal to Main Fire
Alarm Panel (MFAP) which in turn shall actuate the solenoid of the deluge valve
concerned. This result in creation of pressure differential in the deluge valve and
leads to latter’s actuation. During this operation pressure in the water delivery line
falls rapidly resulting in start up of main electrical driven pump. In case of power
failure, pressure in the header shall go on decreasing causing start up of diesel engine
driven pump.
In case of cable galleries, cable tunnel and cable vaults etc. the actuation of deluge
valves are affected by signal from fire detection and alarm system provided in the
premises. Cable galleries shall be provided with linear heat sensing cable detectors
(digital type) as per TAC norms. In case of coal and coke conveyor galleries
actuation of deluge valve shall be affected by signal from fire detection and alarm
system. LHS cable and amber type detector shall be provided for detection and
stopping of the conveyors respectively. Amber detector shall be provided with
purging facility and minimum two nos of amber detectors shall be provided for each
conveyor. In the event of fire in the premises/conveyor galleries, the detection system
shall give signal to Main Fire Alarm Panel (MFAP) which in turn shall actuate the
solenoid of the deluge valve concerned. There shall be provision for manual
operation of the system also by operating quick opening valves of each deluge valve.
List of Control /Power Signals
Following signals / controls shall be required on the Main fire alarm control panel
from each of the deluge valve of the HVWS system
1. Fire alarm signal from each transformer through the actuation of pressure
switch located on the detection line near to Deluge valve.(DV)
2. Deluge valve fail to open after command to solenoid valve incase of fire.
3. Alarm from DV to know that it has operated with actuation of pressure

switch located on the delivery side of Deluge valve
4. ON/OFF command to operate solenoid valve of DV at water line
5. 24V DC power shall be provided for solenoid valves from the FDA system.
Local Control Panel
The fire alarm local DV panel shall be provided with minimum facilities

• DV operated
• DV fail to open
• Electronics Hooter
• Switch for power On/Off
• Push Button (Break Glass Type)
• Acknowledge switch for Alarm accept
However all Signals shall be exchanged to MFAP through Local Panel.
Note: Local deluge valve panel, main alarm panel, detectors and other items of FDA
shall be micro processor based (intelligent type) system
06. DESIGN CRITERIA
Following salient parameters shall be followed for the design of the system.
i/ Water application rate for HVWS/WATER MIST SYSTEM - 10.2 lpm/m2

of the surface area of the oil premises/entire transformer including bottom
surface, radiators etc. For MVWS in cable galleries , 6.1 lpm/m2 on each
tray. For MVWS in conveyor galleries 10.2lpm/m2 for exposed area of
conveyor shall be considered. The working pump capacity shall be decided
based on the water requirement (whichever is higher) and selection of pump
shall be from TAC approved pump capacities. The capacity of water
reservoir shall be as per TAC norm, however minimum capacity shall not be
less than equal to one hour pumping.
ii/ The system shall be so hydraulically designed that the pressure at the
hydraulically most remote projector in the network shall not be less than
3.5 bars for HVWS and 2.8 bar for MVWS installations. For cable
premises/ LPG, Propane, fuel oil storage tanks, loading, unloading area
and pumping station, pressure at remotest sprayer shall not be less than
2.8 bars whereas for transformer and other HVWS system area pressure
shall not be less than 3.5 bars. In case of Water Mist System pressure shall
be as per relevant National/ International norms.
iii/ Velocity in the feed pipe shall not be more than 5 m/s.
iv/ Velocity in the main header pipe shall not be more than 3 m/s.
v/ The header shall be laid under ground and tapings for the individual
deluge valve shall be taken there from.
vi/ Q.B. detectors shall be installed in rings as per TAC norms around the
protected area. Maximum spacing between detectors shall be 2.5 m.
vii/ Projectors (for transformers) shall be installed in rings encircling the

protected area. One ring shall be provided at the top and subsequently
rings for every 3 m from top to bottom shall be provided.
viii/ There shall be common header for HVWS/WATER MIST SYSTEM and
MVWS systems which shall be fed from the pump dedicated for the spray
system. The hydrant header and spray system (HVWS/WATER MIST

SYSTEM & MVWS) headers shall be inter-connected with a non-return

valve in between so that hydrant system can be a back-up for the spray
system.
ix/ In cable galleries, the protected area shall be divided into several zones,
each of which shall be fed by individual deluge valve. In event of fire,
water shall be sprayed on the zone concerned (i.e. zone under fire) along
with preceding and succeeding zones. Zone lengths for cable galleries
shall be 30 m.
x/ Distribution of sprayers in cable galleries : The sprayers shall be installed in

rows at the central aisle between the cable trays and spaced at not more
than 3 m from each other.
07. EQUIPMENT SPECIFICATION
07.01 Deluge Valve Assembly
Deluge valve assembly functions on differential pressure operation allowing quick

opening of the valve and thereby rush of water to the protection system. The valve
consists of inlet, outlet and priming chamber. The inlet and outlet chambers are
separated from the priming chamber by the valve chamber and a diaphragm. In the
`Set'position, pressure is applied to the priming chamber through a restricted prime
line. The pressure is trapped in the priming chamber and holds the clapper on the seat
due to the differential design. In the `Set'position the clapper separates the inlet from
the outlet keeping the system piping dry. When the pressure is released from priming
chamber, the clapper moves and allows the inlet water supply to flow through the
outlet and to the fire extinguishing system. All component / equipment of the system
including Deluge valve shall be UL / FM / IS approved and marked.
The deluge valve assembly will consist mainly of the following :
- Isolation valves on both upstream and downstream sides.
- Inline strainer
- Deluge valve proper
- Actuator/pilot assembly
- Drain valve
- Pressure gauges
- Pressure switches
- Solenoid valve
- Deluge valve housing
- By Pass valve arrangement (Butterfly valve)

- Local deluge valve panel
The deluge valve shall be of resetting type, taking minimum time for resetting. The

deluge valve shall be UL/FM/TAC/IS approved make.
07.02 Spray nozzles (Projectors and sprayers)
Water spray nozzles for the system shall be of suitable orifice size and varying
discharge angles to cover fully all the area supposed to be protected. The nozzles
shall be of Gunmetal with Nichrome finish or Stainless steel. The nozzles shall be
normally open type, Spray nozzles(projectors) shall bear UL/FM/TAC/IS approvals.
07.03 Strainer
Y type strainer shall be provided on the inlet side of each deluge valve assembly. The
strainer shall prevent deposition of foreign particles in the valves and thereby
malfunctioning of control valves. The material of construction of the strainer shall be
gun metal and it will bear TAC/IS approval.
07.04 Quartzoid bulb detectors
The Q.B. detectors shall bear TAC/UL/FM approval and shall have a temperature
rating of minimum 79 degree centigrade. However the tenderer shall take into
account the temperature at which they shall operate.
07.05 Solenoid Operated Valve
The solenoid operated valve shall be a 24 V DC operated valve which will get
energised on receipt of power supply from the respective zone of the main fire alarm
panel. The status of its function (open/close) shall be indicated in the main fire alarm
control panel. In case the solenoid valve fails to open within a stipulated time period,
the corresponding signal shall appear in the main control panel.
07.06 Fire Detectors (Part of Fire Detection & alarm system)
Detectors have been described in detail elsewhere in the package specification.

Following types of detectors shall be used for automatic actuation of MVWS
system:- Cable galleries: Analogue addressable type smoke detectors
07.07 Pipes, valves & fittings
Pipes and pipe fittings in general shall comply with the requirements of BIS codes.
Piping layout must follow good engineering practice. Proper attention shall be given
to obtain full functional requirement of piping system with a layout which provides
sufficient clearance for other equipment and other personnel and easy access for
operation and maintenance.
All piping shall be complete in all respects and shall consist of necessary valves,
fittings, supports, air release and drain valves and other accessories. The air release
and drain valves shall be provided at high and low points respectively. Each of the
branch connection taken from the network shall be provided with an isolation valve.
Wherever over-ground pipelines are crossing roads and railway tracks, they shall be
laid on pipe bridges to provide the necessary clearance for the traffic movement. A
minimum clear height of 6.0/8.0 m above road top level shall be maintained.
All pipe work shall be designed to provide complete flexibility to prevent

development of undesirable forces or moments at points of connection to equipment,

at anchorages or at guide points, due to thermal expansion. Flexibility shall be
provided by changes of direction or by use of bends, loops, offsets etc.
The specification of pipes is as below.
i/ T.S. for Pipes between deluge valve and main header
The material of construction and manufacturing standard of pipes, fittings,

fasteners, gaskets etc. shall be as described below. Fittings shall be supplied as per
IS:1239-1992 Part II for pipes upto 150 mm dia and shall be fabricated from pipes
for dia 200 mm and above.
i. Pipes upstream of deluge valve/ control valve
a. Upto 150 mm nominal size - MS ERW black pipes conforming to IS

1239 (Part-1) heavy grade with plain ends.
b.200 mm to 400 mm size - MS ERW black pipes conforming to IS
3589 (Part-1) - thickness as specified
below:
Nominal Dia O.D X Thickness in mm
DN 200 mm : 219.1 x 6.35

DN 250 mm : 273.0 x 7.14
DN 300 mm : 323.9 x 7.14
DN 350 mm : 355.6 x 7.14
DN 400 mm : 406.4 x 7.14
ii. Pipes (downstream of deluge valve / control valve) for Spray system are
given in the following table
Nominal pressure (PN) - 10 Kg/Cm2
Test Pressure (PT) - 15 Kg/Cm2
Sl. Items Nominal Specification

No. dia.(mm)
1. Pipe 65 and below IS-1239 (Part-1) - '
90 heavy, G.I.
80 IS-1239 (Part-1) - '
90 heavy, G.I.
100 to 150 IS-1239 (Part-1) - '
90 heavy G.I.
200 to 450 IS-3589 Gr.410 ERW pipe commercial quality or
equivalent.
Thickness same as in clause 08.07.i above.
2. Pipe fittings A 234 Gr. IS-1239/3589/2062
2.1 Screwed fittings 65 & below IS-1239 (Part-1) - 90 Galvanised
2.2 Fabricated
fittings
Bends 150 and above Mitred bends with radius 1.5 DN from black pipe.
Tees/Crosses 150 and above Fabricated from black pipes by smithing.
Reducers 150 and above Fabricated from black pipes by taper cutting and welding.
3. Bolting All sizes IS – 1367
4. Gaskets All sizes Sheets rubber to IS-635-`79 type-A, 3 mm thick
compressed Asbestos to IS-2712-`79
5. Flanges All sizes Slip on flanges to IS-6392 - `71 machined from Carbon

Sl. Items Nominal Specification

No. dia.(mm)
Steel plates to IS-2002-`92 Gd. 2 with bore to suit pipe
O.D.
iii Pipe Fittings
Fittings shall be supplied as per IS:1239-1992 Part II for pipes upto 150 mm dia and
shall be fabricated from pipes for dia 200 mm and above.
iv Valves
General
Valves shall be provided on pipe work for stopping and starting of flow, controlling
flow rate, diverting flow, preventing back flow, controlling pressure, relieving
pressure and for venting and draining of pipelines etc.
Valve selection shall be made based on the following considerations :
- Suitability of valve materials in regard of properties of fluids, temperature,

pressure, erosion and shock.
- Valve size.
- Main function of the valve (viz. throttling, stop, permitting flow in one
direction, diverting flow, relieving pressure etc.)
- Friction head losses.
- Ease of operation, i.e. method of actuation-closing time.
- Maintenance considerations.
The valves to be provided shall include but not be limited to the following:
- Isolation valves on the main header at various locations.

- Gate valves in the branch pipes from header to DV and from DV to the
served area.
- NRV on all pipe lines requiring unidirectional flow only.
- Quick opening safety shut off valves.
- Manual drain valves.
The valves & sluice gates shall be designed, manufactured and tested as per relevant
Indian Standards or as per other International standards acceptable to the Purchaser
and will be suitable for the duty conditions specified below.
Technical Parameter for Valves
S. Nominal
Items Specification
No. dia.(mm)
1. Isolation/ Below 50 Forged Carbon steel gate valve, screwed as per API

S. Nominal
Items Specification
No. dia.(mm)
Gate – 602 standard, class 800 # ASTM A-105, trim 13%
Valve Cr, Bolt/Nut – B7/2H, Socket end threading as per
ANSI B.16.11 Gasket SPW S.S. 304 with CAF
Hand Wheel - Cast steel
50 to 300 Cast Carbon Steel flanged gate valve as per
standard API-600 class 150 # , Body & bonnet
material ASTM A 216 Gr. WCB, Trim 13% Cr S.S,
Spindle & Gland bush – A1S1 410. Handwheel C.S,
Gasket SW S.S-304 + LAF, flange drilled to ANSI
– B.16.5 along with companion slipon welded
flange (without hub) drilled as per B.16.5 and
gasket, Nut & bolt etc. Hand Wheel - C.S.
2. Throttlin 50 and Gunmetal globe valve, Screwed, as per IS-778-`84

g below Class-2
3. Non 0 to 300 Cast Carbon Steel flanged check valve as per
Return IS:5312 (Part1-1984 CRA 90/BS-1969 (1991) short
valve body. Material of body, cover, disc & hinge – C.S
to ASTM A216 gr WCB, seat ring & disc. Ring –
13% cr .S. Hinge pin / door pin – S.S to AISI – 410
Gasket – CAF as per IS:2712-1979. 3.0 mm thick,
pr. Rating PN – 1.6 N/mm2. Hydraulic testing as per
IS:5312 (Part-I)-1984 (RA 90). B.S. 6755 (Part-I)
flange drilled to ANSI-B-16.5 along with
companion slip on flange (without hub) drilled as
per B-16.5, Black hexagonal nut & part 1 & 3,
1992, class 4.6/4.
4. Butterfly 100 to The sizes of manual butterfly valves shall be same
valve 200 as the pipe size.
Design Water design
Standard : Manufacturing BS:5155 / API:609
Material Specification
Body ASTM A216 Gr WCB/CI:IS 210 Gr FG-200
Disc A351 Gr CF8 / ASTM A 182 Gr F304
Seat / Body Liner Nitrile Rubber
End Connection Wafer design
Gasket CAF
Shaft AISI 410
Operation Wrench / gear operated
Position Normally open or normally closed
All sluice gates shall be non rising spindle type.
All underground valves will be provided with valve chambers with RCC covers. The
size of chambers shall be suitable for easy maintenance of the valve. Complete civil
work for this is in the Tenderer'
s scope.
Note: Valves shall be supplied with companion flanges
07.08 Pipe supports and fixtures

Necessary pipe supports & fixture, pipe thrust block or pipe bridge to run the pipes
overhead/underground or in the pipe trench as the case may be, shall be included in
the scope of the tenderer. The tenderer shall study the location of protected premises
and their auxiliary equipment and accordingly plan the pipe routing and the location
of spray nozzles, deluge valves and manually operated valves. The fire protection
equipment and the fixtures located in the vicinity of the transformers should not
pose any operational problem. At places, where no supports/trenches are available
the tenderer shall consider dedicated supports required for the pipe lines/spray
nozzles etc. for the system.
07.09 Equipments in Fire water pump house
All equipments to be installed in the Fire water pump house (FWPH), viz., Main
Pumps, diesel engine driven standby pumps, jockey pumps, valves, hoisting
facilities, ventilation fan, instrumentation gadgets etc. have been described elsewhere
in the package specification. Major facilities are enumerated below:
i) Horizontal centrifugal Fire water pump.
ii) Electric drive motors mounted on the drive support of the pump,
complete with terminal box for armoured cables and the Motor leads,
Tilting pad thrust bearing / anti friction bearing and accessories for one
number of the above pumps.
iii) Diesel Engine drives with associated battery & charger
iv) Fire water jockey pumps
v) Electric drive motors mounted on the drive support of the pump,
complete with terminal box for armoured cables and the Motor leads,
Tilting pad thrust bearing/ antifriction bearing and Accessories for Two
Nos. of the above jockey pumps.
vi) Complete set of foundation Bolts, Nuts, Base-plate, Sole-plate and Steel
embedded parts.
vii) All necessary integral sensors required for the pump and drive motor,
including discharge pressure gauges.
viii) Complete lubrication system together with grease fittings and initial
fill of lubricants for thrust bearing, foam concentrates, diesel and
consumables etc.
ix) Ventilation facilities (axial fan) for the fire water pump house.
x) Hoisting facilities of adequate capacity for FWPH complete with

electrics, all structural members and other accessories.
xi) Piping inside pump house, gate valves, non-return valves, cabling,
instrumentation and other accessories.
xii) Complete electrics and instrumentation for all equipments in

FWPH.
07.10 Deluge valve housing

Deluge valve room/housing shall be provided to protect the deluge valve and
other equipment and accessories from mechanical damage as well as
environmental condition. Deluge valve housing shall be provided as per
TAC norms.
i) DV housing shall be of brick wall construction in three sides with window
and lighting provision . Roof shall of RCC. DV housing shall have one
side opening with MS flat fencing with grill gate. MS grills/fencing shall
be made from expanded metal sheets as per IS 412-1975. Shortway and
longway of the grill/mesh will be 40mm and 75mm respectively. Width
and thickness of the mesh shall be 3.25mm and 1.60mm respectively.
Piping inside pump house, gate valves, non-return valves, cabling,
instrumentation and other accessories.
07.11 Fixed Type Dewatering Pumps
Dewatering pumps of adequate size and quantity shall be provided to drain

out the sprayed water in the areas Pumps shall be supplied with all
accessories and electrics.
Note: In case of Water Mist System requirement of equipment and their

specifications shall be as per relevant National/ International norms. .
D. GENERAL SPECIFICATION FOR CLEAN AGENT SYSTEM( Inert Gas)
01 SPECIAL INSTRUCTION TO THE TENDERER

01.01 It is assumed that the tenderer has studied the specification and satisfied himself
regarding the workability of the proposed system and takes full responsibility for the
proper system design, best quality of material and workmanship, guaranteed
operation and smooth performance of all the equipment and accessories. The
Tenderer shall satisfy the Purchaser that he possesses the necessary technical
experience for design and has at his disposal suitable facilities and crew to ensure that
his work shall be of the best quality and workmanship. Any loss of plant and
equipment after receipt at site due to imprudence, negligence and unsuitable
treatment and handling shall have to be replaced by the tenderer at his cost. Any
existing services or other property if damaged or demolished during the course of
execution either willfully or negligently, shall be re-erected by the tenderer at his
own cost.
01.02 The approval of drawings and/or inspection by Purchaser and/or their authorised
representative shall not absolve or relieve the Tenderer from any of his obligation
under this contract and they shall be wholly and solely responsible for the satisfactory
operation and guaranteed performance of the systems and equipment forming part of
the system.
01.03 This specification is issued for procurement from indigenous sources. No foreign
exchange or import licence for importing equipment, components, raw materials or
spares will be arranged for or provided by the purchaser. In case the equipment
offered involves expenditure in foreign exchange, same shall be arranged by the
tenderer.
01.04 All material, dimensional standards, tolerances, process of manufacture and testing
procedures shall be in accordance with the latest revision of the standard codes
specified in this Specification. In case where such suitable standards are not

mentioned, any acceptable Indian/International Standards shall be adopted.

01.05 The items described in the specification is indicative and not exhaustive. The
Tenderer shall provide all the equipment and material required for the system to
complete in all respects.
01.06 At the time of award of contract, or at any date preferred by the purchaser the
detailed Quality Assurance Plan to be followed for execution of the contract will be
mutually discussed and agreed to.
01.07 The systems shall be designed & engineered, manufactured, assembled, tested and
commissioned as per the standards laid down in this specification. Detailed
instructions on such aspects if not indicated shall be as per the latest standards, codes
and recommendations of the TAC/NFPA.
01.08 The safety posters/regulation for prevention of accidents shall be displayed by the
Tenderer at appropriate places. Notices and warning signs shall be displayed for all
sources of dangers. All electrical drives and equipment must be equipped with safety
devices. The safety provisions shall conform to the recognized standards, safety
codes and statutory regulations. All safety measures as required to be adopted as per
the statutory regulations and the safety rules of the plant shall be strictly followed by
the Tenderer during the execution of the Contract. Adequate number of first aid
boxes as defined in the State Factory Rules shall be provided and maintained at all
work sites.
01.09 The tenderer shall possess a valid and competent tenderer' s license issued by the
Licensing authorities of the State Government for carrying out the the type, nature
and magnitude of work covered in this specification. Copy of the tenderer’s license
shall be made available to the owner/consultant for verification during execution of
contract if required..
01.10 All linemen, wiremen, electricians, welders, supervisors and engineers engaged by
the tenderer or his sub-tenderer shall possess necessary valid license issued by the
statutory authority and the same shall be submitted for verification, if called for.
01.11 Instruction Manuals
a/ Instruction manual shall give step by step procedure for :
- Erection, testing and commissioning
- Operation
- Maintenance and
- Repair.
b/ Maintenance instruction shall include:
- Diagnostic trouble shooting/fault location charts.
- Tests for checking of proper functioning.
Instruction manual shall also contain:
- Manufacturer'
s catalogues with ordering specification for all items.
- List of consumables with specifications, brand names and annual
consumption figures.
- Drawings relevant for erection, operation, maintenance and repair of
the equipment.

- Procedure for ordering spares.

02. INSPECTION
The tenderer has to submit an inspection procedure for all items to be supplied by
him within 4 weeks of placement of order. The inspection procedure shall be
finalised and approved by the purchaser.
No equipment or part item shall be despatched without provisional acceptance
certificate and despatch instructions issued by the purchaser.
All equipments, assemblies and sub assemblies shall be shop tested as per relevant
standards and test certificates to be submitted by the tenderer. Purchaser' s
representatives / personnel from fire deptartment shall have the option to visit the
place of manufacture for stage inspection. All equipments shall be inspected by the
purchaser before despatch of the equipment. The tenderer has to make all
arrangements for providing the necessary tools, tackles and instruments free of cost
to carry out the inspection.
03. SYSTEM DESCRIPTION
The total flooding system of Clean agents ( Inert Gas ) work on the principle of
making the premises non-conducive to sustenance of fire therein by injecting
sufficient quantity of gas. The rapid injection of sufficient volume of gas into an
enclosure, so that an inert atmosphere is created, extinguishes fire, which is named
as total flooding system.
Clean agent gas conforming to NFPA 2001, shall be used in Computer rooms,
PLC rooms and important control rooms.
When detectors detect fire, the signal is communicated to the main control panel,
which shows the address (along with location) of the actuated detector. On
detection of fire the respective hooters of the zone will also be actuated. On
confirmation of fire by detectors the respective Air-conditioning & Ventilation
system will trip and evacuation alarm signal will appear in the premises. There
will be a selector switch for manual and automatic actuation of the system. Gas
will be discharged automatically in the affected premises after a time lag of 30
seconds. In case of manual operation, after time lag of 30 seconds the push button
switch of the affected premises shall be manually operated which will actuate the
discharge of Clean gas developing required concentration and there by
extinguishing the fire.
Further, if manually operated push button system is inoperative due to any reason,
Clean agent can be discharged by manual lever provided for the purpose.
Each system shall have equal number of reserve cylinder complete with all
accessories. All instrumentation points actuated by the FDA system shall be
addressable (intelligent) and controlled by FDA panel.
04. DESIGN CRITERIA
04.01 Clean agent based automatic fire protection system shall be designed as per NFPA
2001. In case of LPCB/VDS designed system gas concentration shall be as
specified in these norms and not limited to the concentration of NFPA 2001. The
design, manufacture, testing and performance of all the critical equipment and
components covered in this specification shall be UL / FM / VDS / LPCB
approved and listed therein.. All major components of the system except pipes,

cables and support structures etc. shall have UL / FMRC / VDS / LPCB approved.
04.02 The quantity of gas required for the system shall be based on the gas required to
blanket the volume of area protected and the time that the discharge must be
maintained to assure complete extinguishing of fire (10 sec for clean agent) after
actuation.
04.03 In order to optimize the requirement of gas and considering the space for cylinder
banks, it may be planned to club together requirements of two or more adjacent
premises. The tenderer shall ensure that the appropriate logic is followed for
discharge of gas in respective premises.
04.04 Tenderer will include provision for automatic actuation of the system by FDA in
the premises concerned. Annunciation for system operated will be provided in
MFAP and Annunciation panel. Provision for time delay and evacuation alarm
shall also be given. The FDA Panel shall have necessary Hardware and software
to activate (operate) Automatic fire extinguishing system provided with directional
valves( if applicable) for different zones / premises.
04.05 The tenderer shall size the pipe accordingly to achieve the design concentration of
gas required for extinguishing the fire in the premises.
The concentration level shall not exceed the NOAEL and LOAEL level as per
NFPA guidelines.
04.06 ELECTRICS
Tenderer to include power supplies and control interlocking as described in this
chapter. All wiring - junction boxes, push button station, indication lamps, hooters
etc. shall be included into scope of tenderer. All areas shall have illuminated board
"FIRE - EVACUATE CLEAN GAS WILL BE FLOODED". Each area shall have
hooter adjacent to illuminated sign.
Main fire Alarm Panel shall have annunciation for fire in above areas and after
confirmed signal (operation of two detectors) signal will be initiated for tripping
of A/C system and visual indication `START - FLOODING'shall be there. From
Main Fire Alarm Panel signals shall also be initiated for illuminated sign/hooters
of respective area.
Manual pushbutton of each area shall be located near exit and shall be break glass
type with attached hammer. Manual push button shall operate valve for flooding in
respective premises and as well as for connecting banks of gas cylinders to main
pipe.
Tenderer to develop logic for above and submit working scheme along with the
tender. Any interface devices required to hook up this system with the Main Fire
Alarm Panel shall be included by the tenderer as part of the scope as a whole.
One no. of Wall mounted annunciation board near cylinder bank shall be provided
for (duplicate) annunciation to facilitate manual operation of valves.
04.07 EQUIPMENT SPECIFICATION
04.07.01 Each system in general shall consist of the equipment not limited to the following

for successful operation:
- Bank of Clean agent cylinders each fixed with cylinder head valve and
non-return valve.
- Bank of standby cylinders fitted with - cylinder head valves connected
with manifold.
- Gas manifold and high-pressure hoses.
- Pressure operated control valves.
- Pilot cylinders with firing unit (electrical actuator)
- Discharge nozzles
- Manual release push button
- Pipes and fittings
- Fire detection and alarm system
- Caution hooters
- Online electronic weighing arrangement for cylinders to display the
weight on the main fire alarm panel
- Caution boards & evacuation alarm
- Inhibitors
- Safety relief valves
- Trolley for the transportation of cylinders
04.07.02 CYLINDER BANK
The required quantity of gas will be stored in seamless steel cylinders confirming
IS: 7285 duly approved by CCE, Nagpur. Each cylinder shall be provided with gas
release device all suitably connected to the gas manifold which will discharge the
gas in protected premises in case of any outbreak of fire. The total number of
cylinders in the bank shall be determined depending upon the area/volume of the
protected premises and the capacity of individual cylinders. All cylinders in the
bank shall be inter-changeable. Equal number of standby cylinders shall also be
provided to be used after depletion of main cylinder bank and connected to the
main header so that in case of successive fires the reserve bank can be used to put
out the second occurrence of fire.
04.07.03 GAS MANIFOLD
Each cylinder in the bank shall be fitted with a discharge head, which shall be
connected to a common manifold through high pressure connecting pipes of tubes.
In case rigid pipes are used for the purpose anti-vibration coils shall be provided.
All cylinders in the battery and the common manifold shall be mounted and
suitably supported in a rack provided for the purpose. The rack shall be designed
in such a manner that servicing and checking of individual cylinders shall be
convenient and the cylinders are rigidly held in position. The design shall ensure
no chance/minimum possibility of accidental discharge of cylinders.
04.07.04 DISCHARGE HEADS AND VALVES
All valves under constant high pressure and those not under constant pressure
shall have shall have a minimum bursting pressure as per NFPA -2001 norms and
also as per manufacturer’s recommendations..

All discharge heads and valves shall be so arranged that these shall not be
susceptible to mechanical, chemical or other damage.
04.07.05 DISCHARGE NOZZLES
Discharge nozzles shall be sufficient in number as per IS/NFPA norms and so

located that the gas discharge pattern shall completely cover the protected area
house having adequate concentration in the high hazard locations.
04.07.06 PIPES AND FITTINGS
All pipes and fittings, including the manifold shall have a minimum bursting
pressure of 350 kgf/sq.cm. The complete distribution system shall be free from
leakage when tested at a pneumatic pressure of 140 kg/sq.cm. with all nozzles
outlets closed.
All sections of pipes having dead ends shall be fitted with suitable pressure relief
devices designed to operate between 168 kg/sq.cm. and 210 kg/sq.cm.
The pipes shall be of ASTM A-53 or A-106/A type (Seamless Carbon Steel High
Pressure minimum Sch. 80 pipe).
04.07.07 LOCK OFF DEVICE (INHIBITOR)
Each system shall incorporate a suitable locking device to make the system
inoperative before undertaking any repair/maintenance within the protected area.
The system shall be capable of putting on normal operation after completion of the
repair/maintenance work.
04.07.08 CAUTION SIGN
Necessary caution displays in the form of Audio-visual type indicating the hazards
of inert gas flooding shall be installed at strategic places of the premises provided
with total flooding system.
The visual display shall be of flashing type and the audio hooter/siren shall be of
distinct tone and capable of being heard in the range of 500 m from the source.
04.07.09 MATERIAL OF CONSTRUCTION
Cylinder Valve - Bronze/GM

NRV - Brass
High pressure hoses - Copper
Spray nozzles - LTB

E. LOW EXPANSION FOAM SYSTEM
01 Low expansion foam system shall be provided for all the flammable oil storage tank
farm area. System shall be designed as per the latest IS and NFPA norms. System
shall consist of water supply piping network, foam storage tank, inline inductors,
proportioning unit, foam chambers, etc. Water for the foam system shall be generally
drawn from the pumping network of the water spray system. However, in case water
from the water spray system is not available/adequate then separate pumping network
shall be envisaged for the foam system. In that case system shall have electrical
driven main pumps, 100 % standby diesel driven pumps and 2 nos. of jockey pumps.
02 For automatic operation of the system Q.B type detectors shall be provided all around
the tank to sense the occurrence of fire by heat sensing principle.
03 Foam storage tank along with piping and valves shall be of stainless steel material.
04 Foam piping along with valves from storage tank upto proportioning unit/ inline
inductor shall also be stainless steel material.
05 Foam concentrate of AFFF type having minimum life of 15 to 25 years shall be

supplied as per IS/NFPA norms.
06 All the accessories, equipment required for the system as per TAC, IS and NFPA
norms shall be supplied irrespective of whether such items are specifically mentioned
or not.
F. WATER MONITOR AND WATER CUM FOAM MONITOR
Water and water cum foam monitor of 2580lpm capacity shall be provided as per
IS8442-2008 in Switch yard, blast furnace area, sinter plant area, coke oven and by
product area, raw material storage bed area, oil storage and handling areas including
tank form areas.
All the accessories, equipment required for the system as per IS norms shall be
supplied irrespective of whether such items are specifically mentioned or not.
01 WATER MONITOR
Supply and erection of 2580 lpm fixed type water monitor bearing IS:8442:2008
mark complete with all accessories. Water for monitors shall be tapped from
adjacent Hydrant header. Tenderer shall also include pipeline for tapping of water
and isolation valve for each monitor.
01.01 Technical Particular :
i Size of Monitor 75mm
Ii Flow rate : 2580 lpm at7.0 Kg/Cm2 pressure
Iii Jet length : Horz. - 60 m (minimum)
Iv Rotation angle :
Horizontal plane : 360o
Vertical plane : Minimum 135o (90o Upwards and 45o
Downward )
v Design pressure : 15 Kg/Cm2
vi Back pressure at base flange : 7.0 Kg/Cm2
vii Base flamge spec : 100 NB/150 NB drilling dimension as

per IS:8442
viii Nozzle : 38 mm FOG type and jet type with
instantaneous coupling
ix Material of construction : As per IS 8442-2008
various parts of the monitor
x Lubrication Provision shall be made for grease

lubrication of joints
xi Water barrel pipe thickness as per IS:8442-2008
01.02 Anticorrosive Treatment and Painting (as per IS 8442-2008) :
• All the steel components subject to direct water contact shall be hot dipped
galvanized to a minimum thickness of 0.03 mm.
• Monitor shall be painted with fire red or post office red confirming to shade no
536 or 538 of IS-5. Paint shall confirm to IS:2932.
01.03 Testing
• The entire monitor assembly shall be hydraulically tested to a pressure of 23

Kg/cm2 for a duration of 5 minutes to show no sign of leakage or bursting.
• The performance of the monitor shall be tested to check its flow and discharge
parameters as per IS8442.
• Painting shall be peel tested.
01.04 Accessories
The supply shall include a nozzle spanner made of forged steel along with each
monitor.
02 WATER-CUM-FOAM MONITOR
Supply and erection of 2580 lpm fixed type water-cum-foam monitor bearing
IS:8442:2008 mark complete with all accessories. Water for monitors shall be
tapped from adjacent Hydrant header. Tenderer shall also include pipeline for
tapping of water and isolation valve for each monitor.
02.01 Specification
• Material of construction for various components of monitor shall be as per IS
8442-2008.
• Swivel joint (worm and worm wheel type) and change over valve assembly
shall confirm to grade 2/3 of IS:318 as specified in IS:8442:2008
• Water barrel shall confirm to IS8442-2008.
• Foam barrel with inductor shall be of Brass tube as per IS 407 or Al as per
conforming to IS:1285 and 2673.
• Foam compound control valve shall be of SS to SS 304
• Pick up tube shall be of 1” dia. Bore flexible rubber of PVC with chrome
plated brass strainer.
• Drain valve shall be of copper alloy as per IS :778
• Hand wheels of C.I. to IS:210

• Nuts and bolts for base flange and change over valve shall conform to IS:1367
1990(96) Cl. 109 and Cl.12 respectively and gasket shall be of CAF 40 as per
IS:2712:1998.
• Lock pins for swivel joints shall be of Brass to IS:291:1989.
• Each monitor shall be provided with a multipurpose combination nozzle for
jet spray and fog arrangement
02.02 Technical Particulars.
• In general the water cum foam monitor shall conform to IS:8442:2008
Flow rate Water 2580 lpm at 7Kg/ Cm2

Foam 16000 to 22000 lpm at 7
Kg/Cm2
Horizontal throw Water 60 m (min.) at 7Kg/ Cm2
Foam 50 m (min.) at 7Kg/ Cm2
Vertical throw Water 30 m (min.) at 7Kg/ Cm2
Foam 24 m (min.) at 7Kg/ Cm2
Horizontal rotation 360o either direction
Vertical rotation Minimum 135o (90o Upwards
and 45o Downward )
• The monitor shall be mounted on a 100 NB MS pipe with flange connection.
• Instantaneous change over of discharge from water to foam or vice versa shall
be possible with the change over valve.
• Foam compound control valve shall be capable of introducing 3% to 6% of

foam compound.
• The flexible 1” dia. Pick up tube shall be of at least 3m length.
• Near the base flange, a drain connection shall be provided with a GM drain
valve of 15mm (1/2”) size to drain the water out of the vertical post of the
monitor. The drain pipe shall be long enough to discharge water away from
the base flange.
• The end of the water barrel shall have external threads conforming to
IS:2643:1975 (Part-I) with class A tolerance on which the nozzle with internal
threads conforming to IS:8442-1977(90) shall be fixed.
• The nozzle outlet end shall be provided with external threads to enable fixing
either a fog nozzle or a blank cap as required. Blank cap shall be supplied
along with the monitor.
• Pressure gauge shall be of 2” dial and 0-14 Kg/cm2 range.
02.03 Anticorrosive Treatment and Painting (as per IS 8442-2008)
• All the steel components subject to direct water contact shall be hot dipped
galvanized to a minimum thickness of 0.03 mm.

• Monitor shall be painted with fire red or post office red confirming to shade no
536 or 538 of IS-5. Paint shall confirm to IS:2932.
02.04 Testing
• The entire monitor assembly shall be hydraulically tested to a pressure of 23

Kg/cm2 for a duration of 5 minutes to show no sign of leakage or bursting.
• The performance of the monitor shall be tested to check its flow and discharge
parameters as per IS 8442
• Painting shall be peel tested.
02.05 Accessories
The supply shall include a nozzle spanner made of forged steel along with each
monitor.
02.06 Marking
Each monitor shall be clearly & permanently marked with the following
i. Manufacturers name & his trade mark
ii. Year of Manufacture
iii. Discharge capacity in lpm
iv. BIS certification marking : Monitor may be marked with standard mark
G. DRAWINGS AND DOCUMENTS
Drawing and documents are to be submitted by the Tenderer for all the systems as
indicated below:
For Approval by purchaser/consultant after placement of order
i. G.A Drg. for HVWS/MVWS/WATER MIST SYSTEM/Gas/Foam/

monitor/Passive system. All system drawings should have approval of
TAC / other authorized agency.
ii. Detailed water/gas/foam requirement calculation.
iii. G.A. drg. of FWPH showing all piping arrangements & pump sets etc.
iv. Process and Instrumentation drawing for working of pumps, other
equipments in FWPH, HVWS/MVWS/WATER MIST SYSTEM gas and
foam system.
v. General arrangement drawings for all electrical equipment, showing
dimensional and mounting details, cable entry and front view details.
vi. Pipes, Cable and conduit routing drawings alongwith isometric view
drawings.
vii. Power and control circuit diagram for panels/equipment.
viii. Computerized flow and pressure calculation for water, gas and foam system.
ix. Portable fire extinguishers- Distribution of extinguishers w.r.t type &
capacity as per IS-2190.
Drawings/documents to be furnished for information by the tenderer
a/ Manufacturer'
s routine test and type test certificates for all equipment and

cables.
b/ Detailed technical catalogues/data sheet/brochure for all the equipment.
c/ Ordering specifications to sub-suppliers.
d/ Instruction manuals for erection, maintenance and operation of all the
equipments.
e/ Certificate of approval from TAC and similar other authorizing body for
various component of the system.
As built drawings/documents
The Tenderer shall submit following As Built drawings/documents in five sets.
- All approved drawings/documents

- All test charts and inspection certificates in bound volume.
- CAD version of drawings

NMDC LIMITED

FOR
ARCHITECTURE
(GS – 11)
MECON LIMITED
RANCHI - 834002

SL. NO. DESCRIPTION NO. OF PAGES.
01. GENERAL 2-3
02. FLOORING 3-4
03 SKIRTING / DADO 4
04 PLASTERING 4
05 PAINTING 5
06 ROOF DRAINAGE AND WATER PROOFING 5
07 FALSE CEILING AND UNDER DECK INSULATION 5
08 DOORS AND WINDOWS 6-7
09 GLAZING 7
10 WATER SUPPLY AND SANITATION 7
Chapter 11 Architecture Page 1 of 8

01 ARCHITECTURE
01.01 General
01.01.01 Scope
This part deals with the requirements of materials for use in construction work
with regard to quality, testing, approval and storage, before they are used on work.
This part is supplementary to Part-H: Workmanship and Other requirements of the
Technical Specifications for civil works.
01.01.02 Standard
A high standard of quality is required for all materials used in construction work.
They shall be the best of the kind obtainable indigenously in each case and shall
be procured from manufacturers of repute in order to ensure uniformity of quality
and assurance of timely supply.
01.01.03 Approval and Tests
01.01.03.01 All materials to be used in construction shall be subject to approval of the

Engineer. The Contractor shall apply sufficiently in advance with samples of the
materials including the supporting test results from the approved laboratory and
other documentary evidence from the manufacturer wherever applicable and
indicating the types of materials and their respective sources. The delivery of
materials at site shall commence only after the approval of the quality, grading and
sources of the materials by the Engineer.
01.01.03.02 The quality of all materials once approved shall be maintained throughout the
period of construction and periodical tests shall be carried out to ensure that it is
maintained. Such routine tests shall be listed under the different materials and or
as may be ordered by the Engineer from time to time.
01.01.03.03 Where a particular “Brand” or “Make” of material is specified in the Schedule of

Items or Technical Specifications, such “Brand” or “Make” of material alone shall
be used on the work. Should it become necessary for any reason (such as non-
availability/ceased to be produced), to use any material other than the specified
“Brand” or “Make”, the Contractor shall submit sample of the same to the
Engineer for approval together with test certificates and other documents
necessary for examining and giving approval thereof Should such change or
substitution of materials, subsequently approved, results in use of material of price
lower than that of the material specified in the Schedule of Items or Technical
proportionately reduced. Similarly, in case the substitution results in use of
material of price higher than that specified in the Schedule of Items or Technical
proportionately increased.
01.02 Codes

referred to. Where standards are not yet published by the BIS, NBC, BPE or IRC,
adoptable British Standards or other International Standards shall apply.
2.00 General Specifications for Architectural Works
02.1.0 FLOORING
02.1.1 Terrazo Tiles / Cast-in-Situ
02.1.1.1 Tiles will generally be 250 x 250 x 20mm laid over cement mortar bedding to
resulting an overall thickness of 40mm
02.1.1.2 40mm thick cast in-situ mosaic flooring shall be used.
02.1.2 Ceramic / Vitrified Tiles
02.1.2.1 Ceramic tiles with matt finish will be used in toilets. The tiles will be 300 x 300 x
6.80mm (minimum.) of approved shade, brand and colour.
02.1.2.2 Vitrified tiles of size 600 x 600 x 9.50mm (minimum.) of approved shade, brand
and colour shall be used
02.1.3 Acid / Alkali Resisting Tiles
Areas coming into contact with acid / alkali vapours or fumes will be given acid
/alkali resistant tiles 20 mm thick, jointed with acid / alkali resistant cement
mortar. Bedding will comprise of potassium silicate mortar conforming to IS 4832
(Part-I) and resin based mortar like epoxy for jointing. Total thickness of flooring
will be 40mm
02.1.4 PVC Floor Finish
02.1.4.1 2mm thick antistatic PVC tiles as per IS:3462 and laid as per IS:5318 over
concrete under bed of 38mm will be provided in all control room, electronic
cubicle rooms, conference room, etc.
02.1.5 Finish for Stair Cases

02.1.5.1 Risers and treads of staircases will be provided finish matching with the
Skirting/floor finish with 25mm nosing . Staircase wall will be given skirting of
same finish to a height of 300mm. On treads of stair stepper tiles /antiskid tiles
will be provided.
02.1.6 Ironite / IPS Floor
02.1.6.1 Ironite flooring with metallic hardener / non metallic hardener of 40mm thickness
shall be used.
02.1.6.2 40mm thick IPS flooring shall be used.
02.1.7 Stone Floor

02.1.7.1 18/20mm thick kota stone floonng shall be used
02.1.7.2 18/20mm white marble flooring shall be used
02.1.7.3 18/20mm granite flooring shall be used.
02.1.7.4 Coloured interlocking paver block (80mm) made with M-30 grade concrete will
be used in parking.
02.1.8 Miscellaneous
02.1.8.1 Angles 75 x 75 x 6mm (minimum) with tugs wilt be provided for edge protect
Cutouts/openrngs in floor slabs, edge of drains covering gratings, edge of R C C
cable /pipe trenches of any other p1 where breakage of edges / corners is expected
02.1.8.1 Architectural features with ceramic wall tiles cladding shall be used as per
requirement.
02.1.8.2 False flooring with 8mm thick granite tiles topping to be used
02.1.8.4 False flooring with 2mm thick PVC tile topping to be used
02.2.0 SKIRTING /DADO
02.2.1 Minimum 100mm / 125mm skirting matching with floor finish will be provided in
all areas unless specified other wise elsewhere.
02.2.2 Toilets will be provided with dado up to the height of 2100mm from floor with
colour / design glazed tiles of minimum 5mm thickness generally as per IS:777.
02.2.3 Areas coming in contact with acid / alkali spillage / fume, dado of acid /alkali
resistant tilling willi provided to a height of 2l00 mm set in potassium silicate
mortar and joints pointed with resin bounded mortar.
02.3.0 PLASTERING
02.3.1 External face of all walls will be provided minimum 20mm thick cement mortar
plastering.
02.3.2 Internal face of all walls will be provided with minimum 15mm cement mortar
plastering
02.3.3 Inside surfaces of walls will be provided with 2mm thick plaster of paris punning
over the plaster surfaces in office areas, corridor, control room and all other air-
conditioned rooms etc. Wall putty approved brand shall be provided wherever
required.
02.3.4 Ceiling of all buildings except over false ceilings will be given 6mm thick cement
sand plaster 1:4

02.4.0 PAINTING
02.4.1 Details furnished below are the minimum acceptable standard for painting
02.4.2 Exterior grade acrylic paint of approved brand and shade will be provided on
external faces of wal sunshades, etc.
02.4.3 Inside surfaces will be provided with Acrylic emulsion paint for Control Room.
Control Equipment Rooms, all air conditioned areas and all other areas and above
dado in toilet etc.
02.4.4 All plastered ceilings will be painted with Acrylic synthetic distemper/emulsion
paint over a coat of cement primer
02.4.5 Painting for structural steel will be as described in technical specifications.
02.4.6 Battery rooms I laboratories will be painted with acid/alkali resistant paint
i) All paints will be of approved brand and make as per the approval of
owner.
ii) A minimum of two finishing coats of paint over a primer will be provided.
iii) All fire exits will be painted in Post Office red colour shade which will
not be used any where except to indicate emergency or safety measure.
iv) All painting on masonry or concrete surfaces will preferably be applied by
rollers.
v) Surface texture finish shall be used
02.5.0 ROOF DRAINAGE AND WATER PROOFING
02.5.1 The gradient will preferably provided by sloping the structural framing system
itself. Gradient may also be provided using screed concrete of grade M20 using
12.5mm downgraded aggregate. But the average thickness of such screed concrete
will be restricted to about 50mm. In the case of metal roofing system the roof
slope will be 1 vertical:3 horizontal.
02.6.0 FALSE CEILING AND UNDER DECK INSULATION L

02.6.1 Cup board false ceiling system will consist of 600 x 600 x 12.5mm gyp board /E-
Board (6mm) with one coat of primer and two or more coats of acrylic emulsion
paint. The suspension system will be provided with G.I. system as per
manufacturer’s specification
02.6.2 Suitable M S channel (minimum ISMC 100) gnd will be provided above false
ceiling for movement of personnel to facilitate maintenance of lighting fixtures.
AC ducts etc.
02.6.3 A layout of the false ceiling system shall be prepared incorporating light fixtures,
supply air diffuser, return air grills, fire detectors, fire protection sprinklers etc.
such that the ceiling looks aesthetically pleasing. Work will commence only after
the approval of the layout.

02.6.4 Under deck insulatiop, wherever required, will be as detailed in the tecI
specifications.
02.6.5 Pre coated aluminium C or R section of Luxlon or equivalent make will be used
in false ceiling as per manufacturers specification.
02.7.0 DOOR. WINDOWS & PARTITION
02.7.1 All doors, will be of 35mm thick flush door, windows and ventilators will be of
steel. View panels will be provided in doors wherever required. The fixtures and
hard ware will be of best quality and will be provided as detailed in the technical
specifications.
02.7.2 Wherever functionally required, rolling shutters with suitable operating

arrangement manual/mechanical / Electrical will be provided to facilitate smooth
operations.
02.7.3 Fireproof doors will be provided at all fire exit points as per the recommendations
of LPA. These doors will generally be as per IS:3614 (Part-I and Part-IT). Fire
rating of the doors will be as per LPA requirements. However minimum rating
will be 2 hours. These doors will be double cover plated type with mineral wool
insulation.
02.7.4 Aluminium doors & windows

02.7.4.1 Aluminium glazed glass door with floor spring and toughend shall be used.
02.7.4.2 Aluminium glazing with double layer heat insulated glass shall be used.
02.7.4.3 Aluminium partition with aluminium frame using toughend glass to be used.
Aluminium window with toughend glass to be used.
02.7.5 PVC Doors
02.7.5.1 PVC door with PVC frame work and hardware fitting shall be used.
02.7.6 Hardware fittings for doors and windows:
Fittings for steel doors:
Sl.. Item Nos. of Single leaf Nos. for double

leaf
No.
1. MS AIdrop 1 1
2. MS Tower bolt for top 1 2
3. Mortice lock 1 1
4. MS Hinge 3 6
5. MS Door handle 2 4
(One on each face)
Fittings for flush door shutter:
Sl.. Item Nos. of Single leaf Nos. for double leaf
No.
1. Towerbolt 3 00mm for top 1 2
2. Tower bolt 150mm for bottom 1 1
3. Aldrop 300mm long with 16mm 1 1
sliding bolt
4. Door handleswith continuous plate 1 2
150x38x12mm rod

5. Butt hinge (125 x 63x4mm) with 4 8

cadmium plated MS screws
6. Door stopper 1 2
7. Rubber buffer 1 2
8. Pull bolt lock 1 -
Note: Mortice lock and hydraulic door closer to be used in door.
02.8.0 GLAZING
02.8.1 All ventilators and windows on external face of all the buildings covered in the
scope will be provided with plain glass of minimum 4mm thickness conforming to
IS:5437.
02.8..2 Ground glass / frosted glass of minimum 4mm thickness will be used for all
windows / ventilators in toilets.
02.8.3 Structural glazing will be provided with toughend glass of approved colour.
02.8.3 Toughend glass shall be used in partition and glazing
02.9.0 WATER SUPPLY AND SANITATION

02.9.1 Polyethyiene water storage tank conforming to IS 12701 will be used The tank
will be complete with all fittings including float valve, stop cock etc.
02.9.2 Galvanised iron pipe of medium class conforming to IS 1239 will be used for
internal piping works for potable water supply. For concealed pipes the pipes will
be of heavy class
02.9.3 The toilet block will have the following minimum facilities calculated based on
minimum 25 persons as per stipulations of National Building Code The facilities
will be suitably increased based on the stipulation of NBC for every increase of 25
users Unless specified all the fittings will be of chromium plated brass. The toilet
blocks will be provided with adequate capacity exhaust.
i) All the facilities such as WC, Urinals, wash basins etc. will be of
apaproved colour
ii) WC (Indian type) Orissa pattern (580 x 440mm) as per IS:L2556 (Part-3)
with all fittings including flushing arrangement of appropriate capacity
and type.
iii) WC western type 390mm high as per IS:2556 (Part-2) with toilet paper
roll holder and all fittings includings flushing system of appropriate
capacity and type.
iv) Urinal with all fittings, marble partition and flushing system as per
IS:2556 (Part-6, Sec.1)
v) Wash basin with all fittings as per IS:2556.
vi) Wall to wall bathroom mirror (5.5mm thick float glass) with bevalled
edges including all fittings.
vii) Stainless steel towel rail (600 x 20mm)
viii) Stainless steel liquid soap holder cum dispenser
ix) Installation of water cooler of adequate capacity
x) All C.P. Brass Fittings will be of Mark/Jaquar Make.
02.9.4 All plumbing, sanitary fittings, connections and service lines will be provided as
per requirement All service lines, water supply, plumbing lines and other utility
lines will be concealed with in the brick /concrete work and removable wooden
panels will be provided at intervals for access.

02.9.5 Sewerage system will be provided with adequate ventilation for the pipe work as
well as manhole.

NMDC LIMITED

FOR
INFORMATION TECHNOLOGY
(GS – 12)
MECON LIMITED
RANCHI - 834002

SL. NO. DESCRIPTION PAGE NO.
01 INTRODUCTION 2
02 GENERAL 2
03 SPECIFICATION OF EQUIPMENT AND SOFTWARE 2
Hardware 2-7
Network Configuration 7-8
System Software 8
Application software-General 9-10
Communication cable 10
Cable Laying 11-12
Power Supply system 12
Earthing System 12
Furniture 12
Spares & Consumbles 13
Minor civil works 13
Tools & tackles 13
04 TRAINING 13
05 OBLIGATION OF TENDERER 13-14
06 WORK PLAN METHODOLOGY 14
07 ACCEPTANCE TEST PROCEDURE
Computer hardware and network 14-15
System software and application software
08 DEFECT LIABLITY 15
09 DOCUMENTAION
Documentation (type of media and no of copies) 15-17
Documentation List
10 INFORMATION /DATA/DRAWINGS TO BE FURNISHED BY 17
THE TENDERER ALONG WITH THE TENDER
11 ABBREVIATION 18
Chapter 12 Information Technology Page 1 of 18

01 LEVEL– II AUTOMATION
01.1 Introduction
State-of-the-art Level-II process control automation system shall be provided for the major
shops/units of the proposed steel plant of NMDC at Jagdalpur (Purchaser). The Level-II
automation system shall have provision for interface with the Level-III system (which may be
Manufacturing Execution System (MES) or Enterprise Resource Planning (ERP) or PPC).
The applications shall be modular, multi layered and real-time systems with facilities for
secured remote web based access.
01.2 General
01.2.1 The tenderer shall be responsible for the analysis, design, manufacture, supply, co-ordination,
installation, and interface, integrate with other automation systems, testing, training and
knowledge transfer, documentation, commissioning, warranty and post warranty maintenance
of all component systems, in order to provide a fully functional Automation System.
01.2.2 The tenderer shall provide complete and State-of-the-art Level-II automation system for the
plant. The new system shall incorporate the latest open system technology with TCP/IP
network.
01.2.3 The tenderer shall satisfy themselves thoroughly regarding hardware, networking and software
specified in the tender document and take full responsibility for suitability there of for output,
reliable working as well as ease of operation and maintenance including replacement with
minimum down time.
01.2.4 All software shall be delivered in English language only.
01.2.5 Only licensed copies of operating system, system software, utility software, language
compilers, database, development tool, application software including process model and/or
any other software (like antivirus, firewall, web server as necessary etc.) for development and
maintenance of application software along with requisite number of user licenses shall be
provided for each server. All the supplied software and system utilities must be globally latest
in version (compatible with application software and process models being supplied) and
should be supplied along with media, license and documentation as supplied by the original
supplier.
01.2.6 Requisite number of licenses of operating system, utility software, front-end development tool
and application software shall be provided for each client PC’s.
01.3 Specification of Hardware and Software

The general specification for Hardware and software are given below. However, specification
of hardware to be supplied by successful Tenderer shall be latest depending upon market
availability at the time of ordering.
01.3.1 Hardware
01.3.1.01 Server
Servers shall conform to the following minimum specification. However, the tenderer shall be
responsible for server sizing considering the capacity and scalability requirements.
• Intel Open Server Grade Chipset

• Windows 2008 Standard Edition.(64 bit OS) or latest at the time of delivery

• Cache-2X4 MB L2
• 8 GB expandable upto 32GB, DDR2 FBDIMM @667MHz with ECC RAM. The main
memory and hard disk shall have at least 50% of reserve capacity at full load. Additional
main memory and hard disk shall be provided to meet the above criteria if required.
However minimum main memory and hard disk shall be provided as specified in the
technical specification.
• Hot swappable 4 X 146 GB Minimum 15000 rpm hot swappable SAS HDD with RAID
Controller. RAID controller shall support RAID configurations of 0,1 & 5.
• In built 10/100/1000 MBPS Ethernet LAN Port with I/OAT– 2nos
• External Hard Drive for Backup (Min 1.5TB) – 1 No.
• Min 21 inch wide screen TFT Monitor – same make as of OEM
• DVD super multi optical disk drive.
• 2 Front USB, 4 Rear USB, 2 Serial port, 1 PS/2 Mouse Port, 1 PS/2 Key Board Interface,
Console Interface
• Minimum 5 with at least 1 PCI-express slot
• 104 Keys or above (membrane type) – same make as of OEM
• Optical Scroll Mouse with scroll wheel and pad – same make as of server
• Redundant Hot Swappable power supply
• Redundant fan.
• CPU scaleable by 100 %. Enough Main Memory (RAM) with free slots to scale it up by
100 % by adding memory
• 10/100/1000 MBPS Network adapter teaming (minimum two numbers)
• Antivirus Software with minimum 3 years up gradation license.
• No proprietary cards shall be fitted on its motherboard
• Processor shall be minimum from following configuration
Intel 64 bit Quad Core Xeon 5000 Series, Minimum 2.6 GHz, FBS 1333 MHz
Four way Itanium II 64 bit processor (minimum 1.6 Ghz with 4 MB L3 cache and 533
MHz FSB)
• Two fibre channel host bus adapter for connecting to SAN (if SAN is used)
01.3.1.02 Storage Area Network (SAN)

Storage Area Network (SAN) system where ever required shall be as follows:
• Dual fiber channel RAID controller
• 146 GB x 6 (15000 rpm) fiber channel SCSI Hard disk drive (Hot Swap disk)
• RAID 0 +1 and RAID-5 controller
• Minimum 8 port storage area network switch
• Required software as applicable for storage area network such as SAN management
software, data replication, volume and file management software.
• Redundant RAID controllers
• Redundant Hot pluggable power supply
• Redundant Hot pluggable Fan
• Facility for taking backup
01.3.1.03 External Hard Disk Storage Array

• 146 GB x 8 (15000 rpm) SCSI Hard disk drive (Hot Swap disk)
• RAID 0 +1 and RAID-5 controller
• Redundant power supply

• Redundant Fan
• Preferably Rack mounted
• Facility for taking backup
01.3.1.04 Client PCs :
Sl. No. Specification

CPU Intel core 2 duo with 3 GHz (min) cycle time , FSB 1333 MHz or latest
RAM 4 GB, DDR2 @ 800MHz
Cache 6 MB L2 Cache
NIC Integrated 10/100/1000 Mbps Ethernet LAN port – 2 nos.
Hard Disk 250 GB SATA hard disk – 7200 rpm
Optical drive DVD super multi optical disk drive.
Monitor Minimum 22" wide screen TFT Monitor with inbuilt speaker- make same as PC
Key board 104 keys and above multimedia keyboard, make same as OEM
Mouse Optical Scrolled Mouse with Scrolled wheel and Pad.
Ports 2 front & 2 rear USB ports, 1 Parallel port, 1 PS/2 Port, Keyboard interface,
monitor interface
OS Windows Vista Business/ Windows XP Professional (with service pack 2 or
more) or latest with media CD
Model Tower - Preferably black in colour.
Antivirus Software with minimum 3 years up gradation license(free version not
acceptable)
01.3.1.05 Laptop:
The laptop shall conform to the following minimum specifications:

• Core 2 Duo with 2.0 GHz (min) cycle time, 2MB L2 cache or latest
• 4096 MB main memory – DDR2 RAM 677 Mhz FSB
• 250 GB hard disk
• Internal DVD dual layer writer
• Connectivity :- LAN - 10/100/1000 MBPS Ethernet Card / Bluetooth /WiFi
• Multimedia keyboard
• USB Optical scroll mouse
• Integrated modem
• No. of USB, Fire wire ports :- 4,1
• Onboard video memory :- 256 MB
• Graphics accelerator card
• Screen Size :- 15”
• Rechargeable battery with minimum two hours backup and battery charger
• Windows XP professional/Windows Vista Business with latest service pack (or latest
Windows operating system) with media CD
• Antivirus Software with minimum 3 years up gradation license.
• Carry bag
01.3.1.06 A3 coloured laser printers:

• A3 and A4 Coloured Duplex printing (printing on both sides of paper)

• 16 ppm, heavy duty
• 1200 x 1200 dpi
• Network printing capabilities with hardware (network interface card)
• Interface: Centronics and USB
01.3.1.07 A3 Black and white laser printers:
• A3 and A4 Duplex printing (printing on both sides of paper)

• 21 ppm, heavy duty
• 1200 x 1200 dpi
• Network printing capabilities with hardware (network interface card)
01.3.1.08 A4 black and white laser printers:
• 14 ppm heavy duty

• 1200 x 1200 dpi
• A4 black and white Duplex printing (printing on both sides of paper)
01.3.1.09 Managed Layer 3 Switch (minimum Specification):

General
• 1000 Base Lx interfaces(Min 6 nos. However, exact number will be decided during
detailed engineering)
• 48 numbers of 10/100/1000 Mbps Tx Ports
• Rack mountable
Redundancy
• Redundant Switch Fabric(In case only one switch supplied)
• Redundant Power Supply(internal)
• Redundant fan
Features & requirements:
• Modular and Scalable with full expansion capability managed L3 Switch
• Switching Fabric: min. 130 Gbps.
• 32-Gbps, high-speed stacking(for stackable switch)
• Forwarding rate of 90 Mpps for 64-byte packets
Protocols/Standards support:
• Ethernet (IEEE 802.3)
• Fast Ethernet (IEEE802.3u)
• Gigabit Ethernet-(IEEE 803z, 802.3ab)
• 802.1 p/q - VLAN Tagging
• 802.3x - Flow Control
• Layer 3 or 4 switching and routing
• Port Mirroring
• L2, L3 access control filters.
• Rapid Spanning Tree Protocol (RSTP)(802.1w)/ equivalent

• Multiple Spanning Tree Protocol (MSTP)

• 802.1s - Per-VLAN Group Spanning Tree Protocol
• Port Aggregation Protocol (PAgP) )/ equivalent
• Link Aggregation Control Protocol (LACP)/ equivalent
• Unidirectional Link Detection Protocol (UDLD) and Aggressive UDLD./ equivalent
Network Management features:
• Web based
• Telnet and TFTP access
• RMON
• SNMP agent
Architecture Features:
• Layer 2 switching
• Layer 3 switching
• IP Version 6 (IPv6) support in hardware.
• No. of MAC address : >= 2000
Quality of Service (QoS)
• 802.1 p prioritization with minimum 4 priority queues
• Provision for IP telephony & VOIP support
• Differentiated services as defined in RFC 2474
Expandability
• Minimum 1 slot/ 2 stacks shall be available for future expansion
01.3.1.10 Managed Layer 2 switches(minimum specification) :

General
• Modular and Scalable with full expansion capability managed L2 Switch
• Configurable up to 8000 MAC addresses
• Switching Fabric >= 24 Gbps.
• Forwarding rate >= 17 Mpps
Redundancy
• Redundant Power Supply
Protocols/Standards support:
• Ethernet IEEE 802.3
• Fast Ethernet
• Gigabit Ethernet-(IEEE 803z, 802.3ab)
• 802.1 p/q - VLAN Tagging
• 802.3x - Flow Control
• Port Mirroring
• L2, access control filters.
• Rapid Spanning Tree Protocol (RSTP)(802.1w)/ equivalent
• Multiple Spanning Tree Protocol (MSTP)(802.1s) )/ equivalent
• 802.1x - IBNS-Identity Based Networking Services
• Port Aggregation Protocol (PAgP) )/ equivalent
• Link Aggregation Control Protocol (LACP) )/ equivalent
• Up to 32 VLANs per switch
Network Management features:
• Web based

• Telnet and TFTP access

• RMON
• SNMP agent
Architecture Features:
• Layer 2 switching (managed)
Quality of Service (QoS)
• 802.1 p prioritization with minimum 4 priority queues
• Differentiated services as defined in RFC 2474
The number of fibre modules shall be decided during engineering stage. However, minimum one
spare fibre module per switch shall be provided.
01.3.1.11 Requisite number of Hand Held Terminal shall be planned in place where there is limitation
of placing a client PC for fetching data.
01.3.1.12 Location & size of server room, locations of PCs/printer and other peripherals shall be
decided at engineering stage.
01.3.2 Network Configuration
1) The TCP/IP (with full quality of service -QoS features) gigabit Ethernet network shall be
essential for the implementation of the process control system and interfacing with Level-I
Automation system and Level-III system. Necessary connectivity (fibre/Cupper) of supplier’s
managed layer 3 switch with plant wide gigabit network shall be under Tenderer’s scope. However,
Plant wide network have been considered under separate package. Redundant communication link
shall be provided between Level-II and Level-I system. Necessary hardware, software and
network equipments shall be provided for the same.
2) Methodology for assigning the actual IP address for equipments shall be finalized during the
detail design stage with approval from purchaser.
3) Plant wide Networking switches with necessary fiber module will be available in the server room
of respective new shops (upcoming) to facilitate communication with other shops and the Level-
III system. None of the switches of the plant wide network shall be used for connecting the
servers/clients of the Level-II automation system. The necessary connectivity of LAN of different
new shops with switch of proposed plant wide network shall be established by tenderer.
4) The network shall be designed to support multi-vendor communication based on international

standards organization’s open system interconnection standard (OSI). It shall be easily
expandable to keep pace with growing application requirements.
5) The LAN shall be based on 1Gbps (TCP/IP gigabit Ethernet) network with single mode fiber
optic cable and Cat 6 UTP (unshielded twisted pair)/ STP (shielded twisted pair) cable as the
medium of communication and cable shall be connected in structured cabling. Cat 6 cable may be
used inside the control rooms for short distances (limited to 90 meters) wherever required. Where
as, for the clients located outside the plant/ building premises (more than 90 meters) FO cable
shall be used to provide the connectivity.

6) The actual cable length of fiber optics cable and Cat 6 UTP/STP cable shall be as required and
will be estimated at the engineering stage.
7) There shall be enough provision for additional clients in future. PCs and the network equipment
shall be powered from 5/15 ampere UPS socket outlets with proper Earthing. The information
outlets shall be connected to the network switch. Switches shall be connected point-to-point
making a ring of redundancy. Network cable shall trace separate/ alternate routes for making ring
of redundancy. 100% redundant Fiber module shall be provided in each switch. Number of
switches shall be decided during engineering stage.
8) Servers shall be connected using 1000 Mbps network interface card port of server and 1000 TX
port of switch in a structured fashion using information outlet. The FO cable shall be of minimum
6 core single mode with heavy duty PVC sheathing and shall be laid in cable tray/trenches /pipe
away from High Tension lines running between the various designated buildings / control rooms.
9) Indoor cabling between switch and PCs shall be of Cat 6 UTP/STP cable in PVC pipes in a
structured fashion from information outlet to patch panel and from patch panel to switch in wall
mounted racks. For shop floor over head laying of Cat 6 UTP/STP cable medium duty GI conduit
shall be used.
All equipments shall support TCP/IP with full QoS features. Necessary Internet connectivity will be
provided through plant wide gigabit network to achieve the secured web based access.
01.3.3 System Software
01.3.3.1 Operating system for server

Process control servers shall have operating system with real time features. All process control
servers shall have UNIX or Windows Server – 2008 (or latest).
01.3.3.2 Utility Software:

• Language compilers like C/C++ for servers/clients for development of application software
(wherever required).
• Oracle10g (or latest version) - Relational data base management system for data base
server, process control server and standby server
• Oracle 10g with RAC (real time clustering features) (where ever required)
• Web server software (where ever required)
• Front end development tools for GUI
• Any special software /development tool necessary for development of supplied application
software including models, graphics for server/clients.
• Any special software /development tool necessary for development of web based
applications used in the supplied software.

01.3.4 Application Software - General
01.3.4.1 The tenderer shall fulfill all requirements of the application software as per technical
specification and process & production requirements.
01.3.4.2 The general features of the application software are given below:-
• Variable names and all comments used in the application software shall be in English
language only.
• The latest software shall provide easy to use user interface with multi windowing support.
Operator shall be able to carry out all the required operations through the Level-II GUI for
getting maximum benefit form Level-II system.
• Application software shall have menu driven form/display. A system administration menu
has to be provided. Details will be provided during engineering stage.
• Uniform software design and programming standard shall be used for all automation system.
• Ease of software maintenance, so that parameters can be changed with out changing the
source code. No hard coding shall be allowed.
• Application software shall have built-in features of model tuning to take care of local
conditions at site. It shall allow further model tuning with on line production data after
successful commissioning.
• Error logging system shall be provided in the application software
01.3.4.3 The application system running on clients shall be developed under a common software
platform, with multi-windowing capability and shall have following features:
• Easy to use user interface
• Display of real time process value
• Process and equipment control parameters
• Menu driven forms
• Display screen for equipment /plant status at multiple places
• Data entry/change of control parameters
• Generation of reports
• Display of alarms
• The software architecture shall support application programs to run from a central server.
Except for the process Control Operator GUI of Process control servers, preferably, no
application programs shall reside in client PC. The application shall be initiated from a
web browser (wherever required)
• Continuous logging of all alarms, process data, set points, equipment failure etc. as
necessary. Alarms can be printed on demand.
01.3.4.4 Data Logging and Recording into History File (Logs and History)
The system shall perform data logging of process and set values. These logs shall be kept in
database for 2 months. Other data such as production data, delay backup shall be kept in database
for minimum 13 months & for historical purposes. It shall be possible to retrieve the data as and
when required. Actual duration of log shall be decided during engineering.
01.3.4.5 Trending / Debugging

• Current & Historical graphical trends of set points, process values and reporting

01.3.4.6 Communication with Level-III system

Requisite data regarding production results, alarm logs, quality logs, delay logs, material usage
information, maintenance details, any other necessary events & logs shall be transmitted to Level-
III system. The details shall be worked out at requirement specification/ engineering stage. In order
to prevent the loss of data in case of a link failure, Level-II automation system shall be capable of
storing these logs for at least fifteen (15) days and shall retransmit the same to Level-III system
after communication link resumes. Necessary interface to receive production plan and any other
information from Level-III system shall be provided.
01.3.4.7 Production and Quality reporting system

• Recording of periodical production plan
• Recording of production
• Generation of MIS reports
• Generation of quality and production deviation report
• Generation of Test and Inspection reports
01.3.4.8 Alarm logging, Display and Print out

The computer shall monitor alarm conditions for the parameters monitored, display it on a PC, log
it and generate printouts on demand.
01.3.4.9 Clock Synchronization

Tenderer shall designate a time server which shall synchronize with all systems of the unit /
package. Necessary hardware and software shall be provided for clock synchronization of all
computers, network equipments and Level-I system. There shall not be any data loss or application
error during clock synchronization. The tenderer shall specify the clock synchronization interval.
01.3.4.10 House Keeping

Software shall be provided to perform housekeeping services such as archiving, taking backups /
restoration of data from backup/archives etc. Procedures shall be properly documented and
demonstrated.
Complete backup (including setup data, tuning data, etc.) shall be provided after the acceptance of
hardware and software and tenderer shall restore the backup and run the server with restored copy.
Separate menu-based facility for backup/restore for system software, application s/w and data. On-
line backup/restore facility without disturbing the running system should be possible.
Automatic deletion of temporary files (generated by application software) shall be provided.
01.3.5 Communication Cable:

Communication cable for connecting server, PCs, printers (local as well as remote),
PLC/DCS/ICS, any other instrumentation system and connecting to the plant wide network shall
be provided by the supplier.
Specification of Fibre Optic Cable (Single Mode Fiber optic for Outdoor)
• Single Mode fiber 9µm/125µm
• Attenuation@1310nm <= 0.35dB/km
@1550nm <= 0.25dB/km
Cat 6 UTP/STP cable : as required

01.3.6 Cable laying - as required for

• Communication cables
• Power Cables in the computer premises for individual equipment
01.3.6.1 Computer network cable laying method:
UTP/STP cable laying & termination:

1) For indoor surface cable laying, medium duty PVC channel/pipe (ISI) of adequate size shall
be used.
2) For shop floor overhead cable laying, medium duty GI conduits shall be used. The conduits
shall be laid along the structural columns, girders, trusses etc. and shall be clamped properly
at every meter of the pipe run.
3) The cables shall be dressed and terminated in accordance with the recommendations made in
the relevant TIA/EIA standard document, manufacturer’s recommendation and/or best
practices.
4) Cable shall be neatly bundled and dressed to their respective panels or blocks. Each panel or
block shall be fed by an individual bundle separated and dressed back to the point of cable
entrance into the rack.
5) Each cable shall be clearly labeled on the cable jacket behind the patch panel at a location
that can be viewed clearly without removing the bundle support ties. Cables shall be properly
marked and distinctively coloured for ease of identification.
6) An axial spacing of 150 mm (minimum) shall be maintained between power and network
cable.
7) Cables shall not be attached to ceiling grid or lighting support wires.
8) Holes in walls, ceiling etc. shall be made and plugged to their original finish after drawing the
cable.
9) Adequate heat insulation shall be provided for cables passing through hot zone.
01.3.6.2 Fibre optic cable laying & termination

1) GI pipes shall be used for exposed FO cable laying in plant shops.
2) GI pipes shall be firmly supported in position by means of heavy gauges saddles either
screwed in concrete/brick walls using suitable plugs or screwed to MS brackets/cleats welded
on to building structures. The spacing between the supports for both horizontal and vertical
runs shall not be more than one meter for straight runs. At bends or termination to
junction/pull boxes, the nearest support shall be within 300 mm from such fittings.
3) Exposed pipes shall run parallel or perpendicular to column/building lines to match the
existing architectural arrangement.
4) The fibre stack shall be neatly coiled within the fibre termination panel. No slack loops shall
be allowed external to the fibre panels.
5) Each cable shall be individually attached to the respective termination panel by mechanical
means.
6) All network cabling shall be structured, tested and certified.
7) Each fibre cable shall be stripped upon entering the termination panel and individual fibre
routed in the termination panel.
8) Each cable shall be clearly labeled at the entrance to the termination point. Cables labeled
within the bundled shall not be acceptable. Cables shall be properly marked and distinctively
coloured for ease of identification. GI pipes housing the FO cables shall be heat insulated in
areas subjected to heat.

9) Dust caps shall be provided on the connectors and couplings.

10) GI pipe shall be used for routing cables embedded through concrete foundation/floors/walls
generally in plant buildings. GI pipes shall be medium gauge, hot dip galvanized electric
resistance welded, screw type conforming to IS: 1239(part-I) latest revision. All pipe fittings
shall conform to IS: 1239(lPart-II) latest revision.
11) Underground cable shall be laid generally about 1.0 meter below the finished ground level
and shall be provided with at least 75 mm sand cushioning both at top and bottom with brick
top cover and sand filling for mechanical protection. Where power and network cables run
side by side, the axial spacing shall not be less than 300 mm. Identification flags/ cable
marker for underground cable laying shall be provided. Inspection pit at appropriate distances
shall be provided for under ground cables.
12) The excavation of trenches shall be done straight as far as possible. Width of the trench shall
be in accordance with the number of cables to be laid but in any case shall not be less than
300 mm.
13) After cable laying , the trenches shall be back filled in layers with each layer being well
rammed, consolidated and sufficient allowance made for settlement. In case of road crossing,
the damage to the road done shall be made good to its original finish. For crossing of road,
railway tracks etc the cable shall be laid in GI pipe.
14) In each cable run, some extra length shall be kept at suitable points to enable one or two
straight through joints in future. When a number of cables are laid together, the extra cable
length shall be adjusted to stagger the straight through joints.
15) Adequate heat insulation shall be provided for cables passing through hot zone.
01.3.7 Power Supply System

Tenderer shall supply power distribution boards, switches, emergency switches, and power cabling
for supplying power to computer equipment. The power supply system shall comprise of
following:
• Dedicated UPS(Minimum -30 minutes backup) for Level-II system
• Power Cables, Power distribution Board – as required.
• Circuit Breakers etc. - as required
• Local UPS (Minimum -30 minutes backup )- if required, etc.
01.3.8 Earthing system

Earthing of the computer system (server and PCs) and associated peripherals at the server room,
control rooms, different locations (to be finalized at engineering stage) including civil work
(Earthing pit) shall be provided as per relevant IS.
01.3.9 Furniture
Suitable furniture for the computer equipment’s shall be supplied. The furniture of reputed make
shall include tables, racks and chairs (at least one table & chair for every server & client) etc. for
equipment and operators, storage cupboard, book shelves, shoe racks, maintenance workbench,
etc. in sufficient numbers. Necessary storage cupboard shall be provided in server rooms for
storing manuals etc.
Aesthetically designed console tables shall be provided for servers in server rooms, in place of
tables. Servers and switches shall be housed in suitable enclosures.

1.3.10 Spares & Consumables
1.3.10.1 Commissioning spares

All commissioning spares along with list shall be provided as per requirement.
1.3.10.2 Operating Spares –Deleted.
1.3.10.3 Consumables
The Tenderer shall provide all consumables as required for installation, successful commissioning
and demonstration of plant Performance Guarantee parameters at their own cost. The consumables
list along with quantity shall be provided.
1.3.11 Minor Civil Works

Minor civil works such as chipping/ cutting of floors for making grooves, making holes/ opening
through walls, ceiling or floors, drilling of holes through steel structures and frames, grouting of
frames, hooks on walls/ceiling etc. required for execution of work. After erection, surface shall be
made good by plastering/painting to their original shape and finish.
1.3.12 Tools and Tackles

• Test equipments, tools, etc. for all relevant hardware and/or software systems.
• Test and maintenance equipment shall be provided for maintenance and troubleshooting of FO
cables.
01.4 Training
The following training shall be imparted for Level-II automation system:
Sl.No. Item
1 Operating System, utility software, debuggers, web server
2 Oracle Database
3 Development tool
4 Communication Software
All the Training to be conducted by OEM or its authorized training partner at a fully equipped
training center with facilities where extensive hands-on exercises can be performed with system
similar to one under supply. Curriculum, duration and number of participants for each program
shall be finalized in consultation with purchaser at a later stage.
01.5 OBLIGATION OF TENDERER

01.5.1 Preparation and submission of all relevant drawings and documents for information/ approval.
01.5.2 Software maintenance and updates as required for successful operation of the systems.
01.5.3 Successful tenderer shall supply the latest hardware/software at the time of ordering with due
approval of purchaser/consultant.
01.5.4 All tools and testing equipment required for installation and commissioning of the complete
system shall be supplied.
01.5.5 Test certificates and details of test procedures shall be furnished.
01.5.6 Software implementation methodology:
The following methodology shall be adopted for the implementation of the application software
at basic and detail engineering stage:

01.5.6.1Submit documents and information at both basic and detail engineering stage.
01.5.6.2 Prepare requirement specification and submit to the purchaser for approval.
01.5.6.3 Discussions with the purchaser and/or his designated consultant.
01.5.6.4 Incorporate comments, prepare revised requirement specification and submit for approval.
01.5.6.5 Obtain approval of revised requirement specification.
01.5.6.6 Prepare System design document, Submit system design for information only
01.5.6.7 Program coding, testing and installation.
01.5.6.8 Hot test including model tuning.
01.5.7 All drawings, designs, configurations, software, models etc. listed in TS and GTS are indicative
and minimum only. Tenderer may suggest a better and more comprehensive solution.
01.6 WORK PLAN AND METHODOLOGY
The tenderer shall furnish the work plan methodology from the start of award of the contract to
the completion of the contract, for approval by purchaser/designated representative.
01.7 ACCEPTANCE TEST PROCEDURE
All tests on software, hardware, network, communication, etc. shall be carried on the basis of a
pre-agreed protocol clearly listing out steps/procedures involved in testing with its responsibility
and minimum expected results as per specifications, engineering and other documents. All the
components of the Level-II automation system like network, hardware, software, application and
mathematical Model shall run together. Provisions shall be made for off-line testing of Level-II
systems prior to actual deployment.
01.7.1 Computer hardware and Network

1) The acceptance test shall be carried out by the tenderer in the presence of the purchaser /
representative of purchaser. The complete hardware shall be visually inspected to ensure the
completeness of the scope of supply along with agreed specifications including erection and its
fitness for operation. In order to qualify for acceptance, each of the computer system and all
individual equipments including network equipments shall operate up to 24 hours a day for seven
(7) consecutive days at an over all average up-time efficiency of 98.5%.
2) Besides the above acceptance clause for individual equipments, the integrated operation of the
full system with entire network shall be demonstrated up to 24 hours a day for seven (7)
consecutive days at an overall average uptime efficiency of 98.5%. The network shall be tested
for attenuation and signal loss.
3) Up-time efficiency is defined as productive and error free use of equipment.
Any unutilized time during the test shall also qualify as uptime provided there are no hardware
and software malfunctions.
Uptime efficiency shall be computed as under:
(Uptime x 100) / (Total available time)
4) The tenderer's personnel shall successfully demonstrate network operations as per mutually
agreed procedure in the presence of authorized representative(s) of the Purchaser during the
testing period to ensure that the network operations confirm to the specified performance.
In case the required uptime efficiency is not obtained as mentioned above, the acceptance will be
repeated for same time period.
5) A total period of 30 days shall be allowed for completion of acceptance test for hardware and
network after start of acceptance test.

01.7.2 System Software and Application software

Hot test shall be carried out for fifteen (15) continuous working days of error free operation. In
case of detection of bug / errors, the test shall be restarted from zero date (beginning) after fixing
of the bug. In case any change in application software is required to meet the process and
production requirements, the tenderer shall do the same without any extra cost. Being turnkey
supplier, the tenderer shall ensure that all requirements for the tests are met before the start of
acceptance test.
i) Hot test shall be carried out after one month of stable operation of the plant and shall be
scheduled with PAC/FAC of plant.
ii) During the hot test period, the application software /Level-II automation system shall be
tested with all live data including communication with Level-I (from PLC/DCS/ICS/any
other special controller). All the modules shall be tested and demonstrated for error-free
performance as per the specification and approved documents. The functions as specified in
the contract and the approved requirement book shall be demonstrated.
iii) Error free functioning of operating system/ system software/ database/ utility software/
communication software/ any other special software supplied by the tenderer shall also be
demonstrated for consecutive period of 15 day (24 hours a day) during the hot test period.
iv) Model shall be tuned as per the site conditions before the start of hot test. The test should be
completed within one month of the start of the test.
v) Acceptance certificate shall be provided by Purchaser on successful completion of hot test.
01.8 Defect Liability (Warranty)
Tenderer shall provide defect liability services for hardware, system software and application
software in accordance with commercial clause as defined in commercial documents.
Tuning/customization/modification/bug removal of application software shall be carried out as per
plant actual operating practices during defect liability services period.
Post defect liability services shall be provided on mutually agreed terms and conditions (if required)
01.9 Documentation
All documentation shall be in English language.
01.9.1 Documentation (Type of media and no. of copies)

Documentation shall be as follows:
Sl. ITEM No of Hard No of Copies on

No. copies CD-ROM/ DVD-
ROM
1. Operating system, System Software and utilities 1 3
software, database, communication software.
2. Development tool 1 3
3. Hardware manuals As per 3
commercial
clause

Sl. ITEM No of Hard No of Copies on

No. copies CD-ROM/ DVD-
ROM
4. Requirement Specification -do- 3
5. System Design Document -do- 3
6. User Manual of Application software including -do- 3
models
7. Maintenance Manual for troubleshooting of all -do- 3
application software including process model,
system software, configuration, hardware,
network, etc. should be provided clearly
spelling out possible causes, checks and
measures for corrective action.
8. Additional set of all training manuals for -do- 3
purchaser’s archive and not for participants
9. All other additional documents/ manuals as -do- 3
mentioned below under 01.9.2
10. Licenses 1
01.9.2 Documentation (List)
The following list of Documents shall be submitted for approval/information
01.9.2.1 At Basic engineering stage

• Layout drawing showing location of all computer equipment and furniture.
• Single line diagram for power supply to computer system / equipment.
• Network configuration diagram (for equipment and cabling)
• Detailed requirement specification containing:
- List of hardware and system software.
- Detailed description of each module, operator dialogues, displays, reports, etc. Period of
storage for all logs, displays and report shall be indicated.
- Functions and their detailed procedures
- Detailed description of process models their explanation.
• Details of quality assurance measures for Level-II Automation system implementation for
information.
01.9.2.2 At Detail engineering stage :

• System configuration diagram for Level-II (including Network Schematic diagram).
• Final Single line diagram for power supply to computer system / other computer and network
equipments.
• Final computer system equipment installation layout
• Source code shall be provided for all the application software except the know-how of models.
• Model set-up (initialization) data shall be provided by the Tenderer.
• System design document containing:
- Level-II automation philosophy and functional description
- Database structures for application software
- Form /report layout

01.9.2.3 Manuals
The following manuals shall be furnished for information/reference:
• Hardware and Networking
- Installation manual providing step-by-step procedure for installation of the whole system.
- Hardware and networking installation & maintenance manuals for individual equipment as
supplied by OEM.
- Operator's manual providing details of the procedure for operating the equipment including
safety procedures.
- Training manuals in hard copies for maintenance personnel, supported CD ROM's/DVD
ROM’s etc.
- Detailed procedure to recover in case of failure of the CPU, hard disk drives, communication
links between the servers, their clients, etc., shall be furnished.
- Logical screen shots for hardware/software configuration
• System software and application software:
- User/reference manuals for operating system, utilities, language compilers, RDBMS, etc.
- Application software maintenance manual.
- Operator manuals for application software. Detailed procedures for operation in semi-
automatic mode.The manual shall describe all the tasks that an operator needs to undertake
while using the Level-II/III system.
- Model tuning manuals including
Tools & procedures.
Details features of model tuning to suit local conditions
01.9.2.4 As built documentations & drawings.(as per commercial clause)
01.10 Information /data /drawings to be furnished by the tenderer along with the tender
1. List of deviations from the technical specification, if any, with reasons thereof.
2. Reference list of projects where similar system including hardware, system software and
application software has been implemented.
3. Configuration diagram of the Level-II automation system.

ABBREVIATION:
CD-Compact Disc PAC – Preliminary Acceptance certificate

CPU-Central processing unit PAgp- Port Aggregation Protocol
DCS – Distributed control system PC – Personal/Desktop Computer
DDR2 – Double data rate synchronous dynamic PLC – Programming Logic Controller
random access memory interface
DIMM – Dual in-line memory module PPC – Production Planning and control
DVD- Digital Versatile/Video Disc PVC – Poly vinyl chloride
ERP- Enterprise Resource Planning PCI- Personal computer interconnect
EIA- Electronic Industries Alliance QoS – Quality of Service
FAC – Final acceptance certificate RAID - Redundant array of independent disks
FBS- Front Bus Speed RAC – Real time clustering
FO-Fiber Optic RDBMS- Relational Database management system
GB – Giga Byte RFC – RFC -
Gbps – gigabyte per second RMON – Remote Network Monitoring
GI – Galvanised Iron RSTP- Rapid Spanning Tree Protocol
GTS- General technical specification SAN- Storage Area Network
GUI- Graphical User interface SAS-Serial Attached SCSI
HDD – Hard disk drive SATA- Serial Advanced Technology Attachment
IS – Indian Standards SCSI-Small computer system interface
ISI-ISI mark SMF- Single Mode Fiber
ICS-Integrated control system SNMP-Simple network Mail Protocol
LACP – Link Aggregation Control Protocol STP – Sheilded Twisted pair
LAN – Local Area Network TCP/IP – Transport Control Protocol/Internet
Protocol
MAC – Media Access control TFTP – Trivial File Transfer Protocol
MB - Mega byte TIA – Telecommunications Industry Association
MBPS -/Mbps – Mega Bits per second TS – Technical Specification
MES – Manufacturing Execution System UDLD – unidirectional Link Detection Protocol
MIS – Management Information System USB – Universal Serial Bus
MSTP – Multiple Spanning Tree Protocol UTP – Unshielded Twisted pair
OEM – Original Equipment manufacturer VOIP – Voice over IP
OSI – Open systems interconnection

NMDC LIMITED

FOR
PREFERRED MAKES
(GS – 13)
MECON LIMITED
RANCHI - 834002

01 PREAMBLE 2
02 FLUID SYSTEM 3-9
03 VENTILATION, AIR CONDITIONING AND AIR POLLUTION 10-12
CONTROL EQUIPMENT
04 HANDLING & HOISTING EQUIPMENT 12-16
05 REPAIR & MAINTENANCE FACILITIES 16-17
06 ELECTRICAL 17-26
07 INSTRUMENTATION 26-30
08 FIRE PROTECTION SYSTEM 30-31
09 INFORMATION SYSTEM 31-31
10 FLUID SYSTEMS & PIPING ENGG 32-35
11 BY PRODUCT PLANT (BPP) AND EFFLUENT TREATMENT 36-37
PLANT
12 LABORATORY EQUIPMENT 38-38
13 CIVIL & STRUCTURAL 39-41
Chapter 13 Preferred Make Page 1 of 41

01. PREAMBLE
This document “PREFERRED MAKES OF EQUIPMENT AND SUPPLIES” is
a part of the tender specification for various packages of 3.0 Mtpy Steel Plant at
Nagarnar.
The makes of various equipment and supplies in respect of imported/indigenous
equipment/components/materials are listed out in this document. It is essential
that the equipment/component/materials to be supplied from imported/indigenous
sources by the Tenderer will be of any one of the makes listed against that
particular equipment/ component/material in this document. In case of any
contradiction in respect of ‘Preferred Makes’ indicated in this document with the
preferred makes indicated in any other tender document, the one indicated in this
document shall prevail.
In case the Tenderer/ Contractor intends to substitute any particular make of
equipment / components/ materials by a make other than that listed in this
document, the Tenderer shall clearly bring out the same in his tender along with
justification and indicate the alternative makes offered by him. It will be
prerogative of the Purchaser to accept or reject the alternative makes so offered.
Refer clause 01.05.01 of GS-01 also.

02 FLUID SYSTEM
Sl. Item Description Manufacturers

No.
1 Horizontal Centrifugal : Kirloskar Brothers, KSB, Beacon Weir,
Pumps Khimline, Jyoti, Sintech, Mather & Platt,
Flowserve.
2 Vertical Turbine Pumps : Kirloskar Brothers, Mather & Platt, WPIL,
Jyoti, Sintech, Flowserve
3 Vertical Wet Pit Type : SU Motors, Kishore Pumps, Kirloskar
Pumps Brothers, KSB , Sintech, Mather & Platt,
Flowserve.
4 Submersible Pumps : KSB, SU Motors, Kirloskar Brothers, Kishore
Pumps, Darling, Beacon Weir.
5 Slurry Pump : Akay, Sam Engg., MBE, KBL, KSB Pumps,
WARMAN. Sintech
6 Dosing Pump : Shapo Tools, Asia LMI (Madras), Positive
Metering Pumps, Toshniwal, Milton Roy India.
7 Large Industrial RCC : PCTPL, Gammon, BDT, GEA, L&T, Bridge &
Cooling Towers Roof, SPIG Cooling Towers India (P) Ltd.
Mumbai
Natural Draft Cooling Gammon, BDT, GEA, L&T, Bridge & Roof
tower
Package type FRP CT PCTPL, BDT, GEA, Himgiri
8 Pressure Filters : Thermax, Ion-Exchange, Resin India, Driplex,
VA Tech Wabag
9 Sluice Gates : Jash Engineering, IVPL Nasik, Steam &
Mining
10 Traveling Water Screen : Macmet, Triveni, Otokiln, Mecgale (Nagpur),
General Mechanical
11 Sludge Scrapper : Triveni, Neo – Parisrutan, Mata India,
Geomiller
12 Fire Hydrants : New Age Industries, Steelage Industires,
ASCO, Strumech, Vijay Fire, Zenith, Steam &
Mining.
13 Basket Strainers : Filtration Engrs, J.N Marshall, Masturlal
Fabrication, Otokiln, Superflo, ARF Engg,
Purolator Filters, ABB, Filters Mfd. India
14 Duplex Strainers : Filteration Engrs., Otokiln, Superflo
15 Automatic backwash Amiad Filtration, Filteration Engrs., HYDAC


No.
filters (I) Pvt. Ltd., Superflo
16 Rubber Dismantling : BDX, CORI Engineers, D.Wren,
Joints
:
17 Diesel Engine Cummins/Ashok Layland /Ruston/ Kirloskar
18 Softening & DM Plant Resin India / Thermax / Thermax Cullinyan /
:
VA Tech / Ion Exchange / GEA Energy
Systems
19 R O Plants VA Tech, GEA Energy Systems, Ion
:
Exchange, Hindustan Dorr Oliver , Permionics
20 Effluent Treatment Plant VA Tech, GEA Energy Systems, Triveni,
:
Eimco-KCP. Hindustan Dorr Oliver, Aireff
Detox, Ion Exchange
Thickener VA Tech, GEA Energy Systems, Triveni,
Eimco-KCP. Hindustan Dorr Oliver, Aireff
Detox, Ion Exchange
Raw Water treatment VA Tech, GEA Energy Systems, Triveni,
Hindustan Dorr Oliver, Aireff Detox, Ion
Exchange
21 Drinking water Treatment VA Tech, GEA Energy Systems, Ion
:
Plant Exchange, BANCO, Thermax, Triveni, Aireff
Detox, Ion Exchange
22 Electro chlorinator HES Water , CHLOROCONTROL,
PENWALT, MILTON ROY, Ion Exchange
23 Basalt Liners : DEMECH, Vidyut Green Bank, Enviro
Abrasian, Garden Reach Ship Builders &
Engg.
24 Oil Skimmer : JVM Engg (Oil Skimmer Inc).
25 Plate Heat Exchangers : Alfa Laval, GEA Ecoflex, Tranter
26 Surge Tanks : Anup Engg., Zenith Erectors, Haldia., Perfect
Engg., Sakthi Hitech
27 C.I. Valves (gate, globe, : Kirloskar Brothers, Steam & Mining, IVPL
NRV) Nasik, BDK, Fouress, Hawa Engineers,
Ahmedabad.
28 CS Valves (gate, NRV) : Audco, Fouress, BHEL, KSB, Steam &
Mining, BDK, Kirloskar, Virgo
29 Plug Valves : Audco- L&T, Vass Ind., Xomox, Virgo, BDK,
Steam & Mining.
30 Ball Valves : Audco, KSB, AL Saunders, Xomox, Virgo,


No.
BDK, Virgo, Akay Industries,
31 GM Valves : Leader, Steam & Mining, NECO, Upadhyay
Valves, Bombay Metals & Alloys, Kalpana
Valves
:
32 Butterfly Valves L&T, Fouress, Kirloskar Brothers, IVPL
(Manually & electrically Nasik, VIRGO, AL Saunders, Steam &
operated) Mining, Keystone, BDK, XOMOX, Jash
:
33 Diaphragm Valves AL Saunders, Fluid System, BDK , Steam &
Mining.
:
34 Float Valve Leader, IVPL Nasik, IM Engineers, Steam &
Mining.
:
35 Control Valve BHEL, L&T, Fouress, IL, MIL Controls,
NECO Scharbet, Darling
:
36 Solenoid Valve Rotex, Sicmag, Scharder, NECO INDFOS,
Eastern Pneumatic, Bluestar, AVCON, ASCO.
:
37 Air Release Valve IVPL, IM Engineers, Steam & Mining,
Schroder Duncum, Fluid Line Valves.
:
38 Pressure Reducing Valve JNM, Fouress, Bestobell, IL, Mazda, Nirmal
Ind., Forbes Marshal
:
39 Strainer/Filter Otokiln, Superflo, Triveni Plenty, Filter Mfg.
Ind., Purolator, Filteration Engineers
:
40 Electric Actuators Beacon Rotork, Auma, Marsh Engineers,
Keystone, Limitorque, Antrieb, IL, Palghat
:
41 Rotory Pneumatic AL Saunders, Xomox, EL-O-Matic, Virgo,
Actuators L&T, Flocon, Precision Processing Equipt. Co.
:
42 Hoses Aeroflox/Markwel/Senior Flexonics, Inalsa,
Teksons
:
Pipes a) MS/GI SAIL/TATA/Jindal/Zenith/Man/ SAW
/Surindra/ Bansal Skipper
43 MS ERW Black
/Utkarsh/Bhushan/Ajantha Pipes/Venketesh
Udyog
:
b) DI Electro Steel Casting, Jindal Saw, Tata-Kubota
44 RCC Pipes & Fittings : SUR Industrial Pipes, Hind Ceramics, Indian
Hume Pipes, Daya Cuncrching.
45 HDPE Pipes & Fittings : EMCO, KWH Heliplastic , Astral Polyolefins,
Oriplast
46 PVC Pipes & Fittings : Oriplast, Finolex, Bharat Pipe & Fittings,
Supreme Industries.


No.
47 MS Fittings / Forged : Stewards & Lloyds, Heavy Metal Tubes, Nobel
Fittings / SS Fittings Tubes, Rajendra Mech. Ind., Vitrag, Poonam
Enterprises, N.L.Hazra, M.S.Fittings, Veketesh
Udyog, Navkar, Reliable Steel(Reliable Pipes
& Tubes ltd)
48 Seamless, Stainless Steel : Choksy Tubes, MJ Patel, Nagardas Kanji,
Pipes/Tubes Poonam Enterprises, Sandulk Asia, Noble
Tubes, Allied Steel, SAIL Maharastra
Seamless (P) Ltd, Reliable Steel(Reliable Pipes
& Tubes ltd) Mumbai.
49 Fittings for the above : EBY Ind., High-Tech, Hydro technic, Hydro-
Pipes/Tubes Air Engg., Project Toolings, Shivananda,
M.J.Patel, Nobles Tubes, Allied Steel,
Poonam Enterprises, N.L.Hazra, M.S.Fittings,
Reliable Steel (Reliable Pipes & Tubes ltd)
Mumbai
50 Wrapping & Coating for : Rustech Products, HOTACO, IWL, M P Tar
pipes Products
51 Chemical Dosing System Hindustan Dorr Oliver, NALCO, Tellabs
Chemicals, VA Tech, Chembonddrewtreat ltd.,
Vasu Chemicals, Watreat Engineers.
52 Knife Gate Valves : Jash Engineering, Chemtech , Steam & Mining
02.02 Valves For Fuel Gas, Steam, Nitrogen, LPG & Compressed Air Facilities
Item Description Manufacturers
C.I. Valves for Fuel Gas & : Kirloskar Brothers, GM Dalui, Steam & Mining,
Compressed Air (gate, globe, H.Sarker, IVPL, AV Valves, Leader, Associated
NRV) tooling. BDK, Mather & Platt Pumps, Shiv Durga
Iron Works, MCMIRA, Bankim, I. M. Engineers,
Venus Pumps, Crawley & Ray, Metropolitan
industries, Saradamoni, Upadhya Valves, Universal,
Kalpana, R & D Multiples, Durga Engineering,
Jupitar, Expert Engineering, VIP Valves, Dembla
Valves, Prime Industrial Valves, Fluid control
equipment, K.L. Parui & Sons.
CS, FS Valves for Steam, : L&T (Audco Div), Fouress, BHEL, KSB, GM Dalui,
Feed Water, & LPG (Gate, Leader, BDK, NECO, Associated Tooling, Hawa
Globe, NRV) Egr., Vass Ind, Advance Valves, Kalpana Valves,
MCMIRA, Steam & Mining, NSSL Ltd. , Venus
Pumps, Crawley & Ray, Asian Industrial Valve, BDK

Engineering, Econo valves, Metropolitan industries,

Saradamoni, Kirloskar, Upadhya valves, Oswal
Industries, Steel strong valve, Sawan engineers,
Flocwhem, HAWA valves, Expert Engineering, VIP
valves, Dembla, Shalimar valves, Bell-o-seal valves,
G M engineering.
CI, CS, SS & FS Plug Valves : Vass Ind., Xomox, Virgo, BDK, Leader, Steam and
Mining, GM Dalui, H.Sarkar, Audco, Chemtrols ,
Crawley & Ray, Hawa, .Econo valves, Universal,
Fluid control equipment, Durga Engineers
Ball Valves : Audco, Vass Ind, KSB, BDK, Microfinish, Niton,AL
Saunders, Xomox, Virgo, United Engineers, Steam &
Mining, Hi-Tech B.Valves, AKAY, Leader Valves,
Hawa, Tyco valves, Crane process flow, Asian
Industries, H. Sarker, Uniflow, Steel Strong Valves,
Sawan engineers, Universal, Flowchem, Kalpana
valves, Durga, Hawa, Jupitar, VIP valve, Prime
Industrial Valves, Fluid control equipment.
GM Valves : Bombay Metals, GM Dalui, Leader, NECO, Kalpana
Valves
Butterfly Valves : Audco, Fouress, Kirloskar Brothers, IVPL, Inter

Valve, Virgo, AL Saunders, Keystone, BDK, Leader,
AVC Engg., Crawley & Ray, Xomox, Tyco, Hi-Tech,
Intervalve, Steam & Mining, Venus pumps, Hawa
engineers ltd., Crane process flow ltd., Upadhya,
Universal, Kalpana valves, R & D Multiples,Durga,
Hawa valves, Jupitar, VIP valve, Prime Industrial
Valves, Fluid control equipment.
Diaphragm Valves : AL Saunders, Fluid System, Leader, BDK, Xomox,
Steam & Mining, Venus valves, Hawa, CRANE,
Fluidline valves, Kalpana valves, Expert engineers.
Pressure Control : JNM, Fouress, Bestobell, IL, Mazda, Nirmal Ind.,
Valve/Pressure Reducing Vanaz, Kosan Metal, Vass Ind., RK Control, Fluid
Valve Line, Forbes Marshal, Leader, Hawa Valves.
Goggle Valve : Audco, Fouress, Cimmco, L&T
Fabricated Gate Valves : Fouress, Cimmco, L&T, MCMIRA, Universal.
Safety Relief Valve (Pressure : BHEL, Keystone, Bliss Anand, L&T (Audco Div.),
relief Valves) Sempell, Fainger, Leser Valves (P) Ltd., IL,
Anderson, Kosan, Leader, Hawa, Tyco, Asian,

02.03 Valves for Oxygen Services:

Non-Ferrous Valves:
For Isolation : Bestobell (UK), ETH IRELAND (France), RT Orseal
(UK), Truflo (Belgium), Worcestor Controls (UK),
Quick Shut-off Valve : Bestobell (UK), ETH IRELAND (France), RT Orseal

(UK), Truflo (Belgium), Worcestor Controls (UK),
Moorco
Pressure Control Valve : SEVERN (UK), NELES SECK GLOKON (UK), IL
(PCV) &Flow Control Valve (Palghat)
(FCV)
Solenoid Valve : AVCON, SEITZ, ROTEX, ASCO
Safety Relief Valve (SRV) : KUNKLE (USA), KEYSTONE (USA), BROADY
(UK), MOORCO, SEBIM, IL (Palghat),
Pressure Regulators (Self : ESAB, BOC, Speciality Gases, Kamrup Industrial
regulating with pressure Gases, Venaz Engineers, Nirmal Ind.
gauge)for Oxygen
Stainless Steel (SS) : Precision Engg., BDK, Niton, Akay, Leader, Audco,
Sakhi & Co., KSB
(manual) valves
02.04 Miscellaneous Gas Facility Equipment
Oxygen Acetylene & : INOX, Titan Engg., BOC, Asiatic Oxygen

LPG Manifolds
SS Bellows Expansion : Flexican, Flexatherm, SUR Ind., GBM Mfg., TI Flexible
Joints Tube, Madras Hydraulics, Lonestar, Prcision, B.D
Engineers, Anup industries, Indo Thai flexible tubes.
Centrifugal Gas Booster : Andrew Yule, TLT, James Howden (U.K), Donkin (U.K),
Transtechnologies thermal pvt. Ltd.
Gas/Air Compressors : Ingersoll Rand, Atlas Copco, KG Khosla, Kirloskar

Pneumatic, Chicago Pneumatic, Eliat, Cooper, Sulzor,
Corken (USA), SIEMENS
Hoses Flexican, Gaytri Industrial Corpn., Inalsa, Teksons, Sudeep
:
Industries, Markwel, Indo Thai flexible tubes, Hydroflex
pipe pvt. Ltd.
Trap & Strainer for Uniklinger, ESCO, JNM, Dryton Greaves, Forbes
:
Compressed Air & Steam Marshall, Hawa Engrs., Mazda
Actuators

Electrical AUMA India, Beacon Rotork Controls, Limitorque

:
Pneumatic Marsh Engg., Keystone, IL, Massoneilan, EL-O-MATIC,
:
Virgo, AL Saunder, L&T, Flocan
02.05 Pipes & Pipe Fittings
MS ERW BLACK Pipes : Good luck steel, Advance Steel, Surya roshni Ltd, Shyam
upto DN 150 engineering, P.K. Tubes, NEZONE, P.S. Steel, Venktesh
udyog.
MS PIPES OF SIZE : SAIL, BHEL, TISCO, Jindal, Zenith, Saw Pipes,
FROM DN 200 TO DN Welspun, Man Industries, Maharastra Seamless, Indian
1400 (ERW/SW/SAW) Seamless, BST, Advance Steel, Indus Tubes, Mukat,
Lloyds, Surya roshni Ltd., Ratnamani, Shyam, P. K. tubes,
Venktesh udyog.
SS Pipes / fittings : Heavy Metal Tubes, Nobel Tubes, Rajendra Mech. Ind.,
Sterling Supply Agency, Vitrag, Poonam Enterprises,
N.L.Hazra, M.S.Fittings, Jindal Saw ltd., Ratnamani
Metals, Reliable steel
Seamless MS/CS Pipes : Amardeep Steel, Choksy Tubes, MJ Patel, Nagardas
Kanji, Poonam Enterprises, Sandulk Asia, MEC Tubes,
Nagardas & Kusai, Noble Tubes, Allied Steel, Kamlesh
Tube, Menilal & Bro, Uday Tubes, Maharastra Seamless
(P) Ltd, Imperial Steel, Soor Neogi Koumar, Jindal,
Ratnamani, P.k. Tubes, Reliable steel.
MS/CS Pipe Fittings : EBY Ind., High-Tech, Hydro technic, Hydro-Air Engg.,
Project Toolings, Shivananda, M.J.Patel, Nagardas &
Kusai, MEC Tubes, Nobles Tubes, Amardeep Steel,
Allied Steel, Kamlesh Tube, Menilal & Bros, Poonam
Enterprises, N.L.Hazra, M.S.Fittings, Sunrise, Prodorite,
Tube product incorporate, Gujrat Infra pipes, Modern
store, Anil metal, Flash forge, Saradmoni, Sanghvi,
Madras Steel, Upadhya valves, Parmar, Strategic
Engineering, Sawan, Engineering service enterprise, K.L.
parui, Godavari, P.K. tubes, Ferro tubes, Anant extrusion,
R.D forge, Venktesh Udyog, Hari udyog.

03. VENTILATION, AIR CONDITIONING & AIR POLLUTION CONTROL

EQUIPMENT.
Item Preferred Makes

Centrifugal fans for CBDOCTOR, EFE, FLOW LINK, RIECO, FLAKTWOOD, REITZ, ACCEL, DUSTVEN,
Ventilation F. HARLEY, SUBURBAN INDUSTRIAL WORKS, PATEL AIRFLOW, NADI
PASKO ENGG. PVT. LTD., SCINTILLANT PROJECTS, SOIL & ENVIRO
INDUSTRIES, FMI, AEROCON CORP, TLT, LAXMI ENGG.
For AHU Fans: NICOTRA, KRUGER, COMFERÉ
Centrifugal fans for BHEL, TLT, CBDOCTOR, ANDREW YULE, RIECO, BATLIBOI, F.HARLEY,
Dedusting FLAKTWOOD, REITZ, DUSTVEN, ISEL, SUBURBAN INDUSTRIAL WORKS,
PASKO ENGG. PVT. LTD., SCINTILLANT PROJECTS,
INDUSTRIAL FANS (CHENNAI), SOIL & ENVIRO INDUSTRIES, FMI
Tube axial fans / CBDOCTOR, EFE, FLOW LINK, ALMONARD, ACCEL, KHAITAN, AEROVENT,
Propeller ISEL, FLAKTWOOD, MARATHON, LM ENGG, F. HARLEY, SUBURBAN
Fans
INDUSTRIAL WORKS, PATEL AIRFLOW, PASKO ENGG. PVT. LTD.,
SCINTILLANT PROJECTS, TURBOFLOW,
INDVENT FANS, FMI, AEROCON CORP, LAXMI ENGG., AIR TECHNIKO
Man coolers : CBDOCTOR, VENTURA, LM ENGINEERS, KHAITAN, ALMONARD, DUSTVEN,
FLOWLINK, F. HARLEY, PASKO ENGG.
Roof exhausters : CBDOCTOR, EFE, ACCEL, ALMONARD, FLOWLINK, INDFAN, AEROVENT, LM
ENGG., F. HARLEY, PASKO ENGG., INDUSTRIAL FANS, AEROCON
CORPORATION, LAXMI ENGG. WORKS, GANESH ENGG (VADODARA)
Panel filter for air FMI, CADILLAC, CBDOCTOR, FILTECH (INDIA), SPECTRUM FILTRATION,
ANFILCO, AAF
Air washer : CBDOCTOR, EFE, FLOW LINK, F.HARLEY, ALSTOM, DUSTVEN, FMI,
FLAKTWOOD,
ROOTS COOLING SYSTEMS, INDVENT FANS, VOLTAS, BLUE STAR,
ALMONARD, VENTWELL CORPORATION, ABB
Window air VOLTAS, BLUE STAR, CARRIER AIRCON, LG, SAMSUNG, HITACHI,
conditioners : ROOS TEMPKOOL LTD.,
Packaged air VOLTAS, BLUE STAR, KIRLOSKAR, CARRIER, EMERSON
conditioners :
Packaged chillers : VOLTAS, BLUE STAR, KIRLOSKAR, YORK, DUNHAM-BUSH, CARRIER, TRANE,
HITACHI, DAIKIN-MCQUAY
VAM chillers VOLTAS,THERMAX
Air handling units / VOLTAS, BLUE STAR, SUVIDHA, CARRIER, CARYAIRE, ZECO, AIRFLOW,
Fan coil units:


EDGETECH
Cooling towers : PAHARPUR, MIHIR, ADVANCE, GAMMON INDIA, SHRIRAM TOWER TECH.,
BELL, ROOS TEMPKOOL
Refrigerant VOLTAS, SHRIRAM, BLUE STAR, ATLAS COPCO, KIRLOSKAR, HITACHI, YORK,
compressors : DUNHAM BUSH, CARRIER, TRANE, COPELAND, DANFOSS, BITZER
Duct Insulation U.P.TWIGA, LLOYDS, BAKELITE HYLAM, MALANPUR ENTECH, OWENS
CORNING, PARAMOUNT
Pipe Insulation BEARDSELL, LLOYDS, THERMOWELL, PARAMOUNT
Vibration isolators DUNLOP, EMERALD, GERB, GETZNER
Grills / Diffusers / RAVISTAR, DYNACRAFT, COSMOS, AIRFLOW, CARYAIRE, AIRMASTER
Fire Dampers
Pressurized ANERGY, GRUNDFOSS
Expansion Tank
3 / 2 way Control HONEYWELL, JOHNSON CONTROLS, SIEMENS
Valve
Fabricated Duct ZECO, RADIANT, NUTECH, SPIRO
Strip Heater / Pan ALCO HEATING, DAS PASS, RAPID CONTROL
Humidifier
Balancing Valve ADVANCE, CASTLE, FLOWCON
Heat Recovery Unit DRI, FLAKTWOODS, OSTBERG
Actuators SIEMENS, BELIMO, HONEYWELL, JOHNSON CONTROLS
Cyclones & THERMAX, RIECO, ALSTOM, C.DOCTOR, F.HARLEY, EFE, BATLIBOI,
Multiclones: SCINTILLANT, SOIL & ENVIRO INDUSTRIES, CADILLAC, FMI, HAMON
SHRIRAM COTTRELL,
SHRIRAM EPC, APC SYSTEMS & PRODUCTS, F.L.SMIDTH,
Bag filters THERMAX, ALSTOM, RIECO, C.DOCTOR. F.HARLEY, DUSTVEN, BATLIBOI,
(10,000 m3/h to FMI, SCINTILLANT PROJECTS, SOIL & ENVIRO INDUSTRIES, CADILLAC,
80,000 m3/h)
SHRIRAM EPC, HAMON SHRIRAM COTTRELL, APC SYSTEMS & PRODUCTS,
F.L.SMIDTH
Bag filters ALSTOM, RIECO, THERMAX, SIEMENS-VAI, DUSTVEN, BATLIBOI, SMS
(Above 80,000 m³/h) SIEMAG, SHRIRAM EPC, HAMON SHRIRAM COTTRELL, APC SYSTEMS &
PRODUCTS, F.L.SMIDTH
Pulse Solenoid Valve ROTEX, ASCO
Filter Bags BWF, MASTURLAL
Wet scrubbers : ALSTOM, THERMAX, BATLIBOI, RIECO, C.DOCTOR, F.HARLEY, EFE, SOIL &
ENVIRO, SHRIRAM EPC, HAMON SHRIRAM COTTRELL
Venturi scrubbers : BATLIBOI, THERMAX, RIECO, ALSTOM, DUSTVEN,
HAMON SHRIRAM COTTRELL, SOIL & ENVIRO INDUSTRIES, FMI, SHRIRAM


EPC, APC SYSTEM & PRODUCTS
Electrostatic THERMAX, BHEL, VOLTAS, ALSTOM, SIEMENS-VAI, SMS SIEMAG, SHRIRAM
precipitators : EPC, ELEX, HAMON SHRIRAM COTTRELL
Centrifugal Pumps – KSB, BEACON WEIR, VOLTAS, KIRLOSKAR, MATHER & PLATT, SULZER,
End Suction PROCESS PUMPS, CRAWLEY & RAY, JOHNSON, MAXFLOW, VIRAJ
ELECTRICAL, SINTECH PRECISION PRODUCTS, BAREJA PUMPS, GRUNDFOS
PUMPS,
SJ INDUSTRIES.
Centrifugal Pumps – VOLTAS, BEACON WEIR, KSB, KIRLOSKAR, SAM TURBO, CRAWLEY & RAY,
Horizontal Split MAXFLOW, SINTECH PRECISION PRODUCTS, MATHER & PLATT
Casing
Dust Suppression SPRAYING SYSTEMS, F. HARLEY, KAVERI ULTRA POLYMERS, TECPRO
Systems TREMA, PROJECTS & CONTROLS, TPS, CHEMTROLS
04. MATERIAL HANDLING & HOISTING EQUIPMENT / COMPONENTS
Bidders may please note that in case of being successful in turnkey contracts, the
successful Bidder has to adhere to the “List of Preferred makes”. Any claim of
manufacturing equipment/ components by themselves will not be entertained,
until and unless the same is sorted out and agreed in writing by Client/ MECON
during the Tendering stage.
04.01 Equipment
Item Description Manufacturers Remarks

EOT Crane : Armsel, Shivpra, Tubrofurguson, GRIP
(Up to 25 T capacity)
EOT Crane : Anupam, AVON
(Up to 50 T capacity)
EOT Crane : FAFECO, UNIQUE(For M5 Only), WMI,

(Upto 200T Capacity)) HEC, MUKUND, Jessop, AVON, ANUPAM
EOT Cranes (Upto 450T : HEC, Mukand

Capacity)
Underslung Cranes / Jib : Armsel, Shivpra, Turbuferguson, GRIP,
Cranes (Upto 5t only) HiTech, Habenkraft,Century, India Enggg &
Implements
Electric Hoists : Armsel, Shivpra, Brady & Morris, GRIP, Hi-
tech, Century Crane, Elite, Turboferguson,
EddyCranes
Transfer Cars : HEC, Mukand, METCO
Manual Hoists, (Chain : Armsel, Century Cranes, Brady & Morris,


Pulley Blocks) & Hand Hi-tech, Eddy Cranes
Operated Travelling cranes.
Electric Winch : Beekay, Armsel,.
Elevator/Lift : OTIS, OMEGA, Kone, ECE, ThyssenKrupp
Rack & Pinion Elevator : MEKASTAR
Crusher (Impactor, Hammer : Sayaji-McNally Bharat, ELECON.

Mill, Ring Granulator) Pennsylvania USA, METSO
Roll Crusher : L&T, FAM-Techpro, HEC, TRF
Rod Mill / Ball Mill : ELECON, TRF, McNally Bharat, METSO,

FLSmidth
Vibrating Screen : IC, TRF, ELECON, McNally Bharat,
Electromag, Schenck Process
Roller Screen ELECON, Tecpro-FAM, L&T, Krupp, MBE,
TRF
Flip-Flop Screen : Hein Leihman, IC, Tecpro
Vibratory Feeder : Electromag, IC, TRF, Orien Engineers,

(ElectroMagnetic / Mech) ELECON, Tecpro, Magnetic Corp
Apron Feeder : L&T, McNally Bharat, Tecpro, ELECON.
Conveyor Belting : Northland Rubber, Phoenix-Yule, Oriental

Rubber, Fenner, Forech, Nilkant Rubber,
Johnson Rubber
Magnetic Separators (ILMS/ : Electromag, Magnetics Corporation of India,
EMS) Electro magnetic Ind., Electro Zavod.
Lifting Magnets : Electromag Devices, Electromagnetic Ind.,
Kakku
METAL DETECTORS : ELECTROMAG, Magnetic Corporation
High Angle Conveyors : METSO, Flexowel, Macmet
Drag Chain Conveyors : TRF, Equipt Engrs, Stock Redler, Enviro

Abrasion, Karam Chand Thapar, Holtzman
Bucket Elevator : Golden Engineering, Vinar, Cobit, Orien,
Macmet, Bevcon, Holtzman
Reclaimer : METSO, L&T, ELECON, TRF, McNALLY
BHARAT, FLSMIDTH, KRUPP
Stacker : METSO, L&T, ELECON, TRF, McNALLY
Stacker – Cum- Reclaimer : METSO, L&T, ELECON, TRF, McNALLY


Wagon Tippler/ Side Arm : L&T, ELECON, TRF, METSO
Charger
Transfer Cars for Yard : METSO, L&T, ELECON, TRF, McNALLY
Machines BHARAT, FLSMIDTH, KRUPP
Paddle Feeders : ELECON, MBE, TRF, LOUIS, KRUPP
Belt Weigh Feeders & : Kistler – Morse, Sartorius Mechatronics,

Weigh Hopper Transweigh, Avery, Jenson Nicholson, IPA,
NOVA, SUBTLE Weigh electrics, Schenck
Process
Belt Weigh Scale : Kistler-Morse, Transweigh, Avery, Sartorius
Mechatronics, Schenck Process
Conveyor belt pulleys : Elecon, TRF, McNally Bharat, Macmet,
Vinar, KALI, Bengal Tool, Jaya, Masyc
Conveyor Idlers : Elecon, TRF, McNally Bharat, Macmet,
Vinar, KALI, Bengal Tool, Jaya, Masyc,
Hitech, Cobit
Impact Pads : Kaveri, Tega, CONCARE, THEJO
Belt changing Device : Nilos, Shawalmex
Bin Vibrator : Electromag, Electromagnetic Industries, IC
Samplers : Prisector (UK), Ramsay Engg (USA),

Eastman Crusher, Advanced System
Belt Vulcanisers : Shaw Almex, Nilos India, SV Dattar
Front – end – loader : TIL, BEML, HM
Fork-lift-truck : Godrej, Voltas, TIL
Crane Weighing System : IPA, SCHENCK
Crane Radio Remote Control : LOTUS, Sateloy (Finland), Funk electronics

System Piciorgros
04.02 Mechanical Components/ Equipment

Hooks : Herman Mohta, Free Trading Corporation, Steel
Forgings & Engg.
Flexible / Geared : Concord, Wellman, GBM, Alliance, New Allenbery
coupling Works,Elecon, Flender, Fenner, Roma, Hi-Flex


Wire rope : Bharat Wire Rope, Orion Ropes, Usha Martin
Slew Bearnigs : RothErde (Germany), LYC
Bearings for Cranes : SKF, FAG, Tata-Timken, NTN
Bearings for other : SKF, FAG, Tata Timken, Asian Bearings, NRB, MBM,
equipment NTN, Torrington, INA
Oil Seals : Vaco Oil Seals, Rubber Equipment & Engg. Sealjet
India (Pune), Sealpack, Champion Seals, OMCO
Lubricating Systems : Grindwell Norton, Lincoln Helios, BIJUR DELIMON,
SKF Systems, AFMC, Prakash, Hydair, Lubcon
Gear box : New Allenburry, Premium Energy Transmission Ltd,
ELECON, Shanti Gears, Flender, Kirloskar, I.C.-Bauer,
Essen-Pro, SEW
Geared Motor : SEW, DEMAG, LENZE
Hydraulic Systems : Vickers Sperry, Yuken, Rexroth, Hugglands Hannifin-
Parker
Hydraulic Motors : Huggland, Parker-Carlzoni, Rexroth, L&T Poclain,
Hannifin
Hydraulic Coupling : Fluidomat, Ghatge Patil, VOITH, Premium Energy
Transmission Ltd. , ELECON
Hydraulic : Rexroth, Vickers, Wipro, Usha Telehoist, Veljan,
Power/Cylinders Yuken, Oscar.
DCEM Brake : BCH, Industries Syndicate, Storm Kraft, Speed-O-
Control, Electromag
Track type Limit : Electromag, BCH, Speed-O-Control, Jayshree, EP&C,
Switch Bengal Technocrats, PROTO CONTROL
AC Hydraulic : ELDRO, SIME, BUBENZOR, SIBRE, PETHE,

Thruster Brake Industries Syndicate
Pneumatic Actuators : Prepec, Technomech, Nucon Industries, OSCAR
Equipt, Veljan Hydair.
Electro Mechanical : PREPEC, Technomech, PebcoJyothi-Cero, BMH-

Actuators Concare
Rubber liner/ Polymer : TEGA, Kaveri,
(PE / PU etc.)
Cast Basalt liner : DECCAN, Enviro Abrasion
Skirt Board Sealing : TEGA, KAVERI, BMH, CONCARE, FORECH

Arrangement
Belt Scraper/ Belt : Hosch Equipment, Vinar IDC, Kaveri Macmet, Karam
Cleaner Chand Thapper, Cobit Engg
Belt Switches : Jayshree, PROTO CONTROL, EPC
Pneumatic Handling : TTG, Scorpio, FL Smidth
Equipment
Air Blaster : KAVERI, BMH CONCARE, THEJO


Manual Storage : Godrej, VINAR
Equipment (Slotted
Angles)
Pneumatic sample : Kerry Engg, JOST Engg, Kerry Drying & Conveying
Transportation
05. REPAIR & MAINTENANCE FACILITIES (WORK SHOPS/ STORES)
Centre Lathe : HMT

Universal Milling m/c : HMT
Shaper : PAL, P&B, Loyal
Radial Drilling m/c : HMT, Batliboi, Kerry Jost, HEC
Horizontal Boring m/c : HMT, HEC, PAL
Submerged Arc : Advani, ESAB, ADOR, Mogora,
Welding Set COSMIC
Welding Rectifier : Advani, ESAB, ADOR, Mogora,
COSMIC
Welding Transformer : Advani, ESAB, MEMCO
Universal Tool and : HMT, Praga, Batliboi
Cutter Grinding m/c
Hydraulic Press : BEMCO, P&B, Centerprise
Cast Iron Plate : Jash, Madras Gauge, P&B
Power Hacksaw : ITL, P&B, EIFCO
Column Drilling m/c : HMT, Thakoor, Kerry Jost, EIFCO,
Batliboi
Bench Drilling m/c : Accuax, EIFCO, P&B, Thakoor
Double-ended Pedestal : Grind Tools, GECO, AMC, P&B
Grinder
Cylindrical Grinder : HMT, Mysore Kirloskar, ELP
Tools & Tackles : P&B, Mekaster, Centerprise, Ally
Measuring Tools and : P&B, Bombay Tools
Gauges
Garage Equipment : ELGI, USHA, WAP, P&B
Oiling & Greasing : ELGI, P&B

Plasma Cutting : ESAB, ADOR

Machine
Htdraulic Jack : VANCOS, HEMCO
Electric Hand Grinder : BOSCH
NOTE: The above makes and its equivalent are indicative and are subject to approval of technical
data of offered configuration / model of machine.
06 ELECTRICAL
S.N. ITEM DESCRIPTION PREFERRED MAKES
A. HV & POWER DISTRIBUTION EQUIPMENT
1 33 KV, 11KV, 6.6KV OIL FILLED CGL / AREVA/ TRANSFORMERS & RECTIFIERS
DISTRIBUTION TRANSFORMERS LTD/ KEC / INTRA VIDYUT / VOLTAMP / BHARAT
BIJLEE/ ANDREW YULE/ BHEL / ABB/ SIEMENS
2 33 KV, 11KV, 6.6KV DRY TYPE, CGL/ KEC / INTRA VIDYUT/ VOLTAMP / BHEL
DISTRIBUTION TRANSFORMERS
3 DRY TYPE CONVERTER CGL/ VOLTAMP/ / INTRAVIDYUT/ BHEL/ KEC
TRANSFORMER UPTO 3MVA
4 OIL TYPE CONVERTER CGL/ VOLTAMP/ AREVA/ KEC/ ABB
TRANSFORMER
5 33 KV ISOLATOR SIEMENS/ A BOND STRAND/ S&S CHENNAI/ ABB
6 6.6 KV ISOLATOR DREISCHER-PANICKER/ SIEMENS/ A BOND
STRAND/ S&S CHENNAI
7 33KV, 22KV, 11 KV, 6.6 KV VACUUM SIEMENS/ BHEL/ CGL/ SCHNEIDER/ AREVA/ ABB/
CIRCUIT BREAKERS JYOTI (JYOTI – UP TO 11 KV ONLY)/ MEGAWIN (UP
TO 11 KV ONLY)
8 33 KV, 11KV, 6.6KV OIL FILLED CGL/ EMCO/ AREVA/ BHEL/ ABB
FURNACE TRANSFORMERS
9 6.6 KV, 11 KV VACUUM BHEL/ AREVA/ SIEMENS/ ANDREW YULE/ JYOTI/
CONTACTORS CGL/ ABB
10 33 KV, 22 KV, 11 KV, 6.6 KV CURRENT PRAGATI (RESINCAST, INDOOR)/ INSTRANS/
TRANSFORMER (CT) PRAYOG/ INTRAVIDYUT/ INSUTECH INDUSTRIES/
ABB/ JYOTI (RESINCAST, INDOOR)/ KAPPA
(RESINCAST, INDOOR)/ AREVA/ CGL/ BHEL/
MEHRU (INDOOR & OUTDOOR)/ SIEMENS/ WABER
OERSTED/ VOLTAS/ TELK


11 33 KV, 22 KV, 11 KV, 6.6 KV VOLTAGE PRAGATI (RESINCAST, INDOOR)/ INSTRANS/
TRANSFORMER (PT) PRAYOG/ INTRAVIDYUT/ INSUTECH INDUSTRIES/
ABB/ JYOTI (RESINCAST, INDOOR)/ KAPPA
(RESINCAST, INDOOR)/ AREVA/ CGL/ BHEL/
MEHRU (INDOOR & OUTDOOR)/ SIEMENS/ WABER
OERSTED/ VOLTAS/ TELK
12 33 KV, 11KV AND 6.6 KV ABB/ UNISTAR (UNIVERSAL CABLES)/ BHEL/
CAPACITORS MEHER (BANGALORE)
13 33 KV,11 KV AND 6.6 KV SURGE OBLUM/ ELPRO/ WS-INSULATORS/ TOSHIBA/
SUPPRESSORS SIEMENS
14 33 KV, 22 KV, 11 KV, 6.6KV CABLE RAYCHEM/ 3M/ M-SEAL (M-SEAL FOR 6.6 KV)
JOINTING KITS (HEAT SHRINKABLE
TYPE)
15 CABLE TERMINATION KIT RAYCHEM/ 3M/ MECP/ DENSON
16 BATTERY CHARGERS CHHABI ELECTRICALS/ STANDARD/ HI-RECT/
SHERENE ELECTRO CONTROL/ AMARA RAJA/
HBL NIFE/ CALDYNE/ NELCO/ UNIVERSAL/ AE
17 STATION BATTERY
NI-CD BATTERY AMCO/ HBL – NIFE
LEAD –ACID BATTERY EXIDE/ HBL-NIFE/ AMAR RAJA/ AMCO
BATTERY PLANTE EXIDE/ HBL-NIFE/ AMAR RAJA/ AMCO
18 ELECTRONIC ENERGY METERS SEMS/ L&T/ SATEC/ CONZERVE/ DUKATI/ ABB/
(TRIVECTOR / KWH) SIEMENS/ AREVA/ SCHNEIDER
19 PROTECTION RELAYS (NUMERIC ABB/ SIEMENS/ L&T/ AREVA/ SCHNEIDER/ EASUN
RELAYS) REROYLLE
20 PROTECTION RELAYS/ AUXILIARY AREVA (VAJC)/ ABB/ SIEMENS/ AREVA/ EASUN
RELAYS (E/M) REROYLLE
21 RECORDERS (CHARTLESS TYPE) CHINO/ YOKOGAWA INDIA LTD/ OKHURA/ FUJI/
EUROTHERM (CHESSEL)/ TATA HONEYWELL/
HIOKI/ FLUKE/ ABB/ PYROTECH (UDAIPUR)
22 ANNUNCIATORS MINILEC/ SPA/ PROCON/ YASHMUN/ PYROTECH
(UDAIPUR)
23 INDICATING METERS IMP/ AE/ MECO/ L&T/ MOTWANI/ CONZERVE/
RISHAB INSTRUMENTS/ SECURE METERS/ ABB/
SIEMENS/ EMERSON/ RAIL/ TOSHNIWAL INDIA/
ENERCON/ AREVA/ KAPPA
24 HT HRC FUSES S&S/ GE POWER CONTROL/ BUSMANN/ SIEMENS/
ABB/ DRESCHER PANICKER/ AREVA/ CGL
25 HV BUS DUCT ECC (KOLKATA)/ STAR DRIVE (CHENNAI)/ ENPRO
(CHENNAI)/ BEST & CROMPTON/ SIEMENS/ BHEL/
CONTROL & SWITCHGEAR


26 DG SET
ALTERNATOR WITH AMF PANEL KIRLOSKAR ELECTRIC / JYOTI / AWK / JAKSON
ENGINE KIRLOSKAR / CUMMINS/ CATTERPILLAR
B. LV EQUIPMENT
1 LT AIR CIRCUIT BREAKERS L&T/ SIEMENS/ SCHNEIDER/ ABB/ GE POWER

CONTROL/
2 MOULDED CASE CIRCUIT BREAKER SCHNEIDER (MG)/ L&T/ ABB/ SIEMENS/ GE POWER
(MCCB) CONTROL / BCH
3 MOTOR PROTECTION CIRCUIT SCHNEIDER/ L&T/ ABB/ SIEMENS/ GE POWER
BREAKERS. (MPCB) CONTROL
4 MINIATURE CIRCUIT BREAKER. SIEMENS/ L&T/ GE POWER CONTROL/ SCHNEIDER
(MCB) (PROTEC / MG)/ STANDARD/ INDOASIAN/
HAVELLS/ MDS (LEGRAND)/ ABB
5 EARTH LEAKAGE CIRCUIT BREAKER GE POWER CONTROL/ STANDARD/ HAVELLS/
/ RCCB ABB/ SIEMENS/ SCHNEIDER/ MDS
(LEGRAND)/L&T/INDOASIAN
6 HRC FUSE FOR LT APPLICATION GE POWERCONTROL/ L&T/ SIEMENS/ INDO ASIAN/
HAVELLS/ STANDARD/ BUSSMAN/ CONTROL &
SWITCH GEAR/ ABB/ AREVA
7 POWER CONTACTOR / AUX. ABB/ SIEMENS/ SCHNEIDER (TELEMECANIQUE)/
CONTACTORS L&T/ GE POWER CONTROL/ CONTROL &
SWITCHGEAR/ BCH
8 VACUUM CONTACTOR SIEMENS/ L&T/ ABB/ SCHNEIDER
9 ELECTRONIC OVER LOAD RELAYS SIEMENS/ L&T/ BCH/ SCHNEIDER-SAMWHA/ LG
10 THERMAL (BIMETALLIC) OVER BCH/ L&T/ SEIMENS/
LOAD RELAYS SCHNEIDER(TELEMECANIQUE)/ ROCKWELL
AUTOMATION/ ABB/ CONTROL & SWITCHGEAR/
GE POWER CONTROL
11 MASTER CONTROLLER (STEP EPCC/ INDUSTRIAL SYNDICATE/ STROM KRAFT/
CONTROL TYPE) SCHNEIDER (SQUARE D)/ SCHNEIDER
(TELEMECANIQUE)/ ELECTROMAG/ SPEED O
CONTROL
12 RESISTANCE BOXES (FECHRAL EPCC/ ELECTROMAG/ BCH
EDGE WOUND)
13 ELECTROMAGNETIC DC BRAKE EPCC/ BCH / INDUSTRIAL SYNDICATE
ASSEMBLY
14 LT BUS-DUCT STARDRIVE/ ECC/ GEPOWER / CONTROL &
SWITCHGEAR/ UNITED ELECTRIC/ UNILEC
ENGINEERS

C. POWER CONTROL / ELECTRONICS & AUTOMATION ITEMS
1 PLC ABB (800 XA)/ SIEMENS (S7-400H)/ GE-FANUC(PAC

RX /3i)/ ROCKWELL AUTOMATION (Control logix)/
SCHNEIDER (QUANTUM)
2 SOFT STARTERS ABB/ ROCKWELL AUTOMATION/ BHEL/ SIEMENS/
INNOVATIVE TECHNOMICS/ SCHNEIDER (Only for
LT motor)
3 VVVF DRIVES
1. FOR LT MOTORS ABB/ BHEL/ SIEMENS/ NELCO (HITACHI)/ VACON/
SCHNEIDER/ L&T (YASKAWA)/ ROCKWELL
AUTOMATION/ TMEIC/ AMTECH/EUROTHERM
2. FOR HT MOTORS MV DRIVE/ HI- ABB/ ROCKWELL AUTOMATION/ BHEL/ SIEMENS/
LO-HI DRIVE CONVERTEAM (UK)/ TMEIC.
4 ROLLING MILL MAIN DRIVE VFD SIEMENS/ABB/CONVERTEAM/ALSTOM/TMEICGE/H
ITACHI/ROCKWELL
5 UPS EMERSON/DB-ELECTRONICS/ NUMERIC/ GE/
LIFELINE/ FUJI/ HI-REL
6 DIGITAL TYPE MULTI-FUNCTION CONSERVE/ L&T/ SECURE/ RISHABH/ SIEMENS/
METER ABB
D. PANELS & PANEL COMPONENTS (LOW VOLTAGE)
1 POWER CONTROL CENTRES SIEMENS / L&T / SCHNEIDER / GE POWER

2 INTELLIGENT MCC (Drawout / Non- SIEMENS / L&T / SCHNEIDER ELECTRIC /
drawout with intelligent controller of
approved make) ABB * / GE POWER CONTROL*
/ CONVENTIONAL DRAW-OUT MCC (* Only with approved Intelligent controllers as listed

below in case of Intelligent MCC)
3 INTELLIGENT CONTROLLER FOR SIEMENS / SCHNEIDER/ L&T/ ROCKWELL

INTELLIGENT MCC AUTOMATION
4 CONVENTIONAL NON DRAW OUT VENUS/ ANDREW YULE/ BCH/ SCHNEIDER
TYPE MCC / POWER DISTRIBUTION ELECTRIC/ HAVELLS/ STANDARD/ TRICOLITE/
BOARDS (PDB) / ROLL TABLE ADVANCE POWER CONTROL/ HINDUSTAN
DISTRIBUTION BOARDS CONTROL/ CONTROL & SWITCHGEAR/ L & T/
SIEMENS/ GE POWER CONTROL/ ABB/ SWITCHING
CIRCUITS/ KMG A TO Z SYSTEMS/ SEN & SINGH
ENGINEERS/ MEDITRON


5 MAIN LIGHTING DISTRIBUTION
VENUS/ ANDREW YULE/ BCH/ SCHNEIDER
BOARD (MLDB)/ SUB LIGHTING ELECTRIC/ HAVELLS/ STANDARD/ TRICOLITE/
DISTRIBUTION BOARDS (SLDB)/
ADVANCE POWER CONTROL/ HINDUSTAN
LOCAL CONTROL STATIONS CONTROL/ CONTROL & SWITCHGEAR/ L & T/
SIEMENS/ GE POWER CONTROL/ ABB/ NGEF/
SWITCHING CIRCUITS/ KMG A TO Z SYSTEMS/
SEN & SINGH ENGINEERS/ TECHNO-COMMERCE/
POWER & PROTECTION/ ADLAC SYSTEM/ ECC/
MEDITRON/ CONTROL DEVICES/ TECHNOCRAT
ENTERPRISES/ MDS
6 MIMIC PANELS & ANNUNCIATION L&T/ ADVANI OERLIKON/ GE POWER CONTROL/
PANELS BHEL/ BCH/ TRANSRECT/ MINLEC/ TIRUPATI
ELECTRONICS/ ADVANCE POWER CONTOL/
CONTROL DEVICES
7 CURRENT TRANSFORMER ( LV ) ABB/ JAYSHREE/ PRAGATI/ KAPPA/
INTRAVIDHYUT/ INDCOIL/ PRECISE
8 INDICATING LAMPS BINAY/ SIEMENS/ L&T/ ESSEN/ BCH/
VAISHNO/TECNIC/OSRAM/ TELEMECANIQUE/
AREVA/ ESBEE
9 PUSH BUTTONS SALZER/ BCH/ L&T/ SCHNEIDER/ SIEMENS/ GE
POWER/ VAISHNO/ CONTROL DEVICES/ ESSEN/
TECNIC/ CONTROL & SWITCHGEAR
10 TERMINAL BLOCKS EPCC/ ELMEX/ PHOENIX CONTACT/ CONNECT
WELL/ ESSEN DEINKI/ WAGO/ LAPP/ S&S/ HANSEL
11 SELECTOR SWITCHES & CONTROL ABB/ GE POWER CONTROL/ BCH/ EPCC/ KAYCEE/
SWITCHES SIEMENS/ TEKNIK/ L&T/ CONTROL &
SWITCHGEAR/ AREVA/ VAISHNO/ JYOTI/ SALZER
12 CRANE CONTROL PANEL (ABOVE 50 SIEMENS / ABB / SCHEIDER / L&T
T CRANES)
E. MOTORS
1 LT AC CRANE DUTY MOTORS MARATHON/ KEC/ CGL/ SIEMENS/ ABB

2 LT AC ROLL TABLE MOTORS KEC/ CGL/ ALSTOM/ ABB/ SEW/ IC-BAUER/ NORD/
SIEMENS
3 LT AC GEARED MOTORS LAXMI HYDRAULICS PVT LTD/ SEW/ NORD/ IC-
BAUER/ POWER BUILD/ DEMAG/ ROSI/ KEB,
GERMANY
4 LT FLAME PROOF / INCREASED MARATHON/ BHARAT BIJLEE/ CGL/ KEC/ LAXMI
SAFETY SQUIRREL CAGE MOTOR HYDRAULICS PVT LTD.


5 LT SQUIRREL CAGE MOTORS ABB/ BHARAT BIJLEE/ CGL/ KEC/ LAXMI
HYDRAULICS PVT LTD./ MARATHON/ SIEMENS/
ELGI/ JYOTI/ WEG
6 ROLLING MILL MAIN DRIVE AC SIEMENS/ ABB/ TOSHIBA/ ALSTOM/ HITACHI/
MOTORS WEG, BRAZIL
7 HT AC MOTORS (SQUIRREL CAGE/ MARATHON/ CGL/ KEC/ ABB/ BHEL/ JYOTI/
SLIPRING & SYNCHRONOUS SIEMENS/ WEG/ TMEIC
MOTORS)
8 ACTUATOR MOTORS AUMA/ ROTORK/ LIMITORQUE/ MARSH
F. FIELD SWITCHES / SENSORS
1 PROXIMITY SWITCHES (INDUCTIVE/ IFM/ SIEMENS/ SICK/ ROCKWELL AUTOMATION/

CAPACITIVE AND MAGNETO) PEPPERL + FUCHS/ SCHNEIDER/ DELTA/ LINE &
LEINDE
2 ENCODER IFM/ HUBNER/ HEIDENHAINE/ LEONARD/
ROCKWELL AUTOMATION (ALLEN BRADLEY) /
SICK (GERMANY)/ LEIN & LEINDE
3 ZERO SPEED SWITCH JAYSHREE/ SCHNEIDER-SAMWHA/ IFM/
ROCKWELL AUTOMATION/ SIEMENS/
PEPPERL+FUCHS/ PYROTECH/ PROTO-CONTROL
4 SENSORS / SWITCHES IFM/ SICK/ ROCKWELL AUTOMATION/ PEPPERL +
* LIGHT BARRIERS FUCHS/ SIEMENS/ SCHNIEDER/ DIMETIX AG/
* DISTANCE DELTA
* LEVEL
5 SWITCH MODE POWER SUPPLY SIEMENS/ IFM/ ROCKWELL AUTOMATION/
SCHNEIDER/ HONEYWELL.
6 PULL CORD SWITCHES/ BELT SWAY JAYSHREE / EPCC(KAKKU) / AG-MECHANIC/
SWITCHES TELEMECHANIQUE / STROMKRAFT / PROTO-
CONTROL/ PYROTECH
7 LIMIT SWITCHES SIEMENS/ ESSEN/ GE-POWER/ SCHNEIDER/ BCH/
JAYSHREE / EPCC(KAKKU) / AG-MECHANIC/
INDUSTRIAL SYNDICATE/ L&T/ ELECTROMAG/
PROTOCONTROL
8 ROTARY LIMIT SWITCHES EPCC(KAKKU)/AG-MECHANIC/ TELEMECHANIQUE
9 TIMERS & TIME DELAY RELAY ABB/ BCH/ L&T/ GEPOWER/ SIEMENS/ ESSEN/
ELECTRONIC AUTOMATION/ TELEMECANIQUE/
OMRON

G. TELECOM EQUIPMENTS & FDA SYSTEM
1 INTELLIGENT DETECTORS SIMPLEX / NOTIFIER / EDWARDS/ SIEMENS

( PHOTO ELECTRIC, HEAT,
THERMAL) UL /FM /ULC APPROVED
2 INTELLIGENT FIRE ALARM -DO-
CONTROL PANELS
UL /FM /ULC APPROVED
3 ADDRESSABLE MANUAL CALL -DO-
POINTS INCLUDING HAND SETS .
4 MONITOR MODULES , FAULT -DO-
ISOLATION MODULES, CONTROL
MODULES
(UL /FM /ULC APPROVED)
5 UV FLAME DETECTORS PATOL / DETRONICS / SPECTREX
UL /FM /LPC APPROVED
6 BEAM DETECTORS EDWARDS / NOTIFIER / SIMPLEX
7 IR FLAME DETECTORS ODTI / PATOL / DET-TRONIX / SPECTREX
SOLAR BLIND EMBER, FIRE
8 ANALOG LINEAR HEAT SENSING KIDDE / L.G.M / PATOL.
CABLE WITH METAL BRAID STEEL/
BRONZE, COPPER WITH NYLON
BRAID
9 DIGITAL LINEAR HEAT SENSING KIDDE / L.G.M / PATOL
CABLE WITH NYLON BRAID WITH
METAL BRAID STEEL, BRONZE,
COPPER UL /FM /ULC /MIL /LPC
APPROVED CONTROL UNIT FOR
DIGITAL LHS CABLE UL /FM /ULC
/MIL /LPC APPROVED
10 VIDEO DISPLAY UNIT INCLUDING DELL / HP / HCL / WIPRO / IBM
CPU, PC, MONITOR, PRINTER ETC
FOR FDA.
11 SIGNAL CABLE FOR FDA USHA BELTRON / HCL / DELTON / VINDHYA
TELELINK


12 AGNICE FIRE PROTECTION LIMITED / TECHNICO
F.D.A SYSTEM SUPPLIERS (INDIA) PVT. LIMITED. /
FIRE PRO SYSTEMS LTD. / TYCO / SIEMENS
13 IP-PBX AVAYA / ALCATEL / AASTRA
14 IP-PBX SYSTEM SUPPLIER AGCL / WIPRO / ABS / ITI / HCL

15 CCTV CAMERA BOSCH / PELCO /SANYO /SHARP /SONY /SAMSUNG
16 CCTV MONITOR SHARP / HITACHI / PHILIPS / LG / SONY /
SAMSUNG / SANYO
17 NELCO LIMITED / POWER SYSTEMS LTD,
C.C.T.V SYSTEM SUPPLIERS KOLKATA /TOSHNIWAL INDUSTRIES / PANORAMA
ELECTRONICS PVT LTD
18 LOUD SPEAKER TALK BACK(LSTB) / BOSCH / PHI-AUDIOCOM / MEGA.
LOUD SPEAKER
INTERCOMMUNICATION(LSIS)
19 LOUD SPEAKER TALK BACK(LSTB) / PHI-AUDIOCOM / POWER SYSTEMS, KOLKATA /
LOUD SPEAKER MEGA
INTERCOMMUNICATION(LSIS)
SYSTEMS SUPPLIERS
20 TELEPHONE CABLE SUPPLIERS DELTON CABLES / TELE-LINK NICCO / FINOLEX.
21 VHF SYSTEM MOTOROLA / YAESU / VERTEX –STANDARD
22 CCTV CABLES POLYCAB/FINOLEX/THERMOCABLE/SUYUG
H. HT, LT POWER & CONTROL CABLES
1 LT POWER CABLES (PVC / XLPE) UNIVERSAL/ RPG CABLES (ASIAN)/ POLYCAB/

FINOLEX/ TORRENT/ HAVELLS/ KEI/ SPECIAL
CABLES/ TCL / SPECIAL CABLES/ RALLISON/
PARAMOUNT/ CORDS/ LAPP/ CHANDRESH / RAVIN
2 PVC CONTROL CABLES LAPP/ UNIVERSAL/ RPG CABLES (ASIAN)/
POLYCAB/ FINOLEX/ TOSHNIWAL/ DELTON/ KEI/
SPECIAL CABLES/ TCL SPECIAL CABLES/
RALLISON/ PARAMOUNT/ CORDS/ HAVELLS/
RAVIN
3 HEAT RESISTANT CABLES (EPR / CSP LAPP/ UNIVERSAL/ RPG CABLES (ASIAN)/
& SR) FINOLEX/ TOSHNIWAL/ DELTON/ TORRENT/
SPECIAL CABLES
4 HT XLPE CABLES UNIVERSAL/RPG CABLES (ASIAN)/TORRENT/
POLYCAB/ PARAMOUNT ( UPTO 33 Kv)/ KEI
5 SCREENED CONTROL CABLES REFER INSTRUMENT LIST
6 TRAILING CABLES LAPP/ UNIVERSAL/ ASIAN


7 LIGHTING WIRE (PVC) FRLS DELTON/ FINOLEX/ UNIVERSAL/ HAVELLS/
INCAB/ KEI/ GEMSCAB/ PARAMOUNT/ POLYCAB
9 OPTICAL FIBRE CABLE MOLEX / LUCENT / FINOLEX / ERICSON / STERLITE
/ HFCL / OPTEL
10 CABLE GLANDS LAPP/ HANSEL/ PHOENIX/ COMET/ PRECISSION-
QUALITY/ SUNIL & CO./ ELECTROMAC
I. ILLUMINATION & MISCELLANEOUS ITEMS
1 TEMP. SCANNER ADVANI OERLIKON/ ECI/ INSTRUMENTATION

LTD./ MASIBUS/ PYROTECH/ SIEMENS
2 LAMPS BAJAJ/ CROMPTON/ GE LIGHTING/ PHILIPS/
OSRAM/ SIGMA
3 LIGHT FITTING (FIXTURES) BAJAJ/ CROMPTON/ GE LIGHTING/ PHILIPS/
COMPLETE WITH ALL ACCESSORIES SIGMA/ HAVELLS
EXCEPT LAMP
4 FLAME PROOF LIGHT FITTING GOVAN/ BALIGA/ FLEXPRO/ SUDHIR/ CEAG/ FGG/
SIGMA/ EX-PROTECTA VITHAL UDHYOG
5 LIFTING MAGNETS OHIO/ WALKER/ EPMS
6 LIGHTING TRANSFORMER BHEL/ BHARAT BIJLEE/ AREVA/ CGL/ EMCO/
VOLTAMP/ KIRLOSKAR ELECTRIC COMPANY/SAI
ELECT/UNIVERSAL
7 LIGHTING MAST PHILIPS / BAJAJ / CGL/CROMPTON/GE
8 WELDING SOCKETS BCH/ SCHNEIDER/ BEST & CROMPTON/ GEPOWER/
HAVELL/ JAIBALAJI/ HENSEL/ MDSLEGRAND
9 LAPTOP/NOTE-BOOK/ PC HP/LENOVO/COMPAC/ DELL
WIPRO/ IBM
10 CONTROL TRANSFORMERS AEI/ AEP/ VOLTAMP/INTRAVIDYUT/INDCOIL/
KAPPA/ INDUSHREE/ SIEMENS
11 5/15A PIANO SWITCH ANCHOR/ ELLORA/ MDS LEGRAND/ CONA/
PRECISION/ CRAB TREE
12 SWITCH SOCKET OUTLET ALSTOM/ ANCHOR/ BCH/ CGL/ ESSEN/ BEST &
CROMPTON/ AREVA
13 EXHAUST FANS/CEILING FANS CGL/ CINNI/ KHAITAN/ POWERVENT/ VENTWELL/
BAJAJ/ USHA/ ORIENT/ HAVELLS
14 HOOTER/BUZZER/BELL KHERAJ / EPCC(KAKKU)
15 POWER PACK FOR MAGNETS ELECTROMAG/BCH/EPCC(KAKKU)
16 RESISTORS (CRANES) BCH/ ELECTROMAG/ AMP CONTROL/ EPCC/
SIEMENS/ RESITECH


17 LT CAPACITORS GE POWER/ ABB/ CGL/ MEHER CAPACITORS/ UNI
STAR
NOTE
1. For those equipments whose makes are not indicated above, prior approval of
Purchaser / Consultant shall be obtained.
07 INSTRUMENTATION
Sl. ITEM DESCRIPTION PREFERRED MAKES

No
A. Field Instruments:
1. Pressure / Differential Pressure : WIKA, Ashcroft (Precision Industries), Forbes Marshall,
gauge Gauges Bourdon (GIC), A.N. Instruments, Waaree
instruments, Tiwac (Walchandnagar), Hirlekar (DP gauge)
Manometer India, H.Guru
2. Pressure / Differential Pressure : Ifm, WIKA, Switzer, Indfoss, Gauges Bourdon (GIC),
switches. Waaree instruments, Ashcroft (Precision Industries), Orion
(Kasturba)
3. Pressure / Differential Pressure : Emerson, Fuji (Chemtrols), Honeywell, Yokogawa, ABB,
Transmitters Siemens
4. Temperature gauges : WIKA, Ashcroft (Precision Industries), A.N. Instruments,
General Instruments, Waaree instruments, Tiwac
(Walchandnagar), Manometer India, H.Guru
5. Thermocouple & RTD / thermowell : General Instruments, Toshniwal Industries, Tempsens, Pyro-
electric Instruments, Industrial Instrumentation, Waree.
6. Temperature Switch : Ifm, Ashcroft (Precision Industries), WIKA, Manometer
India, General Instruments, Indfoss, Switzer
7. Temperature transmitter : Emerson, Yokogawa, ABB, Honeywell, Fuji (Chemtrols),
Siemens
8. Rotameters : Krohne-Marshall, Instrumentation engineers, Trac,
Chemtrols, Rota Instruments, Eureka instruments
9. Orifice Plate & flanges Assembly/ : Engineering Specialities, Hydro-pneumatics, Micro-
Venturi, Flow nozzle precision, Instrumentation ltd, Chemtrols-Samil, General
Instruments, Unicontrols.
10. DP type Flow / Level Transmitters : Emerson (Rosemount), Fuji (Chemtrols), Honeywell,
Yokogawa, ABB, Siemens
11. Flow Switch : Ifm, Krohne-Marshall, Magnetrol, D.K. Instruments,
Switzer, Levcon
12. Electromagnetic flow meter : Yokogawa, Emerson, ABB, Siemens, Endress & Hauser,


No
Krohne-Marshall
13. Vortex Flow meter : Emerson, Yokogawa, Krohne –Marshall, Honeywell,
Endress & Hauser, ABB
14. Mass (coriolis) flow meter Emerson, Yokogawa, Krohne –Marshall, Honeywell,
Endress & Hauser, ABB
15. PD/Turbine Flow meters Daniel (Emerson), Bopp & Reuther, Smith, Liquid Controls,
Barton
16. Level gauge (magnetic & reflex Chemtrol, Levcon Instruments, Pratolina Instruments,
type) Forbes Marshall, Magnetrol, Waaree Instruments, Techtrol,
Sigma, Asian Industrial Valves & Instruments.
17. Level Switch (Conductivity type) : Endress & Hauser, Vega (WIKA), Switzer Instruments, SB
Electro-mechanical, Techtrol, Level-Tech, Nivo Controls
18. Level Switch (Capacitance/RF type) : Endress & Hauser, WIKA (Vega), K-TEK, SB Electro-
mechanical, Switzer Instruments, Techtrol, Nivo Controls
19. Level Switch (Tuning fork/ Rod : Vega (WIKA), Endress & Hauser, S.B. Electro-mechanical,
type) K-TEK
20. Level Switch (Float type) : D K Instruments, Trac, Chemtrols, Levcon Instruments,
Forbes Marshall, Emerson, Techtrol,
21. Level Switch/ Transmitter (Displacer : Emerson, Eckard (Chemtrols), Trac, D K Instruments,
type) Levcon Instruments,
22. Level Switch/ Transmitter : Vega (WIKA), Endress & Hauser, Siemens
(Ultrasonic type) (Miltronics),Krohne Marshall, Magnetrol
1. Level Switch/ Transmitter (Radar : Vega (WIKA), Endress & Hauser , Emerson (Rosemount),
type) Siemens, Krohne- Marshall
2. Level Switch/ Transmitter : Dr. Berthold (Concord International), Emerson (Kay Ray),
(Nucleonic type) E+H, ECIL. , OHMART-Vega
3. Level switch (Electro- mech type) : Endress & Hauser, S.B. Electro-mechanicals, Nivo Controls,
D.K.Instruments, TRAC
4. Control valve : Fisher-Xomox, Instrumentation Ltd, Masoneilan (Dresser
(Globe/Ball) Industries), Flowserve (Valtek), Samson Controls, Arca
(Forbes Marshall), MIL Controls, Dembla, Introl (RK
Controls), Metso
5. Control valve Fisher-Xomox, Instrumentation Ltd, Flowserve (Valtek),
(Butterfly) Masoneilan (Dresser Industries), Dembla, Fouress, Tyco
valves (Keystone- Butterfly), Metso
6. Electrical Actuator : Limitorque, Rotork, Bernard (Instrumentation Ltd),
Honeywell, Marsh, Auma, Keystone, Metso
7. Pneumatic Actuator : Fisher-Xomox, Instrumentation Ltd., Masoneilan (Dresser
Industries), MIL Controls, Flowserve (Valtek), Samson
Controls, ABB, Arca (Forbes Marshall), Keystone, Virgo,
Habonim Vaas, SMC Pneumatics, Metso
8. Electro-hydraulic actuator : Reineke, Askania
9. Self- regulating pressure control : Fisher-Xomox. Forbes Marshall, Samson Controls,
valve Flowserve (Valtek) Instrumentation Ltd., Nirmal Industries
10. I/P converters : Fisher –Xomox, Shreyas-Barton, Masoneilan (Dresser
Industries), Moore (Forbes Marshall), Marsh-Bellofram,


No
ABB, MIL controls, Watson Smith.
11. Pneumatic Positioner, : Fisher-Xomox, Masoneilan (Dresser Industries), Arca
(Forbes Marshall), Flowserve (Valtek), Instrumentation Ltd.,
Samson Controls, ABB, MIL Controls, Fouress
12. Electro- pneumatic positioner Fisher-Xomox, Instrumentation Ltd., Masoneilan (Dresser
Industries), Siemens, Samson Controls, Arca (Forbes
Marshall), ABB, MIL Controls, Fouress, Metso
13. Solenoid Valve : Herion, Burkert, Schrader-Schovill, Jucomatic, Rotex, Asco
14. Air filter regulator : Shavo-Norgren, Marsh-Bellofram, Placka, Schrader-
Schovill
15. Compression fittings & valves Swagelock, Parker, Excel-Hydro-pneumatics, Hylok
16. SS Tubes Choksi Tubes, Sandvik, Mahalakhsmi
B. Control room Instrumentation
1. Distributed Control System (DCS) : Yokogawa (CS 3000), Honeywell (Experion +C 300),
Emerson (Delta V), ABB (AC 800 XA), Siemens (PCS 7+
S7400H), Toshiba-V series (Masibus)
2. Programmable Logic Controllers. : Refer Electrical list
3. Digital Indicator : Pyrotech Electronics, Lectrotek, Chino, Micro systems,
Master Electronics, Masibus Instruments, Ranutrol,
Honeywell, PEPL
4. Bargraph Indicator : Chino, Masibus Instruments, Pyrotech Electronics,
Lectrotek, Teletherm, Ranutrol, PEPL, Microsystems
5. Recorders (Chart Less) : Eurotherm, Yokogawa, Chino, Honeywell, Siemens, ABB.
6. Microprocessor based controller : Yokogawa, Siemens, Honeywell, Eurotherm, Fuji, ABB,
Toshiba
7. Digital scanners : Lectrotek, Micro systems, Master Electronics, Masibus
Instruments, MB controls, Procon, PEPL
8. DC Power Supply Unit : Aplab, Phoenix, Elnova, Siemens, Schneider, Pepperl &
Fuchs, MTL, Cosel
9. IS Interface/Zenner Barrier Pepperl & Fuchs, MTL, Stahl,
10. Signal isolators : Pepperl & Fuchs, MTL, Stahl, Yokogawa, Protech (Forbes
Marshall), Phoenix
11. Annunciation system : IIC, Procon, Micro Systems & Controls, Minilec,
Instrumentation Ltd, Lectrotek, Piri systems, Pyrotech
Electronics, MB controls & Systems, Semuda.
12. Instrument Panels/ Control Desk : Rittal, Pyrotech, Radha Krishna Controls, Instrumentation
Ltd., Hoffmann
13. Instrumentation Cable Delton, Universal Cables, Thermopads, KEI industries,
(Screened, paired, triad etc.) Paramount Cables, Lapp cables, Cords cables, MEM,
Uniflex cables, Brooks Cables, Elkay Telelinks, TCL
Cables, Finolex, Toshniwal, Udey Pyro-Cables, Fort
Gloster, Polycab
14. Thermocouple Compensating Cable : Toshniwal Cables, General Instruments, Udey pyro-cables,
Paramount Cables, Delton, Cords cables, MEM, Brooks,
Lapp cables, Elkay Telelinks, TCL Cables, Thermopads,


No
C. Analytical / Special Instruments
1. Gas analysis Instruments : ABB, Emerson, Siemens (Adage), Sick-Maihak
(Chemtrols), Forbes Marshall, Fuji, Honeywell, Yokogawa.
Servomex
2. Gas Detectors Beiler & Lang (CO-Monitor), Draeger, MSA, Oldham
(Industrial Scientific Corporation), Detronics.
3. Calorific Value (CV) analyzers : Reineke, Union, Yokogawa, Thermo-ONIX-Fluid data
(Chemtrols)
4. Moisture Analyzers (Nucleonic) : Dr. Berthold (Concord International), Emerson (Analytical),
Thermo-Electron, Sick
5. Moisture Analyzers (Infra Red) Moist Tech, EMC Electronics (NDC)
6. Moisture Analysers (on line air/ gas) : Invensys (Foxboro), Bartec, GE-Panametrics
7. ORP/PH/ Conductivity meter / : Emerson (Analytical), Polymetron (Forbes Marshall), Hach,
Transmitter Yokogawa, ABB, Honeywell, Ion Exchange
8. Flame Detector : Honeywell, Durag Instruments

9. Vibration sensors & monitors : Bentley Nevada, IRD (Mechanalysis India), Bruel & Kjaer,
Schenck-Avery, SPM Instruments, SKF, Shinkawa (Forbes-
Marshall)
10. Positive Displacement meter : Bopp & Reuther (Toshbro), Moorco (Forbes Marshall),
Liquid Controls, Emerson.
11. Averaging Pitot Tube : Emerson, Forbes Marshall, Switzer Instruments, General
Instruments
12. Infrared radiation pyrometer : Land, Chino, Raytek (Toshniwal), Ircon, Wahl (Nagman),
Keller HCW
13. Dip lance type Molten metal : Ardee Enterprise (Electronite), Ferrotran, Sidermes
temperature measurement system &
T/C Tips
14. Slag detection system : Elof Hansson (EMLI), Land.
15. SPM analyser Emerson, Yokogawa, Durag, ABB, Honeywell, Codel
(Forbes Marshall). Sick-Maihak (Chemtrols)
16. SOx- NOx analyser Forbes Marshall, Emerson, Yokogawa, ABB, Honeywell,
Sick-Maihak (Chemtrols)
D. Testing & Calibration instruments

1. 4-1/2 Digit Digital Portable Fluke/ Yokogawa/Philips
Multimeter
2. Milli volt/ Milliamp Feed & Beamex/Druck/ Scandura/ Yokogawa
Measure
3. Portable Temperature Calibrator Druck/ Scandura/ Beamex
4. Portable Pressure Calibrator with Druck/ Scandura/ Beamex
pumps


No
5. Universal Calibrator and field bus Druck/ Scandura/ Beamex
configurator
6. Insulation Tester Motwane/ Reputed Make
7. CRO Phillips/Hewlett Packard/Yokogawa/Tektronix
8. Soldering & Desoldering Station Q Max/ Weller
9. Vacuum Cleaner Eureka Forbes/ BPL/Philips

10. Tools & tackles Taparia/ Everest
08. FIRE PROTECTION SYSTEM
The list of preferred makes for various fire protection system equipment is given below:
Sl Item Description Preferred makes

No
1. Gate and NRV : Fouress, Audco, Kirloskar Brothers, KSB,
Cast steel (Carbon Steel) Crescent Valves, BDK, IVPL
2. Butterfly valves : Audco, Fouress, IVPL, Kirloskar
(Steel valve)
3. Gunmetal gate, Globe, Check : Bombay metal, Leader, Levcon valves
valve
4. CI-Gate/ Check valve : H. Sarka, KBL, Leader,Kalpana
5. Solenoid valves : Siets Rotex, Norgren, Schrader, Avcon
6. Strainer : Otoklin, superflow, Triveni, Sarojini
Enterprises
7. Level switch / sensor : NIVO controls, S.B. Electromechanical,
MONITOR control
8. Pressure switch : Indfoss, Switzer, Ashcroft, Sukan Engg.,
WIKA
9. Pressure & Temp Gauges : ANI, Gen. Inst., Manometer India, Wika,
Aschroft, Forbsmarshal.
10. Deluge Valves : Vijay Fire Protection System Ltd / Kidde
India, Grinell / Tyco, Total Whalte, HD Fire
11. Water Spray Nozzles : Reliable, ASCO, HD Fire, Laxmi Sprinkler,
Grinell / Tyco, Spray Safe.
12. Q.B. Detector : Reliable, ASCO, HD Fire, Spray Safe, Grinell
/ Tyco
13. Portable Fire Extinguishers : VIPL / Kidde India, Steelage, Zenith,
Kooverji Devshi
14. Steel Pipes (MS / GI) : SAIL, ITC, BST. Jindal, Ajanta, Prakash
Tubes, Zenith, Gujrat Steel Tubes, TATA,
Maharastra Seamless, Kalinga, Surya
15. Steel Pipe Fittings : Tube Bends, Stewarts & Lloyds, MS Fittings,

Shivnanda, Nomaan, EBY Industries

16. Hoses : Newage, Chhatriya Rubber, Jayshree
17. Spanner : Godore, Tapadia
18. Hydrants and Accessories : ASCO Strumech, Newage, Steelage, Vijay
Fire Protection / Kidde India
19. Air Release Valve : Shiva Durga, Steam & Mining Industries, H
Sarkar, Kalpana Valves
20. Coal Tar Tapes / Wrapping for : Hotaco, IWL (India) Ltd., Rustech Products,
pipes (Coatek Tape System), Lloyds
21. Water / Monitor Foam : Newage, HD Fire
22. Foam Concentrate : Newage, KV Fire Chemicals
23. Passive Fire Protection
Cable coating / mastic : Vijay System, 3M, Hilti, KBS, Promat
Fire Barrier System : Vijay System, 3M, Hilti, KBS, Promat
Fire Door : Godrej, Signum, Vijay System, UL Listed
and CGRI Roorkee approved
24. Fixed Fire Protection Systems : Tyco, Kidde India, Agnice, MX International,
(On turnkey Basis) New Fire Engineers, Technical, Newage,
Gunnebo
Note : Tenderes shall note that vendor list for all the fire fighting equipment/system shall
be from MECON/NMDC preferred make list and clearance to be obtained from
MECON/NMDC before placement of order.
09 Preferred Makes for Level-II automation
Sl.
Description Make
No.
A Hardware
1 Server Computers IBM/HP/DELL
2 Client Computers (PC), LAPTOP LENOVO/HP/DELL/TOSHIBA
3 Laser Printers HP/CANON/KYOCERA
4 DMP Printers TVS/WIPRO/EPSON
5 Appliance based firewall CISCO/NORTEL/IBM
B Network Equipment
1 Active components CISCO/FOUNDRY/NORTEL/3COM/EXTREME
2 Passive components LUCENT/AMP/MOLEX/KRONE/DLINK
C Software
1 Mail server software MICROSOFT/IBM
2 Network Management Software IBM/HP/CA
3 Antivirus Software TREND MICRO/SYMANTEC/E TRUST
/MCAFEE/KASPERSKY
4 Firewall MICROSOFT/CHECK POINT/IBM
5 Application software including TECHNOLOGY SUPPLIER
Process control models
D Rack VALRACK/RITTAL/HCL/PRESIDENT
E Local UPS EMERSON/APC/NUMERIC/ LIVE LINE/ HIREL.

10. FLUID SYSTEMS & PIPING ENGG (LUBRICATION & HYDRAULICS)
SL.
ITEM MAKE REMARKS
NO.
1. Hydraulics
a. Medium Pressure / High Pressure Rexroth / Parker / Eaton
Hydraulic System
b. Piston / Vane Pumps & Hydraulic Rexroth / Parker / Eaton
Motors
c. Gear Pump (Low Pressure) Del Pd Pumps (ROTODEL) / IMO /
Tushaco / Rexroth / Parker
d. Screw Pump (Low Pressure) Imo / Alweiler / Nortek / Tushaco
e. Hydraulics Proportional Valve Rexroth / Parker / Eaton
f. Hydraulic Servo Valve Rexroth / MOOG
g. Accumulator with Safety Shut-Off Fawcett Christie / Hydac / Parker
Block
h. Accumulator Charging Kit Fawcett Christie / Hydac / Parker
i. Pressure Filter Hydac (Germany) / Pall / Internormen /
Parker
j. Return Filter Hydac (Germany) / Pall / Internormen /
Parker
k. Heat Exchanger Alfa Laval / Indswep / Tranter
l. Level Indicator Levcon / Buhler / Techtrol / Wika / Dr.
Tiefenbach / Rexroth / Parker
m. Level Switch Shridhan / Stauff / Dr. Tiefenbach /
Buhler / Techtrol
n. Pressure Gauge & Temperature Wika / Forbes Marshall / Stauff / Hydac
Gauge
o. Pressure Switch Rexroth / Hydac / Parker / Danfoss
p. Air Breathers Stauff / Parker / Hydac
q. Contamination Analysis Kit Pall / Parker (UCC)
r. Centrifuge Alfalaval / Westfalia
t. Vacuum Dehydrator Pall / Parker / Nortek
u. Electrostatic Liquid Cleaner Ferrocare
v. Mobile Motorised Pump – Motor Pall / Eaton / Parker / Hydac / Stauff
– Filter unit for oil filling
w. Nitrogen Booster Station Hydac / Parker
x. HP Nitrogen Compressor J.A. Beckar Shone
2. Oil lubrication System
a. Oil lubrication System Lincoln Helios / Shaan Lube / Bijur
Delimon
b. Electrical Heater Escorts / Alco / Nortek
c. Basket Filter Pall / Boll & Kirch
d. Heat Exchanger Alfa Laval / Indswep / Tranter
e. Control Valve Forbes Marshall (Arca) / Samsung /
Fisher
f. Expansion Joint Esbi / Stanflex / Elaflex
g. Air Breathers Stauff / Parker / Hydac

SL.
ITEM MAKE REMARKS
NO.
h. Level Indicator Levcon / Buhler / Techtrol / Wika / Dr.
Tiefenbach
i. Level Switch Shridhan / Stauff / Dr. Tiefenbach /
Buhler / Techtrol
k. Level Indicator Cum Switch Stauff / Wika / Dr. Tiefenbach / Buhler
l. Pressure Gauge & Temperature Wika / Forbes Marshall / Stauff
Gauge
m. Pressure Switch Rexroth / Hydac / Parker / Danfoss
Thermostat Switzer / Hydac / Stauff / Danfoss
n. Differential Pressure Gauge / Wika / Switzer / Hydac / Danfoss / ABB /
Switch Endress Hauser
o. Pressure Transmitter Fisher / Forbes Marshall / Endress Hauser
/ Emerson
p. Temperature Transmitter Fisher / Forbes Marshall / Endress Hauser
/ Emerson
q. Flow Switch Forbes Marshall / Endress Hauser /
Kobold
r. Pressure Reducing Valve Fisher / Forbes Marshall / Samsung
s. Water Sensor (On tank) ASI Casitrol / Nortek / Parker
t. Centrifuge Alfalaval / Westfalia
u. Vacuum Dehydrator Pall / Parker / Nortek
v. Mobile Motorised pump – Motor – Pall / Hydac / Eaton / Parker / Rexroth
Filter unit for oil filling
w. Flow Meter cum Totalizer Rockwin / Forbes Marshall
x. Water in Oil Detector (Drip leg) Parker / ASI Casitrol
3. Air-Oil System (Complete Unit) Rebs / Nortek
4. Grease Lubrication System Lincoln Helios / Bijur Delimon / Nortek
(Complete Unit)
5. Descaling System
a. Centrifugal Pump for Descaling KSB / Halberg
System
b. Piston Pump for Descaling System Uraca / Wepuko
c. Air / Gas Safety Relief Valve L&T / Fainger / Mankenberg
d. Spray Valve For Descaling System Hauhinco / Hunt / Elwood / OH DE High
Pressure Technologies
e. Accumulator for Descaling system WSR (Germany) / BHPV / ISGEC
f. HP Compressor Imgersoll Rand / J.A. Beckar Shone
g. Auto Back Wash Filter Boll & Kirch / Hydac
h. Spray Nozzles Lechler / Spraying System
6. Air Controls (All Components) Ross / SMC / Parker / Festo / Rexroth
SL.
ITEM MAKE REMARKS
NO.
7. Water Pipework
a. Centrifugal Pump (12 bar & KSB / Grundfos / Kirloskar / Voltas

below)
b. Auto Back Wash Filter (Cartridge Boll & Kirch / Hydac
type)
c. Air release Valve Upadhyay / Steam & Mining / BDK
d. Basket Strainer for water Superflo / Hydac / Boll Filter
8. Manual Valve
a. Manual Gate / Globe Valves With KSB / BHEL / AUDCO / Fouress For Oil Lubrication &
& Without Gear For High pressure Descaling Systems
Application
b. Manual Gate / Globe Valves With KSB / Audco / Fouress For Oil Lubrication Systems
& Without gear For Low pressure and Water Pipework
Application (16 Bar & Low)
c. Butter Fly Valve Audco / Crane/Virgo For Water Pipework
d. Ball Valve Audco / Fouress / Hydac For Hydraulic & Pneumatic
Systems and Water Pipework
e. Actuators for operating Valve L&T / Rotex/EL-O-Matic(Emerson) For Oil Lubrication &
Pneumatic Systems and
Water Pipework
f. Check Valve ( Disc Type) – Low Audco / BDK / Fouress For Oil Lubrication Systems
Pressure & Water Pipework
g. Check Valve ( Spring Loaded) – Audco / BDK / Fouress For Oil Lubrication Systems
Low Pressure and Water Pipework
h. Check Valve ( Spring Loaded) – Audco / KSB / Fouress For Descaling & Pneumatic
High Pressure Systems
9. Pipes / Tubes
a. Carbon Steel Seamless Pipes / Jindal / Maharashtra Seamless / MJ Patel / For Hydraulic, Oil
Tubes Indian Seamless / Parker (Imported) / Lubrication, Grease &
Ratandeep / Soor Neogi Pneumatic Systems and
Water Pipework
b. Stainless Steel Seamless Pipes / Jindal / Ratnamani / Choksi Tubes / MJ For Hydraulic, Oil
Tubes Patel / Parker (Imported) / Ratandeep / Lubrication, Grease &
Soor Neogi Pneumatic Systems and
Water Pipework
c. Carbon Steel ERW – SAW Pipes / Jindal SAW / MJ Patel / SAIL (RSP) / For Hydraulic, Oil
Tubes MANN / Well Span / Tata / Ratandeep Lubrication, Grease &
Water Pipework
d. Pipes / Tubes Fitting (‘O’ Ring Hyd – Air / Hyloc Hydro Technic / For Hydraulic, Oil
type) Project Tooling System / Parker / Avit Lubrication, Grease &
Water Pipework
SL.
ITEM MAKE REMARKS
NO.
e. Pipes / Tubes Fitting (Ferule type) Hyd – Air / Project Tooling System / For Hydraulic, Oil
Parker / Avit / Hyloc Lubrication, Grease &
Water Pipework

f. Butt Weld Pipe / Tube Fittings MS Fittings / NL Hazra / MJ Patel / Tube For Hydraulic, Oil
(Carbon Steel & Stainless Steel) Bends Lubrication, Grease &
Water Pipework
g. Polypropylene Clamp, Aluminium Stauff / Hydair Hydraulics/ Oil For Hydraulic, Oil
Clamps Lubrication/ Descaling Lubrication, Grease &
Water Pipework
h. U - bolts HICO Multifin Products Pvt. Ltd. / For Oil Lubrication & Grease
Project Tooling System and Water Pipework
i. Hose with end fitting Hydrokrimp / Indo Industrial / Superseals For Hydraulic, Oil
/ Parker / Aero Quip / Rexroth Lubrication, Grease &
Water Pipework
j. Flanges Echjay / NL Hazra / MS Fittings / MJ For Hydraulic, Oil
Patel / Tube Bends Lubrication, Grease &
Water Pipework
k. SAE Flange Avit / Parker / Hyloc / Stauff For Oil Lubrication,
Hydraulic & Pneumatic
Systems
9. Common Facilities for all Oil
Cellars & Hydraulic Room
a. Submersible Type Sump Pump KSB / SU Motors / Grundfos / Kishore
Pumps
b. Chain pulley blocks & Hand Batliboi / Morris / WH BRADY & CO /
operating traveling cranes INDEF
10. First Fill & Flushing Oil

a. Lubricating Oil Indian oil / HP / BP / Mobil Exxon For Oil Lubrication,
Hydraulic & Pneumatic
Systems
b. Hydraulic Oil Indian oil / HP / BP / Mobil Exxon For Hydraulic Systems
c. Flushing Oil Indian oil / HP / BP / Mobil Exxon For Oil Lubrication,
Hydraulic & Grease Systems
d. Grease Indian oil / HP / BP / Balmer Lourie For Grease Systems
NOTE
2. For those equipments whose makes are not indicated above, prior approval of
Purchaser / Consultant shall be obtained.

11.0 BY PRODUCT PLANT (BPP) AND EFFLUENT TREATMENT PLANT
A. Plant Equipment
Gas Valves Fouress, L&T

Primary Gas Cooler i) Mechanical-
BHPV,HEC,Bengal Tools,Laxmi Probha, L&T,GRSE
ii) Backelite Varnish- Sharlimar, Multicoat Projects
Electro Static Tar Precipitator i) Mechanical-
Batliboi,Bengal Tools
ii) Transformer & Rectifier- Ador Powertron,Hindrectifier
Exhauster Man Turbo,Siemens,Howden Donkin
Heat Exchanger i) Shell & Tube - Reliance,Thermax, Gansons,Texmaco,
Godrej
ii) Plate Type- Alpha lavel,Trantor
Ammonia Column Isgec, HEC
Brick lining Coromandal Prodorite
Agitator Standard Engineers, Remi
Static Mixer Omega Techonolgy,Sulzer
Mechanical Seal Bergmann, Eagle, Poonawala, Flow Serve Sanmer Limited
Scrubbers Gansons,HEC,Reliance,BHPV
Surface aerator Dorr Oliver, Eimco KCP, Paramount, Geo-Mitter, Triveni
Floating aerator Dorr Oliver, Eimco KCP, Paramount, Geo-Mitter, Triveni
Blower Kay / Triveni, Maneklal
Parallel Plate Separator / Tube MM Aqua
Settler
DAF unit Praneet, Daftech
Scrapper for clarifier & Triveni, Neo-Parisrutan, Mata India, Geomiller
thickener
Sluice Gates Jash, IVPL, GM Dalui, H-Sarkar, Associates Toolings,Fluid
Control Equipment
Item description Manufacturers

Pumps
i) Metering pump dosing VK pump, Shapo Tools, Milton Roy India
ii) Horizontal centrifugal pump Kirloskar Brothers, KSB, Beacon Weir, Mather & Platt,
Microfinish, Akay Industries, Jhonson, Sulzer, Kishore
iii) Vertical Centrifugal Pump Kirloskar Brothers, KSB, Mather & Platt, Kishore
C.I. Valves (gate, globe, NRV) Kirloskar Brothers, GM Dalui, Steam & Mining, IVPL, AV

Valves, Shiv Durga, BDK, Fouress, Fluid Control Equipment

CS Valves (gate, NRV, globe) Audco, Fouress, KSB, GM Dalui, L&T, Steam & Mining,
BDK, Kirloskar, AV Valves, Fluid Control Equipment
Plug Valves Audco, Xomox, BDK, L&T,Fluid Control Equipment
Ball Valves Audco, KSB, AL Saunders, Xomox, BDK
Butterfly Valves (Manually & L&T, Fouress, Kirloskar Brothers, IVPL, AL Saunders, BDK,
electrically operated) Xomox, Fluid Control Equipment
Diaphragm Valves AL Saunders, Fluid Control Equipment, BDK, GM Dalui

Control Valve BHEL, L&T, Fouress, MIL Controls
Pressure Relief Valve Audco, Fouress, BDK,BHEL
CS &SS Pipes SAIL, BHEL, TISCO, Jindal, Ajanta, Maharastra Seamless,
Soor Neogi Koumar
Fittings for the above Pipes/Tubes Shivananda, Allied Steel, Poonam Enterprises, N.L.Hazra,
M.S.Fittings, S&L
RCC Pipes & Fittings SUR Industrial Pipes, Hind Ceramics, Indian Hume Pipes,
Daya Cuncrching.
HDPE Pipes & Fittings EMCO, KWH Heliplastic Polyolefins, Oriplast
PVC Pipes & Fittings Oriplast, Finolex, Bharat Pipe & Fittings, Supreme Industries.
Steam Trap Uniklinger,Forbes Marshall
Thermal insulation Lloyds, Rockwool, Finlay
B. Laboratory Equipment for Effluent Treatment Plant
ITEM description Manufacturers

Micro Balance Mettler/Afcoset/Sartorius/Dhona
Glass ware • Borosil/Rivera/Duran/Merck
Plastic ware • Tarson/Micron
Drying oven • Kemi/ADCO/SICO/Labequipment/labtop
Filtration assembly • Millipore/Whatman
Dessicator • Borosil/Rivera
Scientific Microscope • Labovision/Leitz Scientific/Sico
pH Meter • Labindia/Merck/WTW/Hach/Elico
DO meter • YS I55-12/Merck/WTW/Toshniwal Bros
Note: Successful tenderer shall select the vendor from above list. However they may consider
vendors from approved vendor list of MECON/NMDC. Successful tenderer has to take
approval for new vendors which are not included in Preferred Make List and
MECON/NMDC approved vendor list.

12.00 LABORATORY EQUIPMENT
Item description Manufacturer / Supplier

X-ray fluorescence spectrometer PANALYTICAL / THERMO FISHER SCIENTIFIC
( Previously ARL )
Optical emission spectrometer THERMO ( Previously ARL ) / SPECTRO
Carbon-sulphur analyser, Oxygen-nitrogen LECO
analyser, Hydrogen determinator, Proximate
Analyser, Automated sulphur analyser )
Spectrometric sample preparation equipment ( HERZOG / INSMART / UNIMAT
Swing grinding mill , Briquetting Press,
Swivel surface grinder, Spectrometric
sample polishing machine, etc. )
Raw material sample preparation and physical EASTMAN CRUSHER / BB ENGG.
testing equipment
( Jaw crusher, Roll crusher, Pulveriser,
Vibrating screens, Micum drum, Tumbler
drum, Shatter test apparatus, Bulk density
determination apparatus, Sieve shaker, etc. )
RI-RDI equipment for iron ore KANTHAL / NASKAR
FeO meter Imported make
Chemical laboratory THERMO FISHER ( Previously CHEMITO ) /
ADAIR DUTT / SYSTRONICS /S.C.DEY / SRI
RUDRAN
Gas chromatograph THERMO FISHER ( Previously CHEMITO )
Mechanical Testing Equipment BLUE STAR / INSTRON / MTS
Balances METTLER / SARTORIUS
Mechanical testing equipment BLUE STAR / IAEC / INSTRON / ROELL
AMSLER / TINIUS OLSEN
Mechanical testing sample preparation HMT / VOLTAS / GODREJ / BATLIBOI
equipment
Metallurgical microscope LEICA / OLYMPUS / ZEISS
Metallographic sample preparation CENSICO/ METATECH
equipment
Surface roughness tester CARL ZEISS INDIA / TMC MEASURING
INSTRUMENT / FIBRETEC INSTRUMENTS /
LABTECH SYSTEMS
Laboratory Furniture GORDHANDAS DESAI /AAKAR SCIENTIFIC /
EQUIVALENT
Laboratory glassware BOROSIL

13.000 CIVIL & STRUCTURAL EQUIPMENT
Sl.
Description Manufacturers
No.
1 TILES
i) Cement concrete tiles M/s NITCO, Ultra, Stone Crete, Duracrete, Eurocone
ii) Ceramic / vitrified tiles M/s Johnson, Somany ceramics Ltd., NITCO, Spartek,
Khazaria, Orient, Regent Vitrified Ltd., Bell
iii) PVC tiles M/s Bhor Industries,
M/s Premier Vinyl Flooring Ltd.,
Wonderfloor, Polyfloor, Royal touch
2 METALLIC FLOOR HARDNER M/s Triveni Color Industries (Floornate)
M/s Heatly & Grasham (India) Ltd.
M/d De-Rust Chemical Corporation of India (Ferronite)
M/s Cement Research Corporation Pvt. Ltd. (Stilonite),
Ironite, Ashford Formula
3 WOODEN DOORS/ BLOCK M/s India Plywood Mfg. Co. Ltd.
BOARDS / PLYWOOD/PARTICLE M/s Kit Ply Industries Ltd.
BOARD M/s Nuboard M/s Sitapur,
M/s Kutty Flush Doors
M/s Mysore Plywood Ltd., M/s Joinery Manufacturer
M/s Northern Doors
M/s Wood India, Calcutta, M/s Pioneer Timber product
Chandigarh
M/s Sakti Flush doors,
Green Ply, ALPRO, Novapan, Century
4 STEEL DOORS & WINDOWS M/s Sen Havic; M/s AGEW;
M/s Hopes Metal; M/s Multiwyn
M/s NCL Seccolor Ltd.
5 ROLLING SHUTTERS M/s Swastik Rolling Shutters &
Engg. Co. (P) Ltd.,
M/s Hercules Rolling Shutters & Engg Works
6 ALUMINIUM DOORS, M/s Ajit India; M/s Alumilite; M/s Indal;
WINDOWS, WALL SPANS M/s Jindal
7 GLASS M/s Triveni, Modigaurd, Sant Gobain, Tata
(Plain/Frosted, Gariess, Bajra etc) Ashi, Atul Glass Works
8 HARDWARE FITTING & M/s Jayan Metal Manufacturing co.
FIXTURES M/s Shalimar Hardware, Everite,
M/s Godrej & Boyce Mfg. Ltd.
9 Non-Asbestos Poly Propylene M/s Everest, Ramco, Hyderabad Industries Ltd.
Reinforced Cement Concrete Sheets
10 WATERSTOPS M/s Basecon; M/s Pask;
(PVC/RUBBER) M/s Asian Engg. Products;
M/s Capnhans India Ltd;
M/s Fixopan Engrs. Pvt. Ltd.
11 EXPANSION JOINT AND M/s Shalitex; M/s Tiki Tar Industries;
TARFELT WATERPROOFING M/s Shalimar Tar Products; Pidilite Indutries

Sl.
No.
12 INTEGRAL WATER Accoproof, Impermo, Siko, Fosrock, Qualicrete
PROOFING COMPOUND
13 CEMENT BASED; M/s India Waterproofing Co.
WATERPROOFING TREATMENT M/s All India Waterproof Co;
M/s Likproof India Pvt. Ltd.
M/s Modern Waterproofing Co.
M/s Nina Industries, Fosrock
14 PAINTS AND VARNISH M/s Asian Paints; M/s Goodlas Nerolac;
M/s Garware Paints Ltd;
M/s I.C.I. Paints;
M/s Berger Paints;
M/s Jenson & Nicholson; Shalimer
15 CEMENT BASED WATERPROOF M/s Snowcem India Ltd.
PAINTS & RESINBASED M/s Nitco Paints Pvt. Ltd. (Nitcocent);
THERMO PLASTIC PAINTS M/s Hindustan Colour
Chemical Industries;
Asian Paints, Berger, paints, Jenson & Nicholson,
Shalimar
16 PRESSED STEEL DOOR; M/s Sen Harvic
FRAMES M/s Techome
M/s Madhu Industries, Bagalor
17 FALSE CEILING/PANELING INDIA GYPSUM LTD.
18 PER-LAMINATED CEMENT Arm Strong World Industries
BONDED PARTICLE BOARD
19 DECORATIVE LAMINATES Decolam, Formica, Green Ply
20 PVC/FRP DOORS Rajashri plastic, Thermodeck, Sintex
21 DOOR CLOSERS Everite, Hardiwyn,
Dewan Industries
22 SEALANTS GE Silicon, Bostik
23 CONCRETE PAVER BLOCKS Basant Belton,
Adideep Interlock Pavers Pvt. Ltd.
Designers Pavings & Tiles Pvt. Ltd.,
Bessers Concrete Paver Blocks, Ultra, Stonecrete, Grasim,
Tuffstone, Earth Pavers India Ltd.
24 SANITARY APPLIANCES Parryware, Hindware
25 CP BRASS FITTINGS Jaguar, GEM, Kingston, Siko, JAL
26 CP BRASS WASTE COUPLING, GEM, Kingston
BOTTLE TRAPS
27 PVC flushing cisterns Parryware, Hindware
28 Mirror Hindustan Pilkinton, Modigaurd. Atul Glass Works,
Golden Fish, Sant Gobin
29 Stinless Sink Parryware, Nirali, Dayana, Gilma
30 GI Pipes Jindal, Tata, Swastik, Zenieth
31 GI Malleable fittings PEC, MJM, Bimal
32 GM gate, Globe valves, Ball valves Neta, Sant, Leader, Zoloto

Sl.
No.
33 CI water quality pipes IISCO
34 CI soil quality pipes IISCO, Neco
35 SW Pipes & Gulley traps Perfect Kashmira, Perfect potteries, Burn potteries
36 RCC Hume Pipes Indian Hume Pipes, Pranali Premier
37 HDPE pipes & fittings Prince, Premier
38 PVC pipes & fittings Flowgaurd, Supreme, Finolex, Prince, Premier
39 Modular floors Unitile
40 CI manhole covers Neco, IISCO, RIF
41 Blinds Hunter Doughlas, Marvel, Aerolux, Vista
42 UPVC pipes Astral
43 Pumps Kirloskar, Crompton Greaves, Beacon
44 PVC storage tanks Sintex, Century, Polycon, Premier
45 CEMENT ACC, COROMANDEL, RAASI, GRASIM, PRIYA,
L&T (ULTRA TECH CEMENT)
46 REINFORCEMENT STEEL SAIL, TATA STEEL, RINL, IISCO
47 STRUCTURAL STEEL SAIL, TATA STEEL, RINL, IISCO
48 CGI SHEETS SAIL, Jindal
49 ADMIXTURES FOSROC, SIKA, ROFF, ACC
50 Anti-termite compound M/s Pest control (I) Ltd.,
M/s Mysodet Pvt. Ltd.
51 Pre-colour coated galvalume sheets M/s Colour Roof (India) Ltd.
and translucent sheet M/s Tata Bluescope Steel Ltd.
M/s Lloyd Insulations (India) Ltd
M/s Japan Metal Building Systems Pvt. Ltd.
52 Crane Rails M/s SAIL
M/s Jindal
53 Electrodes M/s Ador/Advani Orlikon
M/s Esab
M/s D & H

NMDC LIMITED

FOR
HYDRAULICS
(GS – 14)
MECON LIMITED
RANCHI - 834002

LIST OF CONTENTS FOR GS - 14
GENERAL SPECIFICATION FOR HYDRAULIC, OIL

14.0 LUBRICATION, GREASE, PNEUMATIC SYSTEMS 2
WITH ASSOCIATED PIPING AND WATER PIPEWORK
HYDRAULIC SYSTEMS &

14.01 2 – 25
INTERCONNECTING PIPING
OIL LUBRICATION SYSTEMS & INTERCONNECTING

14.02 26 – 42
PIPING
GREASE LUBRICATION SYSTEMS &

14.03 42 – 48
PNEUMATIC SYSTEM &

14.04 49 – 55
WATER PIPEWORK FROM BATTERY LIMIT (TOP) TO

14.05 INDIVIDUAL UNIT I.E. CASTER, MILL, BLAST 56 – 59
FURNACE, ETC. FROM PUMP HOUSE
14.06 ABBREVIATION 59
Chapter14 Hydraulics Page 1 of 59

2010 MECON Limited. All rights reserved.
14.0 GENERAL SPECIFICATION FOR HYDRAULIC, OIL

LUBRICATION, GREASE, PNEUMATIC SYSTEMS WITH
INTERCONNECTING PIPING AND WATER PIPEWORK
This General Specification covers specification for Hydraulic System, Oil

Lubrication System, Grease Lubrication System & Pneumatic System
with associated piping and water pipework for all packages. However for
individual packages Technical Specification for Hydraulic System, Oil
Lubrication System, Grease Lubrication System & Pneumatic System
with associated piping is provided.
14. 01 HYDRAULIC SYSTEM & INTERCONNECTING PIPING
14.01.01 SCOPE
14.01.01.01 This general specification covers the hydraulic systems required for
various units / equipment. The term 'hydraulic systems' referred herein
generally covers the following:
- Hydraulic power packs consisting of hydraulic fluid reservoirs

with accessories, pumps, motors, filters, coolers, isolation valves,
check valves, instruments etc.
- Accumulator stands consisting of accumulators, safety shut-off

block etc.
- Valve stands consisting of all direction, pressure and flow control

valves, isolation valves, check valves & instruments.
- Hydraulic cylinders/actuators and motors.
- Hydraulic pipework complete with pipes, fittings, valves, hoses,

clamps & supports.
- Instruments, controls and safety devices for indicating and

recording of pressure, temperature & level of fluid in reservoir
etc; for alarms for abnormal conditions and for interlocks for safe
operation.
- Electrical control panel.
- Hydraulic fluid.
- Spent hydraulic oil storage system in each hydraulic room.
- Contamination Analysis Kit.

- Portable filter pump unit.
- Portable nitrogen booster unit / Portable nitrogen compressor.
- Mobile vacuum dehydrator unit / Mobile electrostatic oil cleaner.
- Hydraulic test bench.

- Test kit for proportional and servo valves.
- Sump pump and monorail with hoist for each hydraulic room.
- Viscosity index meter.
Scope of work shall also include supply of equipment, piping, initial fill
& consumables, erection & commissioning of all equipment of hydraulic
systems including interconnecting piping.
14.01.01.02 The hydraulic systems covered herein are intended for actuation of
components of various production and ancillary equipment in the steel
complex to achieve specific functions such as application of
pressure/force/torque, generation of linear or rotary motion etc.
14.01.01.03 The design and construction of the hydraulic systems shall be suitable in
every way for the service intended and shall be oriented towards
maximizing interchangeability of components and minimising
maintenance. Each system shall be complete in all respects including all
accessories essential for proper installation, operation and maintenance,
irrespective of whether such systems are specifically mentioned in the
Technical and General Specification.
14. 01.02 STANDARDS
14.01.02.01 The hydraulic systems shall be designed, manufactured, erected, tested

and commissioned as per the standards laid down in this specification.
Detailed instructions on such aspects as are not indicated herein shall be
as per the codes and practices adopted by the Indian Standards (IS), where
available, or by the American National Standard Institution (ANSI), or by
the Joint Industry Council, U.S.A (JIC) or Comite European des
Transmissions Oleohydrauliques et Pneumatics (CETOP) or as per the
national standards institution of the country of origin or the codes of
practices followed by the manufacturer. These shall be clearly indicated
by the contractor in the proposal and Employer’s approval obtained.
Wherever standards other than IS are used / referred, the Contractor shall
indicate the equivalent IS.
14.01.02.02 Wherever applicable, the Interplant Standards for Steel Industry (IPSS)
shall be followed.
14.01.02.03 Necessary noise abatement measures shall be provided to keep the dBA
level as per statutory requirement.
14.01.03 DESIGN BASIS
14.01.03.01 General
14.01.03.01.01 The hydraulic power systems shall be designed to ensure compatibility of

the system components with hydraulic fluid selected at operating
conditions in the plant and under ambient conditions prevalent at
Nagarnar (Chattisgarh).
14.01.03.01.02 Hydraulic room shall be preferably located on ground floor.

14.01.03.01.03 Hydraulic fluid shall be mineral oil based on its suitability at the operating
temperature of the system, proven performance.
Use of hydraulic fluid other than mineral oil shall be brought into notice
by tenderer.
14.01.03.01.04 Fluid cleanliness required for satisfactory and uninterrupted operation of

the system shall be taken care.
14.01.03.01.05 Specifications of the Hydraulic fluid for each system shall be furnished by
contractor, indicating type of fluid, ISO viscosity range at operating
temperatures, viscosity index, additives required, physical characteristics,
performance test specification, flash point, fire point and Oil Tenderer’s
trade name. Wherever possible equivalents with due regard to local
availability shall be mentioned. The Contractor shall also indicate the
cleanliness level of oil NAS number for each hydraulic system and same
shall be as per this G.S.
14.01.03.01.06 Anodised circuit plate shall be provided for all tank units, power units,
recirculation filter units, valve stands and accumulator stands.
14.01.03.01.07 One no. of sump pump (Approx. 10 m3/hr) shall be provided for sump pit
inside each hydraulic room. Each sump pump shall be provided with level
switch, isolation valve, check valve and pressure gauge at the discharge
side of pump for draining outside the hydraulic room. Discharge line shall
also have a separate line having isolation valve for filling oil barrel in case
of oil spillage in hydraulic room.
14.01.03.01.08 The hydraulic system performs actuation of actuators mounted on

equipment to achieve specific functions e.g., application of
pressure/force/torque, generation of linear or rotary motion etc.
14.01.03.01.09 The design and construction of the Hydraulic systems shall be suitable in
maximising interchangeability of components and minimising
accessories essential for proper installation, operation and maintenance.
14.01.03.01.10 All skids i.e. tank unit, pumping unit, recirculation filter unit, valve stands
and accumulator stands shall be independently mounted on a frame with
drip tray and drain valve.
14.01.03.01.11 Electrical system associated with hydraulic system shall confirm to

electrical chapter of this TS and GTS.
14.01.03.01.12 In the interest of standardisation, the Employer reserves the right of

selecting a particular manufacturer of Hydraulic power system equipment
and / or components and the contractor shall supply equipment /
components of the particular make, if so required.
14.01.03.02 Hydraulic Circuits
14.01.03.02.01 Design considerations

a) Minimise surge pressure using accumulators.
b) All components shall be suitable to withstand the peak surge

pressure.
c) Minimise generation of heat in the system by adequately sizing

the pipework & valves and by reducing bends & restrictions but
without sacrificing the functional efficiency of the system.
Coolers to limit the working fluid temperature around 40°C
(max).
d) Minimise pressure drop in the circuit.
e) Incorporate a reservoir of adequate capacity, pumps with motors,

filters to eliminate undesirable particulate contaminants,
generously sized pipework, accessories and hoses, adequate
cooling system to cool the hydraulic fluid as required,
accumulators, all valves, instruments and all necessary audio-
visual alarms.
f) Incorporate necessary stand-by pumps and filters, by-passes

across cooler, isolation devises, etc. to ensure continuous
operation of the systems, even when some components are under
maintenance, cleaning or repair.
g) Incorporate necessary connections, valves and appurtenances to

facilitate air purging, testing, pickling, flushing, draining,
sampling and commissioning the systems.
h) Incorporate necessary safety features to reduce the risk of fire at

points of application and also at locations around hot zones.
i) Incorporate necessary provisions for emergency operation in the

event of power failure to bring the equipment in safe condition.
Thus accumulator shall be adequately designed to take care of
atleast one operation of all actuators involved in emergency
requirement as per process requirement. Emergency power shall
be provided at solenoid valves etc. mounted on hydraulic
component involved in emergency operation.
j) Each circuit shall be designed such that the load variations and
changes in fluid temperature shall not cause such variations in the
cycle time which shall be inconsistent with the service intended.
k) Hydraulic System shall be designed to ensure safety of the

operating people & of equipment actuated by the hydraulic
system and in case of emergencies such as power failure, bursting
of hoses or pipe connections, opening of safety valves and other
devices etc.
l) Hydraulic system shall be designed taking into account the

maximum pressure anticipated in system.

m) All pressure switches, pressure transmitter and pressure gauge

shall be connected by minimess hose and minimess coupling.
n) Hydraulic system located in unattended areas, basements etc.

shall have remote control facilities to ensure safety of the main
equipment served.
14.01.03.03 Sequence Time Sheet
14.01.03.03.01 A chart shall be supplied showing sequence of operation with relation to

the cycle time, and electrical actuation. This chart should also show
pressure and flow for each portion of the cycle.
14.01.03.03.02 Detailed list of each component and equipment served by each hydraulic
system.
14.01.03.04 Devices for Circuit Control, Protection and Safety
14.01.03.04.01 Over-Pressure Capabilities and Protection
14.01.03.04.01.01 Balanced piston type relief valves shall be provided on the discharge side
of all positive displacement pumps. Over pressure protection shall be
provided elsewhere in circuits where damage to the equipments or
hazards to personnel may result. Check valves shall be provided on the
discharge side of all pump to prevent any back flow.
14.01.03.04.01.02 Hydraulic motor speeds shall be controlled by suitable pressure

compensated flow control valve.
14.01.03.05 Interlocks
14.01.03.05.01 The machinery and all connected equipment shall be brought to a safe
stop upon failure of electric power, control power, hydraulic power, or
control components. The system shall remain inoperative after restoration
of electric power until the controls are reset. If an unscheduled stop would
result in an unsafe condition then the failure shall be announced by audio-
visual alarms and stand-by or stored energy shall be provided that will
permit a delayed or gradual stop under manual or automatic control.
14.01.03.05.02 In the event of a failure in the automatic controls, manual controls shall be
provided that would permit bringing the system to a safe operation or to a
stop.
14.01.03.05.03 Hydraulic systems shall be provided with local control panel in hydraulic
room for start, stop and audio-visual alarms for faults. Hydraulic systems
shall be suitably interlocked with PLC.
14.01.03.06 Fault Alarms
14.01.03.06.01 Audio-visual alarms shall be provided in the local control panel for each
hydraulic system for the following faults:
a) Low pressure in the system.

b) Excessive temperature of fluid in reservoir.
c) High level of fluid in reservoir and stoppage of filling pump.
d) Low level of fluid in reservoir.
e) Low-Low level of fluid in reservoir and cut-off of main pumps

and circulation pumps.
f) Clogging of filters.
g) Motor overload.
14.01.03.06.02 For any of the above faults, necessary audio-visual alarms shall be
provided in the control room/control pulpit for “FAULT IN
HYDRAULIC SYSTEM”.
14.01.04 EQUIPMENT (UNITS OF HYDRAULIC SYSTEM AND OTHER

FACILITIES)
Equipment for hydraulic system shall consist of the following major

components.
- Hydraulic fluid reservoir with accessories.
- Pumps with Electric motors.
- Filters & other oil cleaning facilities including offline circulation

filter cooler unit.
- Isolation / check valves.
- Instruments.
- Accumulator stands consisting of accumulators, safety shut-off

blocks etc.
- Valve stands consisting of all direction, pressure and flow control

valves, isolation valves, check valves & instruments etc complete
with electrical wiring terminating in respective junction box.
- Hydraulic cylinders and motors.
- Pipe work complete with pipes, fittings, valves, hoses, clamps

and supports.
- Spent hydraulic oil storage in each hydraulic room.
- Other facilities required for hydraulic systems:
Portable oil filling unit – 1 no. for each location of hydraulic

room.
Contamination analysis kit – 1 no. for each area.

Portable nitrogen booster unit / Portable nitrogen compressor

– 1 no. for each area as applicable.
Nitrogen charging kit – 1 no. for each location of hydraulic

room (if applicable).
Mobile vacuum dehydrator – 1 no. / Mobile electrostatic oil

cleaner – 1 no. for each area as applicable.
One no. of Sump pump and monorail (as required) to be

provided in each hydraulic room.
Viscosity Index meter along with chart if water glycol is used

for each area.
14.01.04.01 Reservoirs
14.01.04.01.01 Capacity
i) Reservoir shall be of welded steel rectangular construction and the

dimensions shall be proportioned as length: width: height = 2:1.5:1
(approx.) Reservoir shall be fabricated using 6 mm thick (min.) stainless
steel / carbon steel plate & shall have a working (useful) volume adequate
to contain all the fluid that will return from the system, maintain the fluid
level within adequate working height limits during operation. In case of
mineral oil, the working (useful) volume of reservoir shall be determined
as per following approximation:-
Total pumping capacity Working (Useful) volume of Reservoir
Upto 50 lpm 10 mins. of total pump flow

50 (above)-100 lpm 7.5 mins. of total pump flow
Above100 lpm 6 mins. of total pump flow
In case of water glycol / water soluble oil / hydraulic system having servo
valves or high degree proportional valve stainless steel tank shall be used.
Gross volume of reservoir shall be 20% more than the working volume.
Hydraulic tank shall be located at suitable elevation such that pumping

unit shall have flooded suction even at low level cut-off of level switch.
ii) Reservoir shall be provided with:
- Suitable square or rectangular or circular opening with oil tight

cover in each chamber of the reservoir for efficient cleaning of
reservoir. Size of the opening shall be suitable for a man to go
inside the tank, where possible.
- Sloping bottom with 4% slope. Slope shall be towards drain valve

/ clean – out door and away from suction nozzle.
- Baffle plate separating suction & return chamber.

- In each chamber of the reservoir separate (40nb ball valves) drain

valves to be provided.
- Separate air breathers complete with 3 micron replaceable filter

element and dehydrating chamber containing silica gel (for
moisture trapping). The air breathers shall be of sufficient
capacity and in sufficient numbers to maintain approximate
atmospheric pressure even at maximum demands of the hydraulic
system and at maximum return of fluid from system. Combined
breather and filter shall not be used.
- Tube type protected level indicator shall be provided to cover

the entire height of the tank (overlapping). The level indicator
shall have bicolour rotating flapper and isolation valves with limit
switches and drain valve. The level indicator shall be provided
with calibrated scale with markings to show ‘high’ and ‘low’
levels with pump running and where necessary, high level with
pump stoppage.
- Electrical contact type level switches shall be provided with

necessary switches for high level alarm & filling pump cut-off,
low level alarm and low-low level alarm for main & circulating
pump cut-off. The level switches shall preferably be mounted
externally to the reservoir on transparent tube and is moved by the
magnetic field of the float inside the stand pipe. The electrical
contacts or level transmitter are mounted to the indicator scale.
The contact can be adjusted to any position. Contact type switch
shall be provided with LED. The connection of the stand pipe to
the tank shall be by means of standard pipe fittings & flanges and
isolation valves. Provision shall be for continuous analogue signal
4-20mA to control room for on-line monitoring of level and
various alarm / tripping.
- Dial type temperature gauge, mercury in steel design, protected

and mounted in a bulbwell shall be installed in the reservoir with
at least 150 mm immersion and minimum 100 mm dial size with
minimess hose and gauge isolation. At least two (2) nos.
thermometers shall be provided in the reservoir, one (1) no. in the
suction chamber and one (1) no. in the return chamber of the
reservoir. The level of thermometers shall be slightly above the
suction height.
- Temperature transmitter shall be provided with (4-20mA)

signal accessible to main control room for on-line temperature
measurement and for alarm / tripping as applicable for various set
points. Temperature transmitter shall also be used for ON / OFF
of plate type heat exchanger. High temperature alarm and pump
tripping shall also be provided. Local digital display of
temperature at temperature transmitter mounted on tank shall also
be provided.
- Sampling valves (15 NB needle valve) for taking sample of fluid

for checking quality of hydraulic fluid. One (1) no. sampling
valve shall be provided in the return chamber of the reservoir.

- Necessary nozzles with isolation valves in the suction and return

chambers of the tank for connecting mobile vacuum dehydrator /
electrostatic liquid cleaner (If used), as and when required, for
cleaning the hydraulic fluid in the reservoir.
- Necessary nozzles for pump suction line, return line, leakage line,
drain line from main pumps, relief return line and return line from
circulation unit.
- Necessary ladders shall be provided outside as well as inside the

reservoir for climbing on top of the reservoir and for going inside
the reservoir respectively during maintenance.
- All the nozzles connections above the oil reservoir should have
the raised face so as to eliminate the water ingression into the
reservoir.
iii) The reservoir shall be designed and constructed to prevent entry of

foreign matter, including water and shall be separate & removable from
the equipment base. Reservoir shall be fabricated from stainless steel of
adequate strength and thickness. Cast reservoirs shall not be used.
iv) Wherever the reservoir is mounted on floor, the bottom of the reservoir
shall have a minimum clearance of 150 mm from the floor. The legs shall
have appropriate mounting holes.
v) The level of ‘low-low’ level switch in the reservoir shall be at least 50

mm above the topmost level of suction nozzle.
vi) Reservoirs shall be designed for adequate heat dissipation by generously

proportioning tank wall surface and so installed as to allow unhindered air
flow over all surfaces, sides, top and bottom.
vii) The suction pipe shall be below the low-low level of fluid to avoid
cavitation. The return pipe, relief return pipe and return line from
circulation unit, shall be brought down below the low-low level of fluid in
reservoir to avoid aeration. The return pipe & relief return pipe shall be
located in the return chamber of the reservoir and shall be provided with
bevelled cut pipe for smooth flow.
viii) The pipe ends for leakage line from valve stands, drain line from
hydraulic motors, drain lines from main pumps shall be kept above
maximum fluid level in the reservoir to facilitate free return of these low
pressure fluids.
ix) Filling of hydraulic fluid in the reservoir shall be through a separate set of
duplex filters. The fineness of the duplex filters shall be equal to the
fineness of circulation filters for the respective system. The duplex filters
shall be provided with built-in changeover valves at the inlet & outlet.
Inlet of duplex filter shall be connected to outlet of portable oil filling unit
and suction of portable filter shall be in fresh barrel.
x) Draining of hydraulic fluid from reservoir shall be done by filter cooler

circulation pump. Necessary branch connection with isolation valve and

check valve shall be provided on the downstream side of circulation pumps

for draining.
xi) Each reservoir unit shall be provided with an electrical junction box and
shall be pre-wired upto junction box.
14.01.04.02 Pumps
14.01.04.02.01 Motors for Main pumps shall have 25% spare over pump relief setting.
Pump speed shall be 1500 rpm. Main pumps shall preferably be variable
flow, pressure compensated axial piston pumps.
14.01.04.02.02 Each pump discharge line relief valve of suitable adjustable range set to
relieve at 110 % of system pressure.
Each pump should be connected to motor by Bell housing or coupled by

suitable gear coupling / Love-joy coupling.
14.01.04.02.03 Unless specified otherwise, main pumps shall be provided with stand-by
pumps.
The number of stand-by pumps shall be as follows:
Upto 3 nos. working pumps : 1 no. standby pump

For 4 nos. to 6 nos. working pumps : 2 nos. standby pumps
For 7 nos. to 9 nos. working pumps : 3 nos. standby pumps
The standby pumps shall be connected to the circuit and kept ready for
operation. Where only one (1) operating pump is required, an identical
standby pump shall be provided.
14.01.04.02.04 Circulation pumps of adequate capacity (Minimum 30% of total system

capacity) with motors shall be provided for parallel filtration and cooling
circuit. One working and one standby circulation pump shall be provided.
The circulation pumps shall be triple screw type. Pump speed shall be
1500 rpm.
14.01.04.02.05 Both main and circulation pumps shall preferably be floor mounted with
flooded suction and shall not be mounted inside reservoir or on top of
reservoir.
14.01.04.02.06 All pumps shall be provided with isolation valves with limit switches on
suction side and isolation valves on discharge side to facilitate
maintenance. Main pumps shall be provided with flexible connector on
suction side and hose on discharge side, whereas, circulation pumps shall
be provided with compensators on both suction and discharge sides. On
the discharge side of each main pump a manifold shall be provided on
which the pressure line filter, pressure gauge, isolation valve, check valve,
minimess coupling shall be mounted. On downstream side of pump,
unloading type relief valve shall be mounted. The material of the
manifold block shall be forged steel. Necessary check valve, relief valve
and pressure gauge shall be provided on the downstream side of each
circulation pump.

14.01.04.02.07 Electronic Strain Gauge type Pressure switch shall be provided on

downstream side of main pumps and recirculation pumps, with (4-20mA)
signal accessible to main control room for on-line measurement of
pressure. Pressure switch shall have various switching facilities low
pressure / high pressure alarm, low-low pressure / excessive high pressure
pump trip, etc. Necessary minimess hose & coupling to be provided to
connect Pressure switches & Pressure transmitter. Pressure switch shall
have facility for local digital display and setting of various set pressure as
per requirement. Pressure transmitter can be used if process demands.
14.01.04.02.08 Pressure gauges shall be panel mounting type, ¼” BSP back connection
glycerine filled type heavy duty 150 mm dial size of suitable range
complete with bourdon, movement and snubber of AISI 316 SS, in die
cast aluminium alloy, moisture proof case, heavy enamelled black and
stoved with zero adjustment mechanism. To be installed with minimess
hose and push to read type isolation valves.
14.01.04.02.09 One no. loose pressure gauge (For each range) with minimess hose and
coupling shall be provided for each hydraulic system for measuring
pressure at different pressure check points.
14.01.04.02.10 Necessary hose shall be provided on the drain line from each main pump
of variable flow axial piston type. The drain line from each main pump
shall preferably be connected to tank separately. In case the drain lines
from main pumps are connected to a common header, in that case check
valve shall be provided on the drain line from each main pump.
14.01.04.02.11 Necessary branch connection with isolation valve and check valve shall
be provided on the discharge side of the circulation pumps for emptying
the hydraulic fluid from reservoir.
Necessary branch connection with isolation valve and check valve shall
also be provided on the upstream side of circulation filters for filling fresh
hydraulic fluid in reservoir through circulation filters.
14.01.04.02.12 Each pump-motor unit shall be mounted on a base frame with vibration
isolator with drip tray and drain valve. The pumping units shall be
provided with electrical junction boxes and shall be pre-wired upto
junction boxes.
14.01.04.02.13 The following information shall be preferably shown on metallic name

plates on each hydraulic pump:
i) Manufacturer’s name and address
ii) Manufacturer’s part, model and / or serial number
iii) Flow and working pressure
The direction of rotation of each pump shall be clearly indicated on the

pump where it can be readily seen.
14.01.04.03 Filters and other Oil Cleaning Devices

14.01.04.03.01 Filters shall be provided for continuous removal, from the hydraulic fluid,
of contaminants which are likely to cause malfunction of pumps, valves
and actuators and maintain desired cleanliness level of hydraulic fluid.
Adequate filtration level shall be maintained for each system. The
fineness of filters shall depend on the components used in the hydraulic
system. The following cleanliness level of oil shall be maintained for
hydraulic systems:
Systems without Servo Valves : NAS 7

and proportional valves
Systems with Proportional valves : NAS 5
Systems with Servo Valves : NAS 4
14.01.04.03.02 In general, hydraulic systems shall be provided with pressure line filters,
circulation filters and return line filters. All filters shall have >=200.The
fineness of various filters shall be as follows:
a) For Hydraulic system with : Pressure line filters – 3 microns

servo valve and higher Circulation line filters–3microns
end proportional valves Return Line filters–10 microns
(equivalent to servo valves)
b) For Hydraulic systems : Pressure line filters – 5 microns

with normal proportional Circulation filters–5 microns
valves Return Line filters–10 microns
c) For Hydraulic systems : Pressure line filters–10 microns

without proportional and Circulation filters– 5 microns
servo valves Return line filters–10 microns
14.01.04.03.03 Pressure line filter on the downstream side of each main pump shall be
single filter and shall be without bypass valve. Necessary isolation valves
shall be provided across pressure line filters for maintenance. The
circulation filters and return line filters shall be Duplex type with built-in
changeover valve at the inlet and outlet. The circulation and return line
filters shall be provided with bypass check valve. Check valve shall be
provided on the upstream side of return line filters.
14.01.04.03.04 All the pressure line, circulation and return line filters shall be provided
with electrical switches for audio-visual alarm for filter clogging.
Minimess couplings shall be provided across each pressure line,
circulation and return line filter. Each filter shall be provided with
necessary drain and vent connections.
14.01.04.03.05 The material of filter elements shall be compatible with the hydraulic
fluid. Depth type filter shall be used. The filter elements shall be of
disposable type
14.01.04.03.06 The selection of filters shall be guided by:
- Highly stable x value over a wide pressure drop range.

- High dirt retention capacity of filter element.
- Low pressure drop in filter housing.
- Durable housing construction.
- Material of filter element and housing to suit hydraulic fluid.
14.01.04.03.07 The capacity of pressure line, circulation and return line filters shall be
generally as follows:
Pressure line filters : 2 to 2.5 times pump flow at p= 0.5 to

0.8 bar in clean condition
Circulation filters : 3 times of pump flow at p=0.3 to 0.5

bar in clean condition
Return Line filters : 3 times of maximum return flow or 3

times of maximum pump flow,
whichever is greater, at p=0.3 to 0.5
bar in clean condition
14.01.04.03.08 For hydraulic systems where servo valves and proportional valves are
used, one (1) no. mobile electrostatic liquid cleaner shall be included for
each Hydraulic system for cleaning the oil periodically and maintaining
desired NAS class level of hydraulic oil. The electrostatic liquid cleaner
shall be capable of removing particles upto 0.5 micron size from the oil.
One (1) no. mobile vacuum dehydrator shall be included for hydraulic
systems, which shall be connected to the reservoirs of the hydraulic
system to remove water and maintain 3 micron filtration level of oil in
reservoirs. 15 m long cable with plug (suitable for 4 wire input power)
and 10 m suction and discharge hose shall be provided with vacuum
dehydrator / ELC (If provided).
14.01.04.03.09 The offline circulation filter cooler unit and return line filter unit shall be
provided with drip tray and drain line valve. The offline circulation filter
cooler unit and return line filter unit shall also be provided with electrical
junction boxes and shall be pre-wired upto the respective junction box.
For detail of filter for offline circulation filter cooler unit and return line
filter unit, refer details as mentioned above. Details of cooler is as
mentioned below.
14.01.04.03.09.1 Coolers
14.01.04.03.09.1.1 Coolers shall be provided in the hydraulic systems where normal

operation of the hydraulic systems would raise the temperature of the
working fluid beyond 40°C during any time of the year. The coolers shall
be plate type of gasketted design. The plate type coolers (Plate material –
SS) shall designed such that all the four (4) ports shall be on one (1) side
of cooler. Cooler shall have cooling capacity of atleast 30% of installed
power on unit. Cooler shall be generously designed considering water
inlet temperature of 35°C and shall have 20% spare capacity. The cooling

medium shall be water. Plate type cooler shall be designed as per

manufacturer’s standard.
Air cooler of adequate rating shall be provided where cooling water is not
available.
14.01.04.03.09.1.2 Coolers shall be provided with the following:
a) Isolation valves on cooler water inlet and outlet lines.
b) Isolation valves on oil inlet & outlet lines from cooler and on the
bypass line across cooler globe valve shall be provided.
c) Pressure gauge with isolation valve and temperature indicators on

cooler water inlet & out lines.
d) Pressure gauge with isolation valve and temperature indicators on

oil inlet & outlet lines from cooler.
e) Solenoid operated ON/OFF valve and strainer of 250 micron

fineness on cooler water inlet line.
f) Minimess couplings on oil inlet and outlet lines from cooler to

check pressure.
14.01.04.03.09.1.3 Coolers shall be mounted on separate skid and shall be mounted on a

frame with drip tray and drain valve. The cooler unit shall be provided
with electrical junction box and shall be pre-wired upto junction box.
14.01.04.03.09.1.4 The pressure drop across cooler on oil circuit shall be less than one (1) bar
and on water circuit shall be less than 0.5 bar.
14.01.04.04 Accumulators
14.01.04.04.01 Accumulators shall be used for any of following functions as per design:
- Energy storage
- Emergency operation
- Shock absorption and pulsation damping
14.01.04.04.02 The accumulators shall preferably be of bladder type, charged with
nitrogen or inert gas, sized to meet the functional needs and designed to
withstand at least 1.5 times the nominal design pressure of the hydraulic
system and shall conform to the code for pressure vessels prevailing in the
country of origin or to any equivalent international codes for pressure
vessels.
Where large amount of oil is to be supplied to the system in short time,

piston type accumulator with nitrogen gas bottles shall be used. For other
hydraulic systems accumulator shall take care atleast one operation of all
actuators involved for emergency operation as per process requirement.
However, use of piston accumulator shall be brought to the notice /
approval from Employers.
14.01.04.04.03 Each accumulator shall be provided with safety shut-off block containing
isolation valve, drain valve, safety relief valve, pressure gauge, pressure

check minimess coupling. Necessary charging and testing kit for

accumulators, complete with isolation valve, manifold, hose, etc. shall be
provided.
14.01.04.04.04 Each accumulator stand shall be provided with drip tray and drain valve.
The accumulator stand shall be provided with electrical junction boxes
and shall be pre-wired upto respective junction box.
14.01.04.04.05 The following information shall be permanently indicated on each

hydraulic accumulator:
a) Manufacturer’s name and address

b) Manufacturer’s model number, capacity
c) Manufacturer’s serial number, if any
d) Rated maximum operating pressure
e) Charging medium
f) Total fluid capacity
14.01.04.05 Valve stands
14.01.04.05.01 All hydraulic directional valves shall be sub-plate/manifold mounted on

valve stand as per hydraulic schematic. Directional valves of large
capacity shall be hydraulic pilot operated type. Directional valves shall
have manual override.
14.01.04.05.02 Valves shall not be mounted on reservoir. Suitable valve stands shall be
used for mounting valves for the ease of operation and maintenance. The
valve stands shall be of modular vertical column design or Table top
design.
14.01.04.05.03 Each valve stand shall be provided with the following:
a) Isolation valves on the pressure line and pilot pressure line near
each valve stand.
b) Check valves on the tank return line and leakage line near each
valve stand.
c) Isolation valves on A, B lines from each valve stand to actuator.
d) Minimess couplings on pressure line & pilot pressure line at the

entry to each valve stand / valve block and on A, B lines from
each valve stand/valve block.
e) Minimess couplings across pressure reducing valves and on

upstream side of relief valve within the valve stand / valve block.
f) Material of manifold block should be forged Steel.
14.01.04.05.04 Each valve stand shall be provided with drip tray and drain valve.
Electrical junction box shall be provided for each valve stand and the
valve stand shall be pre-wired upto junction box.

14.01.04.05.05 Valves, in general, shall be kept above high fluid level of reservoir except
where the functions of the valves require them to be below the fluid level.
14.01.04.05.06 Sub-plate mounted valves with ‘O’ rings shall have locating pins or non-
symmetrical bolts holes for fool-proof mounting.
14.01.04.05.07 Direction control valves shall be selected for maximum 5 kg/cm2 (P to A

& B to T taken together) pressure drop for blind end flow.
14.01.04.05.08 Speed control valves shall be selected for maximum 5 kg/cm2 (maximum
open condition) pressure drop.
14.01.04.05.09 Total pressure drop in any circuit including manifold block of valve stand,
for the flow indicated for the circuit shall not exceed 15 bar. Pressure drop
shall be measured by short – circuiting A & B ports by providing pressure
gauges at P & T lines and measuring flow by a digital flowmeter.
14.01.04.05.10 Internal leakage line from valves shall be separately drains to reservoir.
14.01.04.05.11 Each solenoid of solenoid operated valves shall be identified. The same
identification number shall be put in both electrical and hydraulic
diagrams, for a particular solenoid.
14.01.04.05.12 Solenoid operated valves shall incorporate the following features:
a) Suitably sealed solenoid enclosure to prevent the entrance of

splashing liquids and airborne contamination.
b) Sufficient internal space to incorporate 150 mm leads and taped

joints.
c) Manual over-rides which can be operated without removing the

solenoid covers but which cannot be operated accidentally.
d) Solenoids shall be continuous duty type.
e) Solenoid indicating lamps.
f) Solenoid valves shall be suitable for 24 V DC.
g) Solenoid valve electrical leads shall be equipped with vibration

proof and weather proof plug type connectors for ease of
replacement and maintenance.
h) Pilot controlled solenoid operated valves shall be provided with

pilot chokes (to control speed of main valve shift to reduce
shock).
i) Identification marks stating manufacturer’s name, type, rating,

model no., port size etc. for valves.
14.01.04.05.13 Proportional and servo valves shall be provided with electronic card and
card holder. The proportional and servo valves shall be suitable for 24 V

DC input & 4-20 mA signal to PLC. The proportional valves shall be

provided with manual override.
14.01.04.05.14 Necessary test kit for proportional and servo valves shall be provided.
14.01.04.05.15 All isolation valves on oil lines for tank unit, pump units, circulation
units, return line filter unit, accumulator stands and valve stands shall be
plug/ball type valves of cast/forged steel. The pump suction line isolation
valves may be butterfly type for space constraint. The isolation valves on
cooler water lines shall be gate valves of cast/forged steel.
14.01.04.06 Hydraulic Cylinders
Hydraulic cylinders shall be designed to meet the working pressure of the

system and tested to a minimum of 150% of nominal design pressure.
Hydraulic cylinders shall have appropriate cushioning to avoid shock at

extreme ends. Port connection on cylinder shall be BSP thread / SAE
mating flanges.
14.01.04.07 Hydraulic Motors
Hydraulic motors shall be designed to meet at least 125% of normal

output torque and 125% of the maximum system pressure. The hydraulic
motors shall be designed with adequate hydraulic protection circuit such
that it will not be overloaded under all conditions of operation of
equipment which is actuated by motor.
Hydraulic motors shall be mounted on a rigid base plate or shall be flange

mounted such that they are capable of withstanding the hydraulic shocks
likely to be imposed. It shall be connected to the driven equipment with a
suitable coupling / transmission device.
Where possibility of over-running and complete stalling of hydraulic

motor is present, suitable relief arrangement shall be provided to allow oil
to circulate freely without overheating the fluid.
Suitable case drain line shall be provided for efficient lubrication of

internal moving parts of hydraulic motor. The drain line shall be
generously sized and shall be connected separately to tank to avoid back
pressure.
14.01.04.08 Spent Hydraulic Oil Storage System in each Hydraulic Room
One (1) no. of carbon steel tank having capacity same as that of maximum
tank capacity in a cellar alongwith one (1) no. of gear pump of 100 lpm
capacity shall be provided to pump out spent oil from spent oil tank to
tanker / barrel.
Spent oil from all hydraulic tanks shall be pumped out to spent oil storage
tank from each system tank in a cellar, using circulating oil pump at each
hydraulic system.
14.01.04.09 Other Facilities

14.01.04.09.1 Contamination Analysis Kit – 1 No. for each area
One (1) no. Portable Contamination Analysis Kit with print out facility
for assessing cleanliness of hydraulic oil for each area shall be supplied.
14.01.04.09.2 Portable Filter Pump Unit – 1 No. for each location of hydraulic room
shall be supplied
This unit shall be complete with motorised pump and filter to fill the oil in
the system tank from oil barrels. The unit shall be trolley mounted
complete with 15 m long cable suitable for 4 wire supply and 5 m suction
& 15 m discharge hose. Rating of the filter shall be same as that of
recirculation filter cooler unit.
14.01.04.09.3 Portable Nitrogen Booster Unit / Portable Nitrogen Compressor – 1 No.

for each area, as applicable shall be supplied
The mobile oil driven mobile nitrogen booster unit shall be equipped with
tank, pump-motor, filter, relief valve, cylinder, pressure switch, pressure
gauge, shut-off valve, check valve, appropriate connections for nitrogen
bottle / accumulator stand. Alternatively, nitrogen compressor for
boosting nitrogen pressure for filling high pressure nitrogen in
accumulators can be provided if the charging pressure is more than 100
bar. Portable Nitrogen Booster Unit / Compressor shall be complete with
10 mtrs long suction hose & 15 mtrs delivery hoses and electrical cables
(15 mtrs) with plug suitable for 4 wire supply.
14.01.04.09.4 Mobile Vacuum Dehydrator Unit – 1 No. / Mobile electrostatic Oil

cleaner – 1 No. for each area, as applicable shall be supplied
One mobile vacuum dehydrator of 200 LPH capacities shall be provided

for each area. Mobile vacuum dehydrator shall be capable of removing
water and maintain 3 micron filtration level.
One (1) no. Mobile electrostatic cleaner for each area (as applicable) shall
be included for Hydraulic systems having servo valves & high generation
proportional valve for cleaning the oil periodically and maintaining
desired NAS class level of Hydraulic oil. Electrostatic oil cleaner shall be
capable of removing particles upto 0.5 micron size from oil.
Both the units shall be complete with long suction (10 mtrs) & delivery
(15 mtrs) hoses and electrical cables (15 mtrs) with plug suitable for 4
wire supply.
14.01.04.09.5 Hydraulic Test Bench – 1 No. for each area shall be supplied
One (1) no. of full fledged hydraulic test bench for testing hydraulic
pumps, valves, hydraulic components, cylinders, motors, etc. shall be
supplied for each area.
14.01.04.09.6 Test Kits for Proportional & Servo Valves – 1 No. for each area
One (1) no. for test kits for proportional and servo valves shall be
supplied for each area, if applicable.

14.01.04.09.7 Sump Pump & Monorail with Hoist for each Hydraulic Room
Minimum one (1) no. of sump pump (Approx. 10 m3/hr) shall be provided
for sump pit inside each hydraulic room. Each sump pump shall be
provided with level switch, isolation valve, check valve and pressure
gauge at the discharge side of pump for draining outside the hydraulic
room. Discharge line shall also have a separate line having isolation valve
for filling oil barrel in case of oil spillage in hydraulic roomof sump
pump.
Monorail & hoist shall be provided in each hydraulic room for

transporting motor / pump etc. from individual power unit to a place for
taking it out of hydraulic room.
14.01.04.09.8 Viscosity Index Meter alongwith Chart for each area (if applicable)
Necessary viscosity index meter (1 no.) alongwith chart to access the

requisite quality of oil shall be supplied in case water glycol or water
waste oil is supplied.
14.01.05 INTERCONNECTING PIPING
14.01.05.01 All hydraulic pipes shall be Stainless Steel, seamless type & fittings shall
also be of stainless steel. However, water pipe from main header to cooler
shall be of carbon steel and accordingly fittings also shall be of carbon
steel.
14.01.05.02 Hydraulic pipelines shall be adequately sized. The size of hydraulic pipes
shall be such that the velocity of fluid in pipeline shall be as follows:
For hydraulic pressure : Velocity approx. 4.0 m/sec

line upto 150 bar pressure
For hydraulic pressure : Velocity approx. 4.5 m/sec

line above 150 bar pressure
For tank return line : Velocity approx. 2.0 m/sec
For suction line : Velocity approx. 0.5 m/sec
For circulation line : Velocity approx. 1 to 1.5 m/sec
14.01.05.03 For hose, the bursting pressure shall be not less than 5 times the
maximum working pressure of the system. All the hoses in hot area shall
be with stainless steel braided cover and silica cloth cover.
14.01.05.04 Specification of Pipes & Fittings
14.01.05.04.01 Carbon Steel (For heat exchanger water line)
I. All tube / pipe sizes should be as given in schematic drawing to be of

following specification.

a) Up to 38 OD for all lines - Seamless tubes to DIN 2391-

Part – 2, 1994 and 37.4 NBK to
DIN 1630 – 1984
b) Above 38 mm OD size - Seamless schedule 40 black pipe

of ASTM – A106 Gr. B – 94 and
Dim as per ANSI B 36.10 – 1995
II. Fittings should be of following specification:
a) Pipes upto 38 mm OD size - Welding nipple with ‘O’ ring CS

to 14C14S14 of IS: 1570 (Part
III)-1979
b) Above 38 mm OD size
i) Upto 50 NB - Socket weld fittings of 3000 #

rating to ASTM – A-105 -1994
and Dim as per ANSI B 16.11 –
1991
ii) Above 50 NB - Butt weld fittings of ASTM – A-

234 WPB – 1994 AND Dim. As
per ANSI B 16.9 -1993 of
schedule same as per that of pipe
III. Flanges should be of - Slip-on flanges of ASA 150

following specification class for
return and drain. ASTM – A –
105 - 94. Dim. as per ANSI – B -
16.5 - 1988.
For slip-on flange raised face flange electrogalvanised hexagonal head

screw & hexagonal nuts shall be used. Grade of hexagonal head screw
shall be 8.8 and that of nut shall be 8.
IV. Shut – off / Isolation valves should be of following specification:
Ball valves (150 class) with SS internals upto 50NB – socket weld type
and above 50 NB – with flanged (ASA 150 class ends).
14.01.05.04.02 Stainless Steel


1995 with material no. 1.4541
and condition-h and dim. as per
DIN 2462, part –I-1981

i) Suction, return & drain lines - Seamless schedule 40 pipe as per

ASTM – A-312-TP304-1995 and
dim. as per ANSI-B-36.19-1985
ii) Pressure lines - Seamless schedule 80/160 pipe

to ASTM – A-312-TP304-1995
and dim. as per ANSI-B-36.19-
1985
a) Pipes upto 38 mm OD size - Welding nipple with ‘O’ ring

DIN 17440-1985 with material
no. 1.4541
i) Upto 50 NB - Socket weld fittings of

3000/6000# rating to ASTM –
A-182-F304-1996 and Dim as
per ANSI B 16.11 – 1991

403- WP304-1996 and Dim. to
ANSI- B - 16.9 -1993 of
schedule same as that of pipe.
III. Flanges should be of following specification:
a) Upto 80 NB in all lines - SAE 4 bolt socket weld type of 3000#

rating with O-rings in low /
medium pressure line and 6000 #
rating in high pressure lines.SS-
304.
b) Above 80 NB in suction - Slip-on flanges of ASA 150 class for

return and drain. SS-304. Dim.
as per ANSI-B-16.5-1988.
All terminations should be terminated by mating flanges suitable for

incoming/outgoing pipe sizes. The P -T- L headers in valve stands, one
end should be provided with mating flange and other end with blind
flanges.
For SAE flange SS socket head screw & hexagonal nuts and for SAE
flange SS socket head screw & hexagonal nuts shall be used.
IV. SS-304 Shut – off / Isolation valves should be of following specification:
a) Suction, return & drain lines (150 class)
Upto 50NB - Socket weld type and

Above 50 NB - With flanged (ASA 150 class

ends)
b) Pressure lines - SS-304 Ball valves of adequate

rating
V. At pump delivery and in pressure lines near cylinders, hoses of suitable

SAE 100R 2/9/11 with female swivel BSP crimp end fittings to be used.
VI. TIG (Argon) welding should be done at all pipe joints which are butt –
weld. Full TIG (Argon) should be for upto 38 mm OD tube. Above 38
mm OD size, only root welding shall be by TIG and further welding by
normal welding.
VII. After fabrication, all SS pipes to be cleaned, degreased and flushed with
oil.
VIII. All pipelines to be clamped with polypropylene heavy series clamps at

regular interval and locations to avoid hydraulic shock during operation.
IX. All necessary interconnecting piping between various units i.e. tank,
accumulator stand, pumping unit and valve stands and between valve
stands and equipment shall be provided. The interconnecting piping shall
consist of high pressure hoses, pipes/tubes, welded nipple type with O-
ring type fittings, SAE four bolt flanges, heavy duty PP clamps, etc.
14.01.06 INSPECTION AND TESTING
14.01.06.01 All hydraulic systems / components shall be inspected and tested at the
manufacturer’s premises by the Employer/Consultant as per approved
QAP by Consultant. Performance tests for hydraulic systems/equipment
shall be carried out at site along with the operation of the main equipment
to which the hydraulic system shall be connected, to check the flow rate,
pressure and temperature of hydraulic fluid, pressure drop across filters &
cooler, power consumption by electric motors etc. as well as proper
functioning of the main equipment as per the requirement of conditions of
Contact.
However, QAP shall generally comprise of the following:
Test Acceptance Criteria
a) Hydrostatic test of tank NO BULGING / NO

LEAKAGE
b) Load test of pump for 30 minutes NO LEAKAGE

At system working pressure
c) Hydrostatic test of all units except NO LEAKAGE

tank for 15 minutes at 1.5 times
system working pressure
d) Internal leakage of pumps at As per Tenderer’s

system working pressure (for engineering data sheet

axial piston pumps only)
e) Pressure drop across filters, As per approved

coolers (oil side) schematic
f) No load current of electric motors Below rated current

as per test certificate
g) Full load current of electric motors Below rated current

as per test certificate
h) Testing of operation / function of NO DEVIATION

temperature switch, level switch
and pressure switch by multimeter
i) Internal leakage of pumps at system As per Tenderer’s

working pressure (for axial piston data sheet
pumps only)
j) Operation / function of all the As per approved

components schematic
k) Pressure drop across each As per approved

hydraulic valves schematic
l) Operation / function of solenoid NO STICKING

valves
m) Operation / function of P.O. NO STICKING

check valves
14.01.07 FIRST FILL & FLUSHING OIL
Scope of supply shall include flushing oil and first fill of hydraulic oil in
required quantity (Tank, pipeline & components) upto successful
commissioning & PG (as defined in Contract).
14.01.08 ERECTION, TESTING AND COMMISSIONING
14.01.08.01 All components and equipment shall be cleaned, both externally and
internally, as mentioned in the equipment Tenderer’s manuals for erection
and maintenance.
14.01.08.02 Hydraulic pipework shall be assembled, tested, pickled, flushed and

commissioned as per piping instructions submitted by Tenderer’s
according to their standard practice.
14.01.08.03 Installation, testing & commissioning of electrical systems associated

with hydraulic system shall conform to General Technical Specification
and electrical chapter of this TS.
14.01.09 SPARES

Adequate quantity of: ‘O’ ring & seal kit for hydraulic components, ‘O’
ring for fittings used, solenoid coils, plug-in connectors, hose, minimess
hose and filter elements for various grade & type of filters shall also be
included in commissioning spares to take care till successful
commissioning (as defined in contract).
Any items required for commissioning but not included in commissioning

spare shall also be supplied at no cost implication to Customer.
14.01.09.02 2-years spares
A list of 2-years spares based on Tenderer’s past experience shall also be

furnished.
14.01.10 PAINTING
All components of the hydraulic system and interconnecting piping shall

be painted as per Painting Specification GS – 09 (GTS).
14.01.11 DRAWINGS AND OTHER DOCUMENTS
14.01.11.01 Drawing and technical information shall be furnished in according to

technical specification. Following types of Drawing and technical
information shall be provided.
14.01.11.02 Block diagram of system.
14.01.11.03 Hydraulic circuit drawings for each tank unit, main pumping unit,
circulation pump-filter-cooler unit, return line filter unit, accumulators
stands, valve stands upto actuators showing each component of respective
unit, including all interconnecting lines by means of approved graphical
symbols with parts list indication in BOM with complete specification,
size, pressure rating, material, model No., make, quantity etc. of each
item.
14.01.11.04 General arrangement drawings for tank unit, main pump-motor unit,
circulation pump-motor-filter-cooler unit, return line filter unit,
accumulator stands and valve stands.
14.01.11.05 General arrangement drawings for the hydraulic cellars / rooms.
14.01.11.06 Interconnecting piping drawing from hydraulic room to valve stand and
from valve stand to consumer points.

14.02 OIL LUBRICATION SYSTEMS & INTERCONNECTING PIPING
14.02.01 SCOPE
14.02.01.01 This general specification covers the lubrication systems required for
various units. The term 'lubrication systems' referred herein covers all
types of lubrication systems including but not limited to centralized oil
and Air-oil lubrication systems, including interconnecting piping and
electrical control panel, positive force-feed lubricators, various types of
oilers and manual devices. The term also covers components of
centralized circulating systems for indicating, recording and integration of
various parameters such as pressure, temperature, velocity etc; control
devices for manual and automatic operation of the systems, safety devices
and alarms for abnormal operating conditions; interlocks for sequencing
and safe operation; hand-guns and other appliances for manual lubrication
and lubricating media.
& consumables, erection & commissioning of all equipment of oil
lubrication systems including interconnecting piping.
14.02.01.02 The selection, design and construction of the systems shall be suitable in
maximizing interchangeability of components and minimising
irrespective of whether such items are specifically mentioned in the
Technical and General Specifications.
14.02.02 STANDARDS
14.02.02.01 The lubrication systems shall be designed, manufactured, erected, tested

and commissioned as per the standards laid down in this specification.
Detailed instruction on such aspects as are not indicated herein shall be as
per the codes and practices adopted by the Indian Standards (IS) wherever
available or American Society of Lubrication Engineers or as per the
standards of the national standards institution of the country of origin or
the codes of practices followed by the manufacturer. These shall be
clearly indicated by the contractor and Purchaser’s prior approval shall be
obtained. Wherever standards other than IS are used/referred, the
contractor shall indicate the equivalent IS.
14.02.02.02 Wherever applicable, the Interplant Standards for Steel Industry (IPSS)
shall be followed.
14.02.03.01 General
14.02.03.01.01 The design should ensure that the components of the lubrication systems
are compatible with the lubricant selected, at the operating conditions in
the plant and under climatic conditions prevalent at site. In selecting the
lubricant, the operating temperature of system shall be given careful

consideration; and oil viscosities shall always be related to operating

temperature.
14.02.03.01.02 Details concerning each lubricant shall be furnished in the form of a chart,
indicating system reference, consuming point references, location of
system, type of lubricant, ISO viscosity grade, manufacturer's code
number for fluid type & grade and quantity for first fill of system
including interconnecting piping. Wherever possible, equivalents with
due regard to local availability shall be mentioned.
14.02.03.01.02 Design velocity shall be at the range of 1 to 3 m/sec max) on discharge

side of pumps and on oil feed lines.
14.02.03.02 Lubrication Circuits
14.02.03.02.01 Each circuit shall be designed so as to ensure adequate supply of lubricant

at the specified temperatures and pressures for the relevant application.
Each system shall be designed taking into account the maximum
pressures encountered in operation.
14.02.03.02.02 Each circuit shall incorporate a reservoir of adequate capacity for

lubricant with accessories, pumping equipment, filters to eliminate
undesirable particulate contaminants, adequate cooling system to cool the
return lubricant where required, pressure tanks where necessary, adequate
heating system to adjust the viscosity of supply lubricant, generously
sized pipework, accessories and hoses, and all necessary audio-visual
alarms such as those for lubricant temperature in reservoir, levels of
lubricant in reservoirs, pump discharge pressure, low lubricant flow, filter
clogging, return lubricant temperatures etc. Unless otherwise specified,
lubrication equipment for centralized systems located in unattended areas,
basements etc. shall have remote control facilities to ensure safety of the
main equipment served by such lubrication systems.
14.02.03.02.03 The circuits shall incorporate necessary stand-by units, bypasses, isolation
devices etc. to ensure continuous operation of the systems even when
some components are under maintenance, cleaning or repair.
14.02.03.02.04 The circuit design shall incorporate necessary connections, valves and
appurtenances to facilitate testing, pickling, flushing, draining and
commissioning the systems.
14.02.03.02.05 Design of each circuit shall be such as to achieve quick response to

functional needs, economic operation of the system and minimum
maintenance. The circuit design shall also ensure safety of the staff and of
the equipment served by the lubrication system, in case of emergencies
such as power failure, bursting of hose or pipe connections, opening of
safety valve or other devices.
14.02.03.02.06 Oil sampling outlets with isolating valves shall be provided at suitable
locations in the system.
14.02.03.03 Centralized Oil Lubrication System
14.02.03.03.01 Oil lubrication system shall be used when it is necessary:

a) To remove heat from the friction surfaces and to ensure fluid film
condition.
b) To create a high hydro-dynamic pressure which ensures separation
of the sliding surfaces in fluid film condition.
c) To lubricate rolling contact bearings which work for long periods
at high speeds.
d) To have, besides lubrication, intensive cooling of the friction
surfaces.
e) To lubricate gears and worms (with the exception of very slow
running and briefly operating mechanism).
14.02.03.03.02 Centralized oil lubrication systems shall be provided for applications

where lubrication is needed for a large number of use points which are
located reasonably close and needing the same grade of oil lubricant.
14.02.03.03.03 Each centralised oil lubrication system shall incorporate oil reservoir of
adequate capacity, pump with electric motor, stand-by pump with motor,
duplex pressure filters (one working, one standby), oil cooler, pressure
tank, valves, pipes, hoses, tubes and all necessary instruments and
controls and suitably designed dust and moisture proof control panel.
14.02.03.03.04 In systems where contamination collected by the lubricating oil is

expected to be high and systems where ingress of water in oil is high (e.g.
Morgoil Systems), two identical reservoirs shall be provided so that while
one tank shall be in operation, the oil in the other tank shall be centrifuged
/ vacuum dehydrated and ultimately cleaned to requisite level. Centrifuge
/ Vacuum dehydrator shall be permanently connected to the tanks of such
systems. The number of centrifuges for each system shall be as described
in clause no. 4.9.2 below.
14.02.03.04 Centralized Air-oil Lubrication System
14.02.03.04.01 Centralized air-oil lubrication system shall be used for lubrication of

following equipment and other equipment as per tenderer’s design:
a) To lubricate mill guides, loopers, etc.

b) To lubricate machinery components such as bearings, sliding
surfaces which require fine film lubricant.
14.02.03.04.02 Centralized air-oil lubrication system shall include oil reservoir with all
accessories, pumps with standby pump, electric motor, duplex filters (one
working + one standby), pressure gauge, pressure switch, relief valve on
downstream side of each pump, progressive, primary & secondary
distributor blocks, air line isolation valve, filter, regulator with pressure
gauge, pressure switch, solenoid valve, flow control valve, pipes &
fittings, electrical control panel etc.
14.02.03.05 Other Lubrication Facilities
14.02.03.05.01 Isolated lubrication points, needing oil lubrication continuously,

shall be provided with sight feed lubricators.
14.02.03.05.02 The connector for the hand lubrication device shall suit connections
provided at the lubrication points.

14.02.04 EQUIPMENT (UNITS OF OIL LUBRICATION SYSTEMS AND

OTHER FACILITIES)
Centralized lubrication systems will be provided for bearings and gears of

drive gearbox. The system shall consist of the following.
- Reservoir.
- Screw pumps with internal relief valves.
- Plate type heat exchanger.
- Filters.
- Immersion heater.
- Pressure vessel.
- Pressure reducing valves.
- Indicating and control instruments near consumer points.
- Interconnecting piping - Carbon steel piping except at wet area,
which shall be stainless steel.
- Other facilities i.e. Vacuum dehydrator, Centrifuge and
Equipment for checking particle & water content in oil.
- Spent lubricating oil storage system in each oil cellar.
- Sump pump and monorail with hoist in each lubrication room.
The system shall consist of the items given below:
14.02.04.01 Reservoir
All systems shall have dedicated reservoir complete with all the
accessories i.e. breather, tube type level gauge, sampling valve, etc. and
instruments i.e. level switch, thermometers, temperature transmitters,
water sensor, etc. Necessary electrical heaters shall be provided.
Normally one no. of tank shall be used for each lubrication system but
lubrication system where water ingress is more i.e. Morgoil, etc. one
working & one standby shall be provided.
Necessary nozzles with isolation valves shall be provided in the reservoir

for connecting vacuum dehydrator.
14.02.04.01.01 For gear oil lubrication systems for rolling mills etc. where contamination
and muck is expected to be high, the useful capacity of reservoir shall be
equal to 30 minutes total pump flow. In case of Morgoil bearings & no-
twist mill bearings of rolling mills, the useful capacity of reservoir shall
be equal to 50 minutes total pump flow. For bearings of electric motor,
steam turbine and gas turbine, the useful reservoir capacity shall be equal
to 5 to 10 minutes pump flow. The total volume of reservoir shall be 15
per cent to 20 per cent more than the useful volume, which will remain as
free air space. The reservoir shall be rectangular type and shall be
generally proportioned as length: width: height = 2:1:1, unless economics
or standardisation dictates other proportions.
However, in case of tank having capacity less than tenderer shall show
sufficient prove from their customer regarding satisfactory operation of
complete unit alongwith tank.

14.02.04.01.02 The reservoir shall be designed and constructed to prevent entry of

foreign matter including water. Reservoirs shall be separate and
removable from the equipment base. Material for reservoir shall be carbon
steel / stainless steel.
14.02.04.01.03 A 3-compartment arrangement shall preferably be used in reservoir

construction. While one compartment shall be used for sucking of oil, the
other two compartments shall be used for return oil and for settling of
water and other solid contaminants from the oil. The volume of return
chamber, settling chamber and suction chamber shall have a ratio of 1:2:1.
The suction chamber containing clean oil for circulation shall be provided
with a float suction in addition to deep suction.
14.02.04.01.04 The reservoir shall be sub-divided into compartments by providing baffle

plates inside the reservoir across the width of the reservoir. Necessary
coarse strainers shall be provided inside the reservoir along the baffle
plate so that when the return oil flows from return chamber to middle
chamber of the reservoir, coarse particles are removed.
14.02.04.01.05 All reservoirs shall have provision for lubricant filling and air breathing,
separately. The filler hole shall have a filter for filtering the lubricant
during filling and shall be fixed with fasteners requiring hand tools for
opening. Filler holes shall be provided with caps or covers permanently
attached to the reservoir by suitable means. Combination breather and
filler assemblies shall not be used. Breather hole(s) shall be provided and
protected by air cleaner(s) containing indicative type silica-gel for
moisture trapping. The air cleaner(s) shall be of sufficient capacity to
maintain approximate atmospheric pressure inside reservoir even at
maximum demand of the lubrication system. The number of air breathers
shall depend on the capacity of the reservoir and the capacity of the
pumps.
14.02.04.01.06 An additional nozzle connection of suitable size shall be provided in the

reservoir for external filling line, but plugged for shipping. Fresh oil shall
be filled to the system tank by a mobile filling pump having adequate
rating (maximum rating of system filter) filter alongwith hoses, etc.
Reservoirs shall be designed for adequate heat dissipation by generously
proportioning the reservoir wall surface and shall be installed as to allow
unhindered air flow over all surfaces - sides, top and bottom. Return fluid
shall have peripheral flow along reservoir side wall from suitably bevelled
cut pipe.
14.02.04.01.07 Suitable dial thermometers protected and mounted in a bulbwell shall be

installed in the suction and return chambers of the reservoir with at least
150 mm immersion length. Thermostats / temperature transmitter shall be
provided in the reservoir for high temperature alarm in case temperature
of oil in reservoir exceeds the set value and for controlling tank heaters.
Signal from temperature transmitter shall be accessible to main control
room for on-line temperature measurement and for auto ON/OFF of
heaters.
14.02.04.01.08 When reservoirs are placed on civil foundation, the bottom of the
reservoir shall have a minimum clearance of 150 mm from the floor.

14.02.04.01.09 The reservoir shall be provided with tube type protected level indicator.
Acrylic Borosilicate glass shall be used for level indicator. The level
indicator shall be provided with isolation valves with limit switches and
drain valve. The level indicator shall be provided with calibrated scale
with markings to show ‘high’ and ‘low’ levels with pump running and,
where necessary, ‘high’ level with pump stoppage. The tube type or flush
type level indicators shall cover the entire height of the reservoir.
14.02.04.01.10 Tube type level indicators shall be provided with necessary switches for
high level alarm and filling pump cut-off, low level alarm and low-low
level alarm & main pump cut-off.
The level switches shall be mounted externally to the reservoir. Wherever

required, level transmitter shall be provided in the reservoir for signal
transmission to control room, for on-line monitoring of level.
14.02.04.01.11 The suction pipe to pump shall be below the low-low level of fluid in the
reservoir, to avoid cavitation. The return oil pipe, the relief return pipe
and the fresh oil filling line shall be brought down below the low-low
level of fluid in the reservoir to avoid aeration. The return oil pipe and
relief return pipe shall be located in the return chamber of the reservoir
and shall be provided with bevelled cut pipe for smooth flow. The return
oil pipe and relief return pipe shall always be located away from suction
pipe (preferably in different compartments of the reservoir) for efficient
and smooth operation.
14.02.04.01.12 The return oil from gear boxes and bearings shall drain by gravity to the
reservoir. Return lines shall slope down to the reservoir at about 3 to 4 per
cent preferably, to the horizontal depending on specification of oil used in
the system based on tenderer practice.
14.02.04.01.13 Provision shall be made for efficient cleaning of reservoir. Suitable square
or rectangular openings with hinged covers shall be provided on top of
tank. Similarly, suitable square or rectangular openings with oil tight
covers shall be provided in each compartment of the reservoir, at the side
walls, flushing with tank bottom plate to facilitate tank cleaning. The top
openings shall be suitably located for entry to each compartment of the
reservoir for cleaning. Openings shall be suitable for man entry. Suitable
opening with cover shall also be provided on top of tank, along the width,
for taking out tank strainers and maintenance. For bigger tanks, tank top
opening shall be with ladder.
14.02.04.01.14 The reservoir bottom shall have about 4 per cent slope towards drain. The
drain shall be piped out for further disposal. The drain connections of the
reservoir shall be provided with isolating valves. For each compartment
of the reservoir, at least one drain connection shall be considered.
14.02.04.01.15 Reservoirs shall be fabricated from steel / stainless steel of suitable grade,
having thickness depending on capacity of reservoirs. Stainless steel tank
shall be used as per requirement of tenderer. The thickness of plate for
reservoirs shall generally be as follows:

Capacity of Thickness of Thickness of

Reservoir in m3 side plates bottom plate
Upto 3 m3 5 mm 5mm
5 to 10 m3 6 mm 6 mm
10 to 35 m3 8 mm 10 mm
35 to 90 m3 10 mm 12 mm
Necessary stiffening plates / channels shall be provided on the external

surface of the reservoir. Interior surface of the reservoir shall be sand
blasted, cleaned and coated with copaphen aluminium
14.02.04.01.16 Lubricant return to the reservoir shall preferably be through horizontal

lines directed over a combination of trays and screens of suitable mesh
size to eliminate turbulence and help defoaming of the lubricant. Spill
from relief valve and other pressure regulators which are free of air and
contaminants shall be discharged 150 mm or more below lubricant level
and away from pump suction to avoid splashing. The return flow from
separate lubricant purification systems shall also be discharged 150 mm
or more below lubricant level.
14.02.04.01.17 Pump suction opening shall be placed such that bottom of suction pipe is
at least 150 mm to 200 mm above the tank bottom to prevent dirt or water
pick up. The suction opening must be kept well below the low-low level
of lubricant (minimum 100 to 150 mm) to avoid air entry and cavitation.
When lubricant level varies widely, a floating suction shall be used to
meet the requirement.
14.02.04.01.18 Necessary sampling connection with valves shall be provided in each

compartment of the reservoir. Necessary water detecting units shall be
provided in the reservoir for Morgoil Oil lubrication systems for giving
signal to start centrifuge / vacuum dehydrator in auto mode.
14.02.04.01.19 The filling of fresh lubrication in the reservoir shall be locally by a mobile
pump filter unit from ± 0.00 level. The spent lubricant from the reservoir
shall be dumped to the spent oil tank in oil cellar. The pumping unit at
spent oil storage system shall be used to dispose oil in drums/oil tanker at
± 0.00 level. For small lubrication systems, the system pumps shall be
used for unloading the spent lubricant from the reservoir. For large gear
oil / Morgoil lubrication systems a separate spent oil pump shall be
provided for unloading the lubricant from the reservoir. Necessary
nozzles shall be provided in the reservoir for connecting spent oil pump.
14.02.04.01.20 Necessary nozzles shall be provided in the reservoir for connecting

centrifuge/vacuum dehydrator.
14.02.04.01.21 The level of low-low level switch in the reservoir shall be at least 100 mm
above the top most level of suction nozzle or 100 mm above the top most
level of pump casing, whichever is higher, to avoid cavitation of the
pumps.

14.02.04.01.22 Necessary ladders shall be provided outside as well as inside the reservoir
for climbing on top of the reservoir and for going inside the reservoir
respectively, during maintenance.
14.02.04.01.23 Reservoir shall be provided with electrical junction box and shall be
prewired upto junction box.
14.02.04.02 Pumping Unit
14.02.04.02.01 Pumping units shall have floor mounted triple screw pump. Pumps shall
be triplex screw pumps with built-in relief valve, coupled to electrical
motor with flexible coupling and coupling guard. RPM shall be 1450.
Electrical motor shall have 25% additional power than that required for
designed pump discharge and flow.
Pumps shall be designed for 20% over requirement. Electrical motor shall
have VVVF control if desired by process, thus in this case system
pressure of lubrication system shall be controlled by VVVF drive.
14.02.04.02.02 One (1) operating and one (1) stand-by pump units shall be provided. For
very large gear oil / Morgoil lubrication systems, two (2) nos. working
pumps shall be provided. In such system a minimum of 50% stand-by
pump shall be provided. Stand-by units shall be piped to the system.
Instruments and controls for the system shall ensure that the stand-by
pump shall automatically start in sequence in case of failure of any one of
the operating pumps. The failure of any one of the pumps shall be
indicated by audio-visual alarms, located on the control panel.
14.02.04.02.03 Pumps shall preferably be floor mounted on base frames with flooded
suction and shall not be mounted inside reservoir or on top of reservoir
without specific approval of purchaser.
14.02.04.02.04 Flexible shaft couplings complete with coupling guards shall be provided
between the pump and motor. The type of coupling shall be suitable for
the application.
14.02.04.02.05 Pumps shall be provided with stainless steel compensator and isolation
valve with limit switch on the suction side and relief valve, check valve,
isolation valve on the discharge side. Combination type of valve instead
of isolation and check valve on discharge side can also be used. Necessary
pressure gauge shall be provided on the downstream side of each pump
and pressure switches shall be provided on the common header on the
discharge side of pumps for low pressure alarm and for automatic starting
of stand by pump in case of failure of working pump. Necessary pressure
transmitter shall be provided with signal accessible to main control room
for online pressure measurement, as per process requirement.
14.02.04.02.06 On the down stream side of pumps, a by-pass line with a globe valve shall
be provided, for closed circulation during cold starting in peak winter
season and for stabilizing the temperature of tank during cold start.
14.02.04.02.07 The mounting surface provided for a separate pump and motor shall be
rigid and shall prevent coupling misalignment due to work load and
temperature variations. Flexible couplings shall be used between the

motor and pump, and be of a type suitable for the application. An

approved detachable safety guard shall be fastened over the coupling and
equipped with a hinged section to facilitate lubrication.
14.02.04.02.08 The pump-motor unit shall be provided with drip tray and drain valve.
Each pump-motor unit shall be provided with electrical junction box and
shall be prewired upto junction box.
14.02.04.03 Heat Exchanger & Heaters
14.02.04.03.01 Heat exchanger shall be of plate type for indirect cooling of oil with water
and shall be installed in oil supply line to consumers. This shall be
capable of keeping the oil temperature in the supply line to consumers
within desired limit. This shall be equipped with necessary valving,
instruments and controls.
Heat exchanger shall be designed considering water inlet temperature of

35°C. Heat exchanger shall have 20% built-in spare capacity.
14.02.04.03.02 Each cooler shall be provided with the following:
a) Isolation valves on cooler water inlet and outlet lines.
b) Isolation valves on oil inlet and outlet lines from cooler and on the
bypass line across cooler.
c) Pressure gauge and temperature indicators on cooler water inlet &

outlet lines.
d) Temperature indicators on oil inlet and outlet lines from cooler.

e) Pressure check minimess couplings on oil inlet and outlet lines
from cooler, for checking pressure drop across cooler.
f) Basket type filter of 250 micron fineness on cooler water inlet line.
g) Necessary control valve with controller on cooler water inlet line

for automatic control of water flow. Control valve characteristic
shall be such that to suit process requirement. Globe valve shall be
provided on by-pass line of control valve in case manual control is
required due to non-functioning of control valve.
14.02.04.03.03 Cooler shall be fitted external to the reservoir and shall be mounted on a
frame with drip tray and drain valve. The cooler unit shall be provided
with electrical junction box and shall be pre-wired upto junction box.
14.02.04.03.04 The pressure drop across cooler on oil circuit shall be less than one (1) bar
and on water circuit shall be less than 0.5 bar, generally.
14.02.04.03.05 Heaters shall be used in the reservoir of the lubrication systems if the
viscosity of the lubricant under ambient conditions would affect the
system operation adversely under all operating conditions.
14.02.04.03.06 Heaters shall preferably be of the electrical type, having heating intensity
of not more than 0.8 watt per sq. cm. In case oil specification demands

less than 0.8 watt per sq. cm heating intensity than in direct heating of oil
shall be done by using heaters shell filled with thermal oil and heaters
shall be immersed in it. Adequate support of heaters / heaters shell with
heater shall be done inside tank which shall also take care of expansion of
total assembly of heaters / heaters shell with heater.
14.02.04.03.07 Electrical heaters shall preferably be of the cartridge type, suitable for
mounting in reservoir and thermostatically controlled.
14.02.04.04 Duplex Filter
14.02.04.04.01 Duplex filters of adequate rating shall be provided in the pump discharge
line of each system. All the filters shall be duplex basket type / cartridge
type (if required) with change over valves. All tanks / reservoirs shall
have coarse stainless steel strainer in the tank return line chamber.
14.02.04.04.02 Duplex filters shall be in stages if the oil filtration level is less. Filters
shall have 0.2 kg/cm2 pressure drop at 125% of rated flow. All the above
filters shall have ß200.
14.02.04.04.03 The filters shall be equipped with differential pressure gauge cum switch,
which will enunciate at the set differential. Once the selection is made to
the clean filter, this annunciation will go off.
The filters shall have a differential relief valve at the bypass. The setting
of valve shall be equal to or slightly more than the setting of differential
pressure gauge cum switch.
14.02.04.04.04 Pressure and return line filters shall be so constructed and installed that
the filter element can be changed for cleaning or replacement without
disturbing the piping or equipment operation. For this purpose, duplex
filters (one working + one stand-by) shall be provided. All filters shall be
provided with 3-way isolation valves across it and drain valves / drain
plugs to facilitate maintenance of filters / filter elements. Necessary vent
valves shall also be provided for filters.
14.02.04.04.05 Filter unit shall be provided with drip tray and drain valve. Electrical
junction box shall be provided for filter unit. The filter unit shall be
prewired upto electrical junction box.
14.02.04.05 Pressure Tank
14.02.04.05.01 All critical systems shall be provided with pressure vessels of adequate
capacity to supply lubricating oil to the consumers in case of pump power
failure / failure of working and stand-by pump for a period, as demanded
by process. The stored oil in pressure vessel shall be supplied to consumer
points by compressed air connected to pressure vessel. The pressure
vessel shall be complete with solenoid operated air valves, control
components, valves, instruments and air booster.
14.02.04.05.02 Pressure tank shall be provided with relief valve for protection against
over pressure, pressure gauge, pressure switches, tube type level gauge to
cover entire height of pressure tank, level switch, drain valve, flow gauge
glass, man-hole with Davit, air line connection with filter, regulator with

pressure gauge, lubricator, isolation valve, etc. Each pressure tank shall be
provided with isolation valve on oil line.
14.02.04.06 Pressure Reducing Valve
Suitable pressure reducing valves with necessary accessories i.e. pressure

gauge on main line and branch line to various consumers shall be
provided to keep the system pressure / individual consumer pressure
constant even if the flow at consumer points varies.
14.02.04.07 Instruments at Consumer Points & on Main Line
Necessary pressure gauge, pressure switch (4-20mA) and flow switch (4-
20mA) shall be provided in the supply line to individual consumer point
such as gearbox and oil film bearings.
Temperature indicator and temperature switch (4-20 mA) shall be

provided in the return line of oil film bearings.
Pressure gauge, pressure transmitter, temperature transmitter, etc. shall be

mounted on main line going to various consumers.
14.02.04.08 Other Facilities
14.02.04.08.1 Vacuum Dehydrator
Vacuum dehydrator of adequate capacity dedicated for each lubricating

system shall be provided to keep the water and oil cleanliness level within
the limit as dictated by process. In case of area where water ingress is
more like that of Morgoil bearings, 1 working & 1 standby vacuum
dehydrator shall be provided. The vacuum dehydrator shall be capable of
working with all types of lubricating oils having different viscosities to be
used for various oil lubricating system. The capacity of Vacuum
Dehydrator shall be generally be equal to capacity of tank divided by 15-
20 hours approximately.
Each Vacuum Dehydrator shall be complete with electrical control panel

and pre wired upto control panel. The Vacuum Dehydrator shall be
mounted on a base frame with drip tray and drain valve.
14.02.04.08.2 Centrifuge
One (1) no. of centrifuge shall be provided for lubrication system where
water ingress is more like that of Morgoil bearings. Centrifuge shall be
capable of removing dirt, dust & solid contamination alongwith oxidation
products which forms sludge alongwith water. Capacity of centrifuge
shall depend on system tank capacity. The capacity of centrifuge shall be
generally be equal to capacity of tank divided by 15-20 hours
approximately.
Each centrifuge shall be complete with electrical control panel and pre
wired upto control panel. The centrifuge units shall be mounted on a base
frame with drip tray and drain valve.

14.02.04.08.3 Equipment for checking particle and water content in oil
One (1) no. Equipment for checking particle and water content in oil
of centrifuge shall be provided for each area.
14.02.04.09 Sump Pump & Monorail with Hoist for each Lubrication Room
Minimum one (1) no. of sump pump (Approx. 10 m3/hr) shall be provided
for sump pit inside each lubrication room. Each sump pump shall be
provided with level switch, isolation valve, check valve and pressure
gauge at the discharge side of pump for draining outside the lubrication
room. Discharge line shall also have a separate line having isolation
valve for filling oil barrel in case of oil spillage in lubrication room of
sump pump.
Monorail & hoist shall be provided in each lubrication room for

transporting motor / pump etc. from individual power unit to a place for
taking it out of lubrication room.
14.02.04.10 Spent Lubrication Oil Storage System in each Oil Cellar Room
One (1) no. of carbon steel tank having capacity same as that of maximum
tank capacity in a cellar alongwith one (1) no. of gear pump of 100 lpm /
300 lpm capacity shall be provided to pump out spent oil from spent oil
tank to tanker / barrel. 300 lpm pump shall be used for tanks having
capacity having more than 125 m3. In case oil viscosity of lubrication
system varies in one cellar than 2 nos. of tank shall be provided. One tank
shall cater to the viscosity range upto 220 ISO VG and other shall be
more than 220 ISO VG.
Spent oil from all lubrication tanks shall be pumped out to spent oil
storage tank from each system tank in a cellar, using separate spent oil
pump at each lubrication system.
14.02.05 INTERCONNECTING PIPING
14.02.05.01 All necessary interconnecting piping between various units i.e. tank,
accumulator stand, pumping unit and control valves shall be provided.
Return line from gear box, etc shall have adequate slope for gravity drain
to tank. The interconnecting piping shall consist of hoses, pipes / tubes,
fittings, flanges, heavy duty PP clamps, etc as detailed out in general
notes. Material for interconnecting piping & fitting shall be Carbon steel
or Stainless steel based on system requirement.

a) Pipe (450 NB & Below) - Seamless carbon steel pipes to

ASTM A 106, Gr. B, Schedule
40, with plain / bevelled ends.

- Seamless stainless steel pipes to

ASTM A 312, Gr. 304L,
Schedule 40, with plain bevelled
ends.
a) Forged fittings – Elbow, Tee, Reducer, etc.
50 NB & Below - 3000 lb forged carbon steel,

ASTM A105, socket welded as
per ANSI B 16.11.
- 3000 lb forged stainless steel

A182, Gr. F304, socket welded
as per ANSI B 16.11.
65 NB & Above - Seamless carbon steel, ASTM A-

234, Gr. WPB, Schedule 40, Butt
welded, Dimensions to ANSI
B16.9.
- Seamless stainless steel, ASTM
A-312, Gr. 304, Schedule 40,
Butt welded as per ANSI B16.9.
b) Screwed fittings
40 NB & Below - 3000 lb forged carbon steel,

ASTM A105, screwed as per
ANSI B 16.11.
- 3000 lb forged stainless steel

A182, Gr. F304, screwed as per
ANSI B 16.11.
III. Flanges for all size - Forged carbon steel ASTM – A -

105 flange to ANSI-B-16.5,
Class 150
- Forged stainless steel ASTM-A-

182, Gr. F304 to ANSI-B-16.5,
Class 150.
IV. Valves
• Shut – off / Isolation valves should be of following specification:
SIZE STANDARD
Suction, Return and drain lines- Ball valves with SS internals PN

16 of Cast / Forged steel. (Upto
40 NB – socket weld type & 50
NB and - with flanged (DIN
PN16) ends).

• Throttling (Globe valve) shall be of following specification
SIZE STANDARD
50 NB and below - Forged carbon steel globe valve,

800 Class with regulating type
disc. MOC- Body ASTM A
105,trim ASTM A182,Gr.
F6.Bolted bonnet, outside screw
and yoke, rising stem, socket
weld/screw end to ANSI B 16.11
65 NB and above - Cast carbon steel globe valve,

150 Class with regulating type
disc. MOC- Body ASTM A 216,
trim ASTM A182, Gr. F6.Bolted
bonnet, outside screw and yoke,
rising stem, raised face, flanged
ends to ANSI B 16.5
• Check valve
50 NB and below - Class 800, Forged carbon steel

lift check valve, body and cap
material to ASTM A 105, trim
ASTM material to ASTM A 182,
Gr. F6. Bolted cap, socket
welded / screwed ends to ANSI
B 16.11 / Forged carbon steel lift
check valve to IS: 10989
65 NB and above - Class 150, cast carbon steel

swing check valve, body and cap
material to ASTM A 234, Gr.
WPA, trim material to ASTM A
182, Gr. F6. Bolted cap, flanged
ends with raised face to ANSI B
16.5 / cast carbon steel check
valve to IS: 10989
IV. Pipes shall be supported by U-Bolts.
V. Hose assembly shall be to SAE or DIN standard for Lubricating oil service
at specified working pressure, complete with reusable type end fittings at
both ends and of required length.
VI. TIG (Argon) welding should be done at route run at all pipe joints which
are butt – weld. Full TIG (Argon) should be for upto 1” NB tube. Above 1”
NB size, only root welding shall be by TIG and further welding by normal
welding. SS pipes shall be full TIG (Argon) welding.
VII. After fabrication, all SS pipes to be cleaned, degreased and flushed with
oil.

VIII. All pipelines to be clamped using polypropylene clamps upto 1” NB.

Above 1” NB electrogalvanised steel pipe clamps (U-Bolts) shall be used
with at regular interval and locations. For hot locations aluminium type PP
clamps shall be used. For high pressure lubrication system, heavy duty PP
clamps shall be used.
IX. All necessary interconnecting piping between various units i.e. tank,
pressure tank, pumping unit and filter cooler units, spent oil pump unit and
from cellar to equipment shall be provided. The interconnecting piping
shall consist of pressure / high pressure (If used) hoses, pipes / tubes, SAE
four bolt flanges, PP clamps, etc.
14.02.06 PAINTING
All components of the Oil lubrication system and interconnecting piping

shall be painted as per Painting Specification GS – 09 (GTS).
14.02.07 INITIAL FILL & FLUSHING OIL
Scope of supply shall include lubrication oil to be used for First fill and
for flushing (if used) in required quantity upto successful commissioning
(as defined in contract), i.e., after commissioning all the system tanks,
filter, accumulators and piping shall be full.
Qty. of flushing oil shall be sufficient to make the system ready for
commissioning.
14.02.08 ERECTION, TESTING AND COMMISSIONING
internally, as mentioned in the equipment Tenderer’s manuals for
erection and maintenance.
14.02.08.02 Lubrication pipework shall be assembled, tested, pickled, flushed and

commissioned as per piping instructions submitted by Tenderer according
to their standard practice.

with oil lubrication system shall conform to General Technical
Specification and electrical chapter of this TS.
14.02.09 SPARES
List of commissioning spares shall be provided. Commissioning spares

shall be supplied with the systems and it shall be part of the supply.
Any spares which is required during commissioning but not listed in

commissioning spares shall be supplied free of cost to customer.
List of recommended spares for 2-years of operation shall also be

provided. A separate price for these 2-years spares shall be indicated.

14.02.10 INSPECTION & TESTING
All Oil lubrication systems / components shall be inspected and tested at

the manufacturer’s premises by the Employer / Consultant as per
approved QAP by Consultant. Performance tests for Oil lubrication
systems / equipment shall be carried out at site along with the operation of
the main equipment to which the Oil lubrication system shall be
connected, to check the flow rate, pressure and temperature of lubricating
fluid, pressure drop across filters & cooler, power consumption by electric
motors etc. as well as proper functioning of the main equipment as per the
requirement of conditions of Contact.
14.02.11 GENERAL INSTRUCTIONS
a) All the pipes and fittings etc. can also be seamless conforming to
DIN standards, as applicable.
b) Oil tray should be provided for all individual skids.
c) Fixing of individual skids shall be with Hilti Bolts and shall be in

tenderer’s scope. Fixing of Hilti Bolts shall be with Hilti
machines which shall be supplied in adequate number and
maintained by tenderer.
d) All equipment shall be supplied with drives, associated electrics,

instruments and control equipment, technological structures (if
any), maintenance and working platforms, railing, safety guards
etc.
e) Material handling facilities (monorail with hoist) for maintenance

of all equipment shall also be a part of supply.
f) Any other equipment / part / facility not specifically mentioned in

the specification, but is necessary technically or safety point of
view for the satisfactory and smooth operation of the system shall
also be included in the scope of the supply of the Tenderer.
g) There shall be properly identification of piping.
h) Air vents with plugs / valves shall be provided at proper places.
i) The Tenderer shall supply complete set of all the special tools and
tackles including required number of tool boxes as required for
erection, maintenance, overhaul or complete replacement of the
equipment and components required for the offered system. All
the tools shall be supplied in separate containers clearly marked
with the name of the equipment they are meant for.
j) After assembly, all the piping shall be dismantled pickled, rinsed

neutralized, air dried, oiled with system fluid and then
re-assembled for inspection and testing.
k) Complete units shall be pressure tested at 1.5 times of system

working pressure.

l) Performance test, of different components, shall be carried out by

running system pumps in presence of client’s representative.
m) All components of lubrication system shall be painted as per

Painting specification GS-09 (GTS).
n) All units to be packed properly in wooden boxes to protect the

equipment against damages due to long Outdoor storage, rain and
transit. All instruments to be checked separately in wooden boxes.
o) Power units to be filled with system fluid to prevent

corrosion/rusting due to long storage Openings of all the units
shall be appropriately blanked for air tightness.

14.02.12.03 Oil Lubrication circuit drawings for each tank unit, main pumping unit,
filter cooler unit, return line filter unit, pressure vessels, power unit to
individual consumers showing each components of respective unit i.e.
pressure gauge, pressure reducing station, pressure switch, etc. including
all interconnecting lines by means of approved graphical symbols with
parts list indication in BOM with complete specification, size, pressure
rating, material, model no., make, quantity etc. of each item.
14.01.12.04 General arrangement drawings for tank unit, main pumping unit, filter
cooler unit, return line filter unit and pressure vessels.
14.01.12.05 General arrangement drawings for the cellars.
14.01.12.06 Interconnecting piping drawing from cellar to consumer points.
14.03 GREASE LUBRICATION SYSTEM & INTERCONNECTING

PIPING
14.03.01 SCOPE
Number of Grease systems shall be decided by tenderer according to his

requirement, however, area wise grease systems shall be provided as
detailed out in this specification. Automatic centralized dual line grease
system shall be designed to provide proper lubrication to all the greasing
points. Motorized multiline grease system can also be used if number of
points is less. Manual (portable) grease gun with suitable fitting to suit
grease nipple shall be provided for all grease points which are not being
greased by Centralized grease system / Motorized multiline grease
system.

& consumables, erection & commissioning of all equipment of grease
14.03.02 TECHNICAL REQUIREMENT
14.03.02.01 This specification covers the grease systems required for various units.
This includes all types of grease lubrication systems including
interconnecting piping, electrical control panel and components of
centralized grease systems for indicating, recording & integration of
various parameters such as pressure, temperature, flow, etc; control
devices for manual and automatic operation of the systems; safety devices
and alarms for abnormal operating conditions; interlocks for sequencing
and safe operation.
14.03.02.02 The selection, design and construction of the systems shall be suitable in
maximizing interchangeability of components and minimizing
irrespective of whether such items are specifically mentioned in the
Technical Specifications.
14.03.02.03 Details concerning each grease shall be furnished in the form of a chart,
indicating system reference, consuming point references, location of
system, type of grease, ISO viscosity grade, manufacturer’s code number
for grade of grease and quantity for first fill of system including
interconnecting piping. Wherever possible, equivalents with due regard to
local availability shall be mentioned.
14.03.03 BASIS OF DESIGN
14.03.03.01 The design shall ensure that the components of the grease systems are
compatible with the grease selected and suitable for long trouble free life
at the operating conditions in the plant and under climatic conditions
prevalent at site. In selecting the grease, the operating temperature of
system shall be given careful consideration; grease penetration numbers
shall always be related to operating temperature.
14.03.03.02 Sealing Devices
14.03.03.02.01 Material of all sealing devices shall be compatible to the grease.

Wherever possible, sealing devices shall be of the pressure sealing type.
14.03.03.02.02 Sealing devices shall be suitable for system operating temperature and
pressure.
14.03.03.03 Over-pressure protection
14.03.03.03.01 Suitable relief valve shall be provided on the discharge side of all positive
displacement pumps and over-pressure protection shall be provided else-
where in circuits where damage to the equipment or hazards to personnel
may result if design pressures are exceeded. Check valves shall be
provided on the discharge side of all pumps to prevent any back flow.

14.03.03.03.02 End pressure relay for both the line of dual line system shall be provided.
These shall serve the need of over-pressure protection as well as for line
changeover by operation of motorized change over valve of ahead of
pump on main line.
14.03.03.04 Fault Alarms
14.03.03.04.01 Audio-visual alarms shall be provided in the local control panel for each
grease system for the following faults:
a) Low pressure in the system.

b) High level of fluid in reservoir and stoppage of pneumatic
operated grease filling pump.
c) Low level of grease in reservoir.
d) Low-Low level of grease in reservoir and main pump cut-off.
e) Motor overload.
14.03.03.04.02 For any of the above faults, necessary audio-visual alarms shall be
provided in the control room/control pulpit for “FAULT IN GREASE
SYSTEM”.
14.03.04 DUAL LINE CENTRALISED GREASE LUBRICATION SYSTEM
14.03.04.01 General
14.03.04.01.01 Automatic Dual Line Centralized Grease Lubrication System shall be

used for lubricating large number of bearing points in a large machine or
group of machines requiring frequent supply of grease for long and
uninterrupted operation.
14.03.04.01.02 An automatic dual line centralized grease lubrication system shall

incorporate grease reservoir of adequate capacity with motorized plunger
type grease pump & motor, stand-by pump with motor, check valves,
relief valves, pressure gauge, pressure switch, grease filters, isolation
valves with limit switches on discharge lines & tank return lines between
pumps and changeover valve, motorized reversing valve, lubrication dose
feeders (metering feeders), end-of-line pressure switches with pressure
gauges, high pressure dual line pipes complete with end fittings for
connection to lubrication points, manifold blocks, grease filling pump
with lifting device for automatic filling of reservoirs, solenoid valves on
grease filling lines, instruments, solenoid valves on grease filling lines,
instruments and controls, suitably designed dust and moisture proof
control panel.
Separate grease systems shall be provided area wise. Further, hot zone
and cold zone shall also have separate grease system.
14.03.04.02 Details of Items for Centralized Grease Lubrication System
14.03.04.02.01 Reservoir for Centralized Grease Lubrication System.
14.03.04.02.02 Each grease lubrication system shall have 1 no. of reservoir having
capacity of 100 ltrs or capable of catering atleast 15 days of requirement
of grease circuit served as per designed greasing cycle.

14.03.04.02.03 It shall be made from general purpose structural steel fitted with
accessories to achieve.
14.03.04.02.04 The reservoir shall be complete with a heavy inertia follower plate to
pump suction, tell-tale rod for indication of grease content, filling
connection with strainers and reservoir cover. Tell-tale rod shall be
equipped with electrical contact limit switches for audio-visual alarms for
low level, low-low level & high level. At low level of the reservoir the
grease filling pump shall start automatically and at high level of the
reservoir the grease filling pump shall stop automatically. At low-low
level of the reservoir the main grease pump shall stop automatically.
14.03.04.02.05 One (1) no. of pneumatic operated grease pump at each location / grease
lubrication system for filling grease reservoir shall be provided.
Pneumatic operated grease pump shall have facility of pneumatic hoist for
locating grease pump over grease barrel. Necessary accessories air
maintenance unit hose, pressure gauge, strainers, valves, etc. shall also be
provided.
14.03.04.03 Pumps for Grease Lubrication System
14.03.04.03.01 Pumps for grease lubrication system shall be of adequate pressure rating
to overcome the tremendous pressure drop in pipelines and in metering
feeders and to introduce grease in bearing through restriction. Suitable
check valve and relief valve shall be provided with the pump to protect
the internal parts from being damaged. Internal operating parts shall be
well lubricated to ensure smooth operation.
14.03.04.03.02 Grease pumps shall be positive displacement plunger type with robust
construction consistent with high pressure service. Care shall be taken
while selecting the pressure rating of the pump for high pressure loss
through pipes and fittings, particularly in case of long piping.
14.03.04.03.03 The grease reservoir shall be mounted on top of the pump for efficient
pumping.
14.03.04.03.04 Main grease pumps shall be driven by electric motors for automatic
systems. Grease filling pumps shall be pneumatically driven with dry
compressed air, the actuating mechanism shall operate successfully with
the dry air pressure of 4 bar. Adequate rating and length of hose shall be
provided at inlet & outlet of pneumatic operated barrel pump.
14.03.04.03.05 For each centralized grease lubrication system shall have one (1) motor
driven operating main pump to meet the system requirement and one (1)
identical motor driven additional main pump shall be provided as a stand-
by unit. Stand-by unit shall be permanently piped to the system.
Instruments and controls shall indicate the need for starting the stand-by
pump in the event of failure of working main pump. The stand-by main
pump unit shall be provided with electrical junction box and shall be pre-
wired upto junction box. Each grease system shall be provided with a
PLC based electrical control panel.
14.03.04.04 Filters / Strainers for Grease Lubrication Systems

14.03.04.04.01 Filters used in grease lubrication system shall be of line mounted type.
The filter element shall be so located that dismantling of filter is not
necessary while taking out the element for cleaning. Body of filter shall
be ‘Y’ type made from steel bar stock to withstand high pressure duty.
Filter element shall be of stainless steel and of 250 micron fineness
(approx.).
14.03.04.04.02 Necessary filters shall be provided in the reservoir filling port to filter the
grease during filling. The filter element shall be easily removable for
cleaning.
14.03.05 PIPEWORK AND HOSE ASSEMBLIES
14.03.05.01 The main headers and sub-headers for grease lubrication systems shall be
of carbon steel with carbon steel fittings. The feed pipes from metering
feeders to lubrication points shall be of stainless steel with carbon steel
cadmium plated fittings. The headers and sub-headers in wet area shall be
of stainless steel with stainless steel fittings.
14.03.05.02 For Grease System, the main dual-line headers shall be Carbon steel &
for wet area it shall be Stainless steel of 30 mm OD x 5 mm thk or 25 mm
OD x 4 mm thk or 20 mm OD x 3 mm thk depending on the length of
main headers.The sub-headers shall be Carbon steel & for wet area it
shall be Stainless steel of 20 mm OD x 3 mm thk or 16 mm OD x 2.5 mm
thk or 10 mm OD x 1.5 mm thk depending on the length of main sub-
headers. The feed lines from metering feeders to lubrication points shall
be 10 mm OD x 1.5 mm thk of stainless steel.
14.03.05.03 For hose, the bursting pressure shall be atleast 3 times the maximum
working pressure of the system. Pipe work and hoses shall be suitable for
operating temperature from + 10°C to + 90°C. All the hoses in hot area
shall be with stainless steel braided cover and silica cloth cover.
14.03.05.04.01 Carbon Steel(Main header except for wet area)
I. All tube sizes, as mentioned in schematic drawing, shall be of following

specification.
- Seamless tubes to DIN 2391

Part – 2, 1994 and 37.4 NBK
to DIN 1630 – 1984
III. Fittings shall be of following specification:
- Welding nipple with ‘O’ ring CS to

14C14S14 of IS: 1570 (Part III)-1979
14.03.05.04.02 Stainless Steel
I. All tube sizes, as mentioned in schematic drawing, shall be of following

specification in wet area & for dose feeders to feed points.

- Seamless tubes to DIN 17458-1995

with material no. 1.4541 an condition-h
and dimension as per DIN 2462, part – I -1981
II. Fittings shall be of following specification:
- Welding nipple with ‘O’ ring DIN

17440-1985 with material no. 1.4541
III. Hoses at consumer point ahead of dose feeder shall be of atleast 500 mm
length & rating shall be SAE 100R 2/9/11 as per requirement and shall be
complete with female swivel BSP crimp end fittings.
IV. Butt weld pipe joints below 38 mm OD shall be full TIG welded and root
run for pipe above 38 mm OD shall be TIG welded. SS pipes shall be full
TIG welded using Argon.
V. After fabrication, all pipes to be cleaned, degreased, pickled, neutralized,

rinsed and oiled. Tubes shall be first cleaned, pickled, etc. and then
assembled.
VI. All pipelines shall be clamped with heavy series polypropylene clamps.
For hot area, aluminium type clamps shall be used.
14.03.06 INITIAL FILL / CONSUMABLES
Scope of supply shall include First fill of grease in required quantity upto
successful commissioning & PG (as defined in Contract), i.e., after
commissioning all the system tanks and piping shall be full.
Quantity of flushing oil shall be sufficient to make the system ready for
commissioning.
14.03.07.01 All grease systems / components shall be inspected and tested at the
manufacturer’s premises by the Purchaser / Consultant as per approved
QAP by Consultant.
Performance tests for Grease systems / equipment shall be carried out at

site along with the operation of the main equipment to which the grease
system shall be connected, to check various parameters like flow,
pressure, etc. as per schematic.
14.03.08 ASSEMBLY, ERECTION, TESTING AND COMMISSIONING
internally, as mentioned in the equipment tenderer’s manuals for erection
and maintenance.
14.03.08.02 Grease pipework shall be assembled, tested, pickled, flushed and

commissioned as per tenderer’s piping instructions.


with grease system shall conform to General Technical Specification and
electrical chapter of this TS.
14.03.09 PAINTING
All components of the grease system and interconnecting piping shall be

painted as per Painting Specification GS – 09 (GTS).
14.03.10 SPARES
Adequate nos. of ‘O’ ring, seal kit for dose feeders & grease components,
‘O’ ring for fittings used, solenoid coils, plug-in connectors and hoses
shall also be included in commissioning spares to take care till successful


furnished.

14.03.11.03 Grease circuit drawings for each system showing tank unit, main pumping
units, relief valve, pressure gauge, motorized change-over valve, isolation
valve, solenoid valve for filling of grease and pneumatic barrel pump &
air maintenance unit including all interconnecting lines by means of
standard graphical symbols with parts list indication in BOM with
complete specification, size, pressure rating, material, model no., make,
quantity etc. of each item.
14.03.11.04 General arrangement drawings for main pumping unit and pneumatic
operated barrel transfer pump.
14.03.11.05 General arrangement drawings for the hydraulic / lubrication rooms where
grease system is located.
14.03.11.06 Interconnecting piping drawing for grease from hydraulic / lubrication

room (Where grease system is located) to dose feeders and finally upto
consumer points.

14.04 PNEUMATIC SYSTEMS & INTERCONNECTING PIPING
Pneumatic systems shall cover compressed air & instrument air.
Instrument air shall only be used for operation of pneumatic cylinders &
air motors. Compressed air shall be used for process requirement and
service care purpose.
The Pneumatic systems will be complete with all equipment pipework,
electrics, instrumentation and controls as required and as specified.
14.04.01 SCOPE
Scope of work shall include supply of equipment, piping, initial fill &
consumables, commissioning spares & 2-years spares and erection &
commissioning as detailed out below.
Equipment shall comprise of all pneumatic valve stands / valve panels

with necessary components for the actuation of pneumatic cylinders,
pneumatic motors and actuators.
Supply of pneumatic cylinders, pneumatic motors and actuators will be

made as per the requirement. It will cover supply of interconnecting
piping between take-over points near building column to pneumatic valve
stand / valve panels and piping between pneumatic valve stands / valve
panels to pneumatic cylinders / motors / actuators.
Supply of adequately sized pressure vessel with necessary pneumatic
control & accessories for emergency actuation of air motor / pneumatic
cylinder, if process demands.
For mobile machines where compressed air is not available air

compressors, air receivers with accessories shall be supplied for normal
operations as well as for emergency operation as per process requirement.
Supply of anodized circuit plates for each pneumatic valve stand.
Supply of Isolation valve for pipelines for pneumatic system at TOP shall
be provided.
Supply of Vortex Flowmeter, pressure transmitter & temperature

transmitter shall be provided for pipelines for pneumatic system at TOP.
Signal from vortex Flowmeter, pressure transmitter & temperature
transmitter shall be made available at PLC. Necessary software shall also
be provided at PLC for measuring actual flow based on pressure and
temperature corrections.
Supply of Pressure gauge and temperature gauge shall be provided on all

main branch lines to various consumers for all types of pneumatic
systems.
& consumables, erection & commissioning of all equipment of pneumatic

The pneumatic systems will be provided complete with isolation valves,

air receivers, air line filter of 5 micron fineness, regulator with pressure
gauge, lubricator, solenoid operated directional control valves, speed
control valves, silencers, pressure gauge, pressure switch, controls,
pneumatic cylinders / actuators, pneumatic motors, interconnecting piping
between take-over points near building column to pneumatic valve stand /
valve panels and piping between pneumatic valve stands / valve panels to
pneumatic cylinders / motors / actuators, interlocks and audio-visual
alarms for fault indication. Instrument quality air will be used for the
actuation of pneumatic cylinders and pneumatic motor.
Anodized circuit plates will be provided with pneumatic valve stands /

valve panels. The pneumatic valve stands / valve panels will be provided
with electrical junction boxes and will be pre-wired upto electrical
junction box.
Design velocity for compressed air and instrument air shall be in the
range of 8-10 m/sec.
All pneumatic components shall be designed to work at 4 bar pressure.
14.04.03 GENERAL INSTRUCTIONS
a) Use of fittings shall be avoided until unless if required for

maintenance.
b) A compressor (one working and one standby) generates the

compressed air required on mobile equipment. A compressed air
receiver is installed to meet peak demands and to ensure
availability of air under pressure for emergency operation of
actuator/motor at design pressure.
c) Lay out of Pneumatic pipelines on the equipment and

interconnecting piping shall be such that these are easily
accessible for maintenance and also that these don’t pose any
problem in operation and maintenance of other equipment
installed on these machines.
Suitable grade of stainless / carbon steel pipes, tubes & fittings

will be used in the pneumatic circuits of equipment.
The inlet air filters of the compressor will be suitable for

operation in the dusty atmosphere, if applicable. Compressor used
on mobile unit will be of two stage air cooled type. Suitable non-
return valve will be provided for each compressor / air receiver
for isolation (Whenever more than one compressor / receiver
would be installed in parallel). Each compressor will be provided
with suitable unloading device (relief valve) as well as all
standard accessories and safety application such as belt tensioning
arrangement, low oil level switch, inter-cooler, safety valve, vee
belt guard, etc. Suitable safety valve will also be provided at the
in-let side of each isolation valve provided at the compressor
discharge line.

Supply of first fill of crank case oil shall be under tenderer’s

scope. Tenderer shall provide complete specification and quantity
of crank case oil.
d) The design, construction, material specification & testing of the
air receivers will conform to the relevant IS/ASME codes. Each
receiver will be provided with safety relief valve, pressure gauge,
manhole, drain pipe & cock etc. of adequate size & ratings. A
metal plate indicating the designed pressure rating, date of
hydraulic pressure testing carried out to the receiver and other
particulars as governed by the statutory rules must be affixed to
each receiver. A three (3) – way cock will be provided between
the receiver and its pressure gauges.
e) All the flanges used in the Pneumatic circuits will be of adequate

rating as per ASTM / DIN.
f) All the isolation and non-return valves used in the Pneumatic

circuits shall be of forged steel / cast steel construction. Pressure
reducing valves and strainer will be provided in the Pneumatic
circuits whenever required.
g) Tenderer will submit pneumatic schematic drgs. showing all

pneumatic components(compressor ,receiver ,etc) and control
circuit for consumers (isolation valve, solenoid operated valve,
speed control, air cylinder/air motor, etc.)
h) QAP of complete pneumatic package will be mutually discussed

and finalized after award of order.
i) Lay out of Pneumatic pipelines on the equipment will be such that

these are easily accessible for maintenance and also that these
don’t pose
Any problem in operation and maintenance of other equipment

installed on these machines.
Suitable grade of stainless steel pipes / tubes & fittings shall be

used for piping shall be used instrument air circuits. Carbon steel
pipes / tubes & fittings shall be used for piping for compressed air
circuits.
j) The design, construction, material specification & testing of the

receivers will conform to the relevant IS/ASME codes for such
pressure vessels. Each receiver will be provided with safety relief
valve, pressure gauge, manhole, drain pipe & cock etc. of
adequate size & ratings. A metal plate indicating the designed
pressure rating, date of hydraulic pressure testing carried out to
the receiver and other particulars as governed by the statutory
rules must be affixed to each receiver. A three (3) – way cock will
be provided between the receiver and its pressure gauges.
k) All the flanges used in the Pneumatic circuits will be of adequate

rating as per DIN / ASTM.

l) All the isolation and non-return valves used in the Pneumatic

circuits shall be of forged steel / cast steel construction. Pressure
reducing valves and strainer will be provided in the Pneumatic
circuits whenever required.
m) Tenderer will submit pneumatic schematic drgs. showing control

circuits and Bill of Material for all components used i.e. isolation
valve, solenoid operated valve, speed control, air cylinder / air
motor, etc.
n) QAP of complete pneumatic package will be mutually discussed

and finalized after order is awarded.
14.04.04 PIPE & FITTINGS
All pipes and fittings used in the pneumatic system shall conform to DIN
/ ASTM as mentioned below.
Design velocity for pneumatic systems shall be 8-10 m/sec.
14.04.04.01 Pipe & Fittings
14.04.04.01.01 Carbon Steel (For compressed air line)


DIN 1630 – 1984
b) Above 38 mm OD size - Seamless schedule 40 black pipe

of ASTM – A106 Gr. B – 94 and
Dim as per ANSI B 36.10 – 1995
a) Pipes upto 38 mm OD size - Welding nipple with ‘O’ ring CS

to 14C14S14 of IS: 1570 (Part
III)-1979
i) Upto 50 NB - Socket weld fittings of 3000 #

1991

234 WPB – 1994 AND Dim. As
per ANSI B 16.9 -1993 of
schedule same as per that of pipe

III. Flanges should be of - Slip-on flanges of ASA 150

following specification class for
return and drain. ASTM – A –
105 - 94. Dim. as per ANSI – B -
16.5 - 1988.


and above 50 NB – with flanged (ASA 150 class) ends shall be used. At
battery limit (TOP) of individual unit i.e. caster, mill, blast furnace, etc.
from compressor room shall be also ball valve. In case size of valve is
more than 125 NB gear type ball valve shall be used.
14.04.04.01.02 Stainless Steel (For instrument air line)

a) Up to 38 OD - Seamless tubes to DIN 17458-

and condition-h and dim. as per
DIN 2462, part –I-1981
b) Above 38 mm OD size - Seamless schedule 40 pipe as

per ASTM – A-312-TP304-1995
and dim. as per ANSI-B-36.19-
1985

DIN 17440 - 1985 with material
no. 1.4541.

3000/6000# rating to ASTM – A
– 182 - F304 - 1996 and
Dimension as per ANSI B 16.11
– 1991.
ii) Above 50 NB - Butt weld fittings of ASTM – A

– 403 - WP304 - 1996 and
Dimension to ANSI - B - 16.9 -
1993 of schedule same as that of
pipe.

a) For all pipe sizes - Slip-on raised face flanges of

ASA 150 class for return and
drain. SS-304. Dimension as per
ANSI-B-16.5-1988
b) Applicable in narrow space - SAE 4 bolt socket weld type of

3000# rating with O-rings in low
/ medium pressure line, SS-304.
For slip-on flange raised face flange SS hexagonal head screw &
hexagonal nuts and for SAE flange SS hexagonal head screw &
hexagonal nuts shall be used.
and above 50 NB – with flanged (ASA 150 class) ends. At battery limit
(TOP) of individual unit i.e. caster, mill, blast furnace, etc. from
compressor room shall be also ball valve. In case size of valve is more
than 125 NB gear type ball valve shall be used.
14.04.04.02 Pipe Support
All pipelines shall be clamped with heavy series polypropylene clamps.

For hot area, aluminium type clamps shall be used.
For pipe size above 250 NB steel pipe clamps shall be used.
14.04.05 INITIAL FILL & CONSUMABLES
Scope of supply shall include First fill of oil in required quantity upto
successful commissioning & PG (as defined in Contract), i.e., after
commissioning all the pneumatic system.
14.04.06.01 All pneumatic systems / components shall be inspected and tested at the
manufacturer’s premises by the Purchaser / Consultant as per approved
QAP by Consultant.
Performance tests for pneumatic systems shall be carried out at site along
with the operation of the main equipment to which the pneumatic system
shall be connected.
14.04.07 ASSEMBLY, ERECTION, TESTING AND COMMISSIONING
internally, as mentioned in the equipment tenderer’s manuals for erection
and maintenance.
14.04.07.02 Pneumatic pipework shall be assembled, tested, flushed and

commissioned as per tenderer’s piping instructions.


with pneumatic system shall conform to General Technical Specification
and electrical chapter of this TS.
14.04.08 PAINTING
All components of the pneumatic system and interconnecting piping shall

be painted as per Painting Specification GS – 09 (GTS).
14.04.09 SPARES
Adequate nos. of ‘O’ ring, seal kit for pneumatic components, ‘O’ ring for
fittings used, solenoid coils, plug-in connectors and hoses shall also be
included in commissioning spares to take care till successful


furnished.

14.04.10.03 Pneumatic circuit drawings for each system showing pneumatic valve
panel, individual mounted pneumatic components to pneumatic cylinders
/ air motors. Air maintenance unit (FRL) shall also be included in circuit.
Atleast 5 micron filter shall be used in FRL. Wherever required
coalescence type filter shall be used as demanded by process. Pneumatic
circuit drgs. shall also include all interconnecting lines by means of
standard graphical symbols with parts list indication in BOM with
complete specification, size, pressure rating, material, model no., make,
quantity etc. of each item.
14.04.10.04 General arrangement drawings for main pumping unit and pneumatic
operated barrel transfer pump.
14.04.10.05 General arrangement drawings for the hydraulic / lubrication rooms where
grease system is located.
14.04.10.06 Interconnecting piping drawing for grease from hydraulic / lubrication

room (Where grease system is located) to dose feeders and finally upto
consumer points.

14.05 WATER PIPEWORK FROM BATTERY LIMIT (TOP) TO

INDIVIDUAL UNIT I.E. CASTER, MILL, BLAST FURNACE,
ETC. FROM PUMP HOUSE
14.05.01 GENERAL
Water pipework shall consist of complete water piping from battery limit
(TOP) to individual unit i.e. caster, mill, blast furnace, etc. from pump
house which shall generally be of following categories:
i) Contact Water
ii) Non-Contact Water
iii) Emergency Water
iv) Drinking Water
v) Chilled Water
14.05.01.01 A by-pass line with necessary flow and pressure control shall be provided
to maintain water flow balance on the contact water system.
14.05.01.02 Manual drain valve at low points and manual vent valves at all high
points of pipework shall be provided. Adequate size of vent and drain
valve shall be provided based on line size.
14.05.01.03 All valves located remotely and requiring frequent operations shall have
automatic ON / OFF control.
14.05.02 SCOPE
Scope of work shall include supply of piping, fittings, valves, instruments,

equipment i.e. backwash filter, etc. and erection and commissioning
alongwith mechanical equipment.
Supply of commissioning spares as applicable shall be included in

Tenderer’s scope and list shall be submitted. Any items required for
commissioning but not listed shall also be supplied if required, at no cost
implication to customer. A list of 2-years spares based on tenderer’s past
experience shall also be furnished.
14.05.02.01 Isolation valve for all types of water at TOP shall be provided.
14.05.02.02 Flow transmitter and pressure transmitter shall be provided for all types of
water at TOP. Signal from flow transmitter and pressure transmitter shall
be made available at PLC.
14.05.02.03 Temperature transmitter shall be provided on both lines of chilled water

and non-contact water at TOP. Signal from Temperature transmitter shall
be made available at PLC.
14.05.02.04 Pressure gauge and temperature gauge shall be provided on all main
branch lines to various consumers for all types of water.
14.05.03 PIPE & FITTINGS

All pipes and fittings used in the water pipework shall conform to DIN /
ASTM as mentioned below. Generally carbon steel pipes shall be used for
dry area whereas stainless steel pipes shall be used for wet area.
Design velocity for water shall be 2 m/sec.
14.05.03.01 Pipe & Fittings
14.05.03.01.01 Carbon Steel


DIN 1630 – 1984
b) Above 38 mm OD size - Seamless schedule 40 black

to 150 NB pipe of ASTM – A106 Gr. B –
94 and Dim as per ANSI B
36.10 – 1995 & DIN 2448 / 169
c) 200 NB to 450 NB - DIN 2458 / 1626 & API 5 L, Gr.

B ERW
d) 500 NB & above - DIN 2458 / 1626 & spiral weld

pipe of Rourkela commercial
quality.
A) Bends
a) Pipes 50 NB & below - Cold bend with radius 3DN &
Socket weld fittings of 3000 #
1991
b) 65 to 150 NB - Seamless butt weld elbow to
ASTM A 234, Gr. WPB
Schedule 40, Dimensions to
ANSI B16.9 & DIN 2605-1 /
2609
c) 200 NB & above - Mitred bend with radius 1.5DN
B) Reducers
a) Pipes 80 NB & below - Seamless butt weld / socket weld
forged to ASTM A-234, Gr.
WPB and Schedule 40,
Dimension to as per ANSI B
16.9 / 16.11 and DIN 2616 /
2609

b) Above 80 NB - Fabricated from pipes / plates

C) Tees
For all sizes - Seamless and fabricated from

pipes / plates
III. Flanges for all sizes - Slip-on raised flanges of ASA
150 following specification.
ASTM – A – 105 - 94.
Dimension as per ANSI – B -
16.5 – 1988 and DIN 2633 / DIN
2632 and dimension as per DIN
2519
Upto 50NB - Ball valves (150 class) with SS

internals– socket weld type.
Above 50 NB to 150 NB - Ball valves (150 class) with SS
internals with flanged (ASA 150
class) ends. In case size of valve
is more than 125 NB gear type
ball valve shall be used.
200 NB & above - Cast steel gate valve as per API
600, flanged end as per ANSI
B16.5, valve of sizes DN 350 and
above shall be provided with gear
mechanism.
14.04.04.01.02 Stainless Steel (For wet area)

a) Up to 38 OD - Seamless tubes to DIN 17458 -
and condition - h and dimension
as per DIN 2462, part –I-1981
b) Above 38 mm OD size - Seamless schedule 40 pipe as
per ASTM – A – 312 - TP304 -
1995 and dimension as per
ANSI-B-36.19-1985

DIN 17440 - 1985 with material
no. 1.4541.


3000/6000# rating to ASTM – A
– 182 - F304 - 1996 and
Dimension as per ANSI B 16.11
– 1991.
ii) Above 50 NB - Butt weld fittings of ASTM – A
– 403 - WP304 - 1996 and
Dimension to ANSI - B - 16.9 -
1993 of schedule same as that of
pipe.
a) For all pipe sizes - Slip-on raised face flanges of

ASA 150 class for return and
drain. SS-304. Dimension as per
ANSI-B-16.5-1988
b) Applicable in narrow space - SAE 4 bolt socket weld type of
3000# rating with O-rings in low
/ medium pressure line, SS-304.
For slip-on flange raised face flange SS hexagonal head screw &
hexagonal nuts and for SAE flange SS hexagonal head screw &
hexagonal nuts shall be used.
Upto 50 NB - Ball valves (150 class) with SS

internals– socket weld type.
Above 50 NB to 200 NB - Ball valves (150 class) with SS
internals with flanged (ASA 150
class) ends. In case size of valve
is more than 125 NB gear type
ball valve shall be used.
250 NB & above - CS gate valve as per API 600,
flanged end as per ANSI B 16.5.
Above 350 NB shall be provided
with gear mechanism.
14.04.04.02 Pipe Support
All pipelines shall be clamped with U-Bolts. For hot area, aluminium type
clamps shall be used.
For pipe size above 600 NB steel pipe saddle shall be used.
14.06 ABBREVIATION
NTM- No Twist Mil

VVVF- Variable Voltage Variable Frequency.

NMDC LIMITED

FOR
STORAGE & ERECTION OF EQUIPMENT
(GS – 15)
MECON LIMITED
RANCHI - 834002

Sl. Description Page No.

No.
01. Scope of Work 2-9
02 List Of Tools & Tackles 10
03 Cold Trial, Preliminary Acceptance Test, 11

Commissioning & Final Acceptance Test
04 Weight Schedule 11
05 Time Schedule 11
06 Resource Plan 11
07 Obligation Of The Purchaser 12-13
08 List Of Exclusions From Contractor’s Scope Of Work 13

And Services
Chapter-15 Erection Page 1 of 13

© 2010 MECON Limited All rights reserved.
1.0.0 SCOPE OF WORK

The scope of work of the Contractor shall include complete erection
services covering unloading, receiving of materials, storage, store
management, transportation to site and subsequent handling at site,
preservation, erection / installation, testing, start-up, commissioning and
performance tests of all plant and equipment supplied by the Contractor
as well as those that may be procured from / fabricated by agencies based
on the Contractor’s drawings, specification and bill of materials.
ERECTION METHODOLOGY
The Contractor shall select and adopt methods and procedures for
equipment erection to suit the nature of equipment and erection work
involved according to his experience in such works.
The Contractor shall closely co-ordinate and co-operate with all other
contractors working at site simultaneously during erection, testing, start-
up and commissioning.
The Contractor shall keep equipment, structures and materials adequately
braced by guys, struts or other approved means which shall be supplied,
and installed by the Contractor as required till the erection work is
satisfactorily completed.
Contractor shall supply safety helmets, gloves, safety shoes, welding
helmet, goggles, safety belts, aprons etc to the workmen as per safety
requirement at site.
1.1.0 STORE CONSTRUCTION
The stores are to be constructed and maintained by the Contractor until
the plant is commissioned and handed over to the Purchaser. The area of
the store shall be decided based on actual site requirement. The plain
land shall be provided by the Purchaser.
1.1.1 Covered Store
All four walls will be brick walls with cement lining. Wall thickness will
be approx. 9-12 inch. A metal door and windows will be provided. The
floor will be leveled and made out of stone boulders and cement plastered
wherever necessary. The roof will be covered by Tin Sheet using pipes to
support the roof with adequate material handling equipment and overhead
truss to move the material within store and to unload in and unload from
store. The store can be of any other construction best suited for proper
storage and protection of equipment. The size and other details of the
store shall be suitably decided.
Some of the material requires Air Conditioned storage. The contractor
shall construct covered air conditioned stores, if required depending on
the nature of storage of equipment. The specification of store shall be
same as above with Air conditioning arrangement.
The drawing for covered stores shall be prepared by the contractor and
the same shall be approved by NMDC/consultant. Construction of stores
shall be as per the approved drawings.

The lighting inside and outside the stores shall be under the scope of
contractor including supply of all the lighting materials.
The contractor shall provide and maintain computers and printers to
maintain the store management records.
1.1.2 Open Area
An open area as per requirement shall be used at suitable location to store
the equipment. This area will be roughly leveled and fenced with barbed
wire and poles with a gate. The equipment will be stored on floor on
sleepers and covered with plastic/tarpaulin sheets.
1.2.0 MATERIAL RECEIPTS, STORAGE & HANDLING
1.2.1 Receipt and unloading of all material including spares for mechanical &
auxiliary equipment & System from stores and any other material
received from equipment supplier, maintaining proper documents of the
items received, handling etc. from the start date until all the material is
erected & commissioned and handed over to the Purchaser is the
responsibility of the Contractor.
1.2.2 The material received from the supplier shall be checked and verified by
the Contractor for completeness of supply as per packing list. An
Equipment Inspection & Verification Report (EIVR) shall be prepared by
the Contractor to report any damage/missing items. Opening of crates and
packing cases, thorough cleaning and checking of equipment etc. in
relation to manufacturers drawings/packing lists and inspect for any
visible damage or defect. Damaged/missing items, if any shall be brought
to the notice of Purchaser.
1.2.3 Any special equipment, which needs air-conditioned storage, shall be
kept in air-conditioned store.
1.2.4 The Contractor shall lodge insurance claim for material / packages
received in damaged condition.
1.2.5 The Contractor shall remove any material from the stores only against
written authorisation. Certain specified performa shall be used for this
purpose.
1.2.6 The Contractor shall also securely pack and forward to the transporter;
certain items which may have to be delivered to the other agencies for
repair/assembly work. For the above said packing, Contractor can use
free of charge cartoons, packing wood, which shall be available at site
due to unpacking of equipment for erection work.
1.2.7 The Contractor shall hand over left over items/commissioning spares to
the stores of the Purchaser against delivery challans.
1.2.8 The Contractor shall maintain proper records of the material transported
and stored by him after receipt from the stores.
1.3.0 STORING OF EQUIPMENT

The equipment shall be stored in closed or semi-closed type stores

according to the protection needed for different types of equipment and
parts. Microprocessor based instruments, analytical balance etc, which
need temperature and humidity controlled storage shall be stored in AC
stores.
1.3.1 Insulation Materials
All insulation materials shall be carefully handled to prevent damage and
shall be protected from moisture. High, medium, low temperature
insulation materials shall be stacked in suitably identifiable units.
1.3.2 Pipes
All pipes shall be carefully unloaded. Ends of all pipes and the openings
of all flanges and nozzles attached to drums, tanks or equipment while in
storage shall be greased, capped, plugged or blank flanged.
1.3.3 The Contractor shall check that valves and fittings are not subject to
corrosion from hydrostatic test liquid remaining saturated in the
packings.
Packing rings, gaskets, flanges, bolts and nuts etc shall be suitably
stacked in racks with marking.
1.3.4 Structural Fabricated Materials
All structural fabricated members shall be stacked in the sequence in
which they are required for erection. All members shall be stacked free
from ground to prevent corrosion and shall be so stacked as not to cause
deformation in any individual member.
1.3.5 For the laboratory equipment and other instruments, which are highly
sophisticated and delicate in nature, extra precautions shall be taken
while handling to prevent accidental failure during loading and unloading
operations. Special care shall be taken during transportation of these to
avoid damage to the equipment due to vibration.
1.3.6 Laboratory equipment, control instrument panels, switchgears, motors,
instruments, control devices, other electrical equipment and accessories
shall be stored in a cool dry covered place. Particular care shall be taken
to prevent ingress of foreign matter, moisture or rodents, in such
equipment.
1.3.7 Welding Rods
Welding rods shall be stored in a hot dry place. During storage, welding
rods for different alloy materials and categories of work shall be stored
separately and identified for proper use.
1.3.8 Protection against Weather & Fire Hazards
The Contractor shall provide at his own cost any required sleepers or
concrete or wooden blocks for supports and tarpaulins for protecting the
equipment etc against inclement weather during installation.

The contractor shall also ensure storage in such a way that it is free from
fire hazards. However, fire fighting equipment like fire buckets, dry
chemical cylinders etc to be kept in sufficient numbers for any
eventualities.
1.4.0 TRANSPORTATION
1.4.1 The Contractor shall provide necessary fixtures, fasteners and other
safety measures to ensure safe transportation of materials from store to
erection site.
1.4.2 The Contractor shall be responsible for arrangement of adequate material
handling equipment like trucks, trailers, forklifts, mobile cranes, tools
and tackles as required for his work.
1.4.3 The necessary lifting tackles, tools, wire ropes, slings of suitable
capacities and other equipment necessary to carry out the work shall be
arranged by the Contractor. All such lifting tackles should have valid test
certificates.
1.4.4 All equipment and rigging shall be examined and checked by Contractor
at frequent intervals to prevent accidental failure and consequent damage
to the equipment, structures and materials to be installed.
1.5.0 CIVIL FOUNDATIONS
1.5.1 The equipment shall be installed on civil foundations. All pits, pockets
and sumps shall be thoroughly cleaned by the Contractor. The foundation
bases shall be cleaned by water and compressed air to expose the surface.
The top of the concrete foundation shall be thoroughly cleaned by the
Contractor prior to placement of equipment on foundation. Concrete
surface shall be roughed up by chipping 5 to 10 mm deep uniformly and
the surface shall be washed & cleaned with water.
1.5.2 The Contractor shall provide benchmarks at 10 to 12 locations in
longitudinal & traverse axis inside the bay wherever necessary for the
purpose of checking the foundations.
1.5.3 The Contractor shall establish necessary benchmarks and sub-center lines
required for the purpose of erection of individual equipment.
1.5.4 The Contractor shall also establish permanent center lines and bench
marks at convenient location for future reference of the plant personnel.
1.5.5 The Contractor shall check rough concrete levels, foundation bolt hole
locations and levels and pockets for all equipment foundations based on
civil drawings before start of erection.
1.5.6 If any discrepancy is noticed in the dimensions, center lines, levels,
locations etc of the foundation or anchor bolts or pockets, the same shall
be rectified by the contractor.
1.5.7 Minor cutting, chipping, cutting of few reinforcement rods if required
and deepening of foundation/pocket up to 50 mm to eliminate any minor
interference of the equipment with their respective foundations etc shall
be carried out by the Contractor.
1.5.8 Any embedded steel inserts necessary for pipe supports, if not fully
exposed, shall be exposed by the Contractor by a depth of maximum
25mm enabling him to weld the pipe supports.
Contractor should provide any missing/additional steel inserts if
necessary.
1.5.9 The concrete surface shall be cleaned from all foreign particles and
degreased before grouting of the equipment.
1.5.10 The Contractor will do dressing and micro chipping of foundations as

well as cleaning of top concrete foundation with air and water prior to
placement of equipment/grouting.
1.6.0 TEMPORARY INSTALLATIONS
1.6.1 The contractor shall provide all temporary ladders, scaffolding materials,
platforms, supports and other necessary facilities required for handling,
erection shall be the responsibility of the Contractor.
1.6.2 The contractor shall arrange access at site required for the erection work
shall be the responsibility of the contractor.
1.6.3 The Purchaser shall provide one point for power and water. The
Contractor shall take responsibility of further extension (laying) as per
site requirement and maintenance of these points.
1.6.4 The contractor shall provide temporary lighting in the erection area.
1.7.0 MATERIAL HANDLING EQUIPMENT AND TOOLS & TACKLES

1.7.1 The Contractor shall mobilise adequate material handling equipment of
adequate capacity like mobile cranes, fork lifts, trailers, winches,
derricks, pulley blocks, slings etc in addition to other erection tools and
consumables.
1.7.2 The Contractor shall provide all necessary construction tools and tackles,
portable compressors, small hand tools, instruments, building equipment
etc required for erection work.
1.7.3 The Contractor shall furnish a tentative list of tools and tackles and other
erection material required for carrying out the erection and
commissioning of the plant.
1.7.4 The erection contractor shall make necessary arrangement for providing
mobile crane to ensure timely completion of erection work. The mobile
crane should be able to handle single link weight of 100 t or as required
considering maximum weight to be erected
1.8.0 CONSUMABLES & OTHER ERECTION MATERIALS
1.8.1 Contractor shall supply all required consumables and erection materials
including, but not limited to oxygen, acetylene gas, argon gas, solder
lugs, welding rods, oil, grease, kerosene, trichloroethylene, shim stocks,
tags, jointing compounds, gaskets, insulation materials, Prussian blue,
petrol, diesel, solvents, sealing compounds, bolts & nuts, rivets, piano
wires, wood blocks, spacers, templates, jute and cotton waste, cloth,
emery paper etc as required for the completion of the work according to
the contract. All materials used in connection with erection work shall
comply with appropriate Standards
1.8.2 The Contractor shall supply all erection materials including packing
plates, machined taper wedges, shims etc. The materials required for the
fabrication/machining of these plates shall also be supplied by the
Contractor.
1.8.3 Painting - the Contractor shall arrange for touch up painting. The paint
shall be specified by the Purchaser and supplied by the Contractor.
1.8.4 Permanite gaskets of various thicknesses shall be provided by the
Contractor.
1.8.5 Supply of pickling pumps, flushing pumps, pickling and neutralising
materials, temporary pipeline connection with valve for forming loops,
fabrication of pickling tanks etc. to carry out pickling by in-situ process
shall be done by the Contractor.
1.9.0 SITE FABRICATION – WELDING
The welding and the welded work shall conform to IS:316 and IS:9596,
Preparation of Joints - The edges shall be prepared by flame cutting
torch, correctly to the shape, size and dimensions of the groove as per the
site conditions and no machine tools shall be deployed for the purpose.
Wherever necessary, parts to be welded shall be properly assembled and
held firmly in position by means of jigs clamps etc prior to and during
welding. Tolerances for assembly of welded joints shall be as per
IS:9595/AWS D1.1 or equivalent.
Qualification and Testing of Welders - The Contractor shall satisfy the
Consultant that the welders appointed by the Contractor are suitable for
the work for which they are responsible and shall produce evidence to the
effect that welders have satisfactorily completed appropriate tests
Welding Procedure - Welding procedure shall be prepared by the
Contractor in line with IS:7307 and tests shall be carried out to qualify
procedure.
Jigs and Manipulators - Jigs and manipulators shall be used where
practicable and shall be designed to facilitate welding and to ensure that
all welds are easily accessible to the operators.
The joints shall be radiographically tested by the Contractor, wherever

necessary.
The Contractor shall employ competent persons to supervise and inspect
welding work to ensure that the standard of workmanship and the quality
of the materials comply with the requirements laid down in this
specification.

Destructive Testing of Welds if required shall be carried out. These shall

be carried out at the discretion of the Consultant as per details mutually
agreed.
Dye penetrant, chalk-kerosene test, magnetic particle, X-ray / Gamma-
ray radiography and ultrasonic testing shall be employed to ensure that
the welds are free from defects if the same has been specified in the
drawings or if required at site in consultation with NMDC/consultant.
Unless otherwise specified, extent of non-destructive testing shall be as
agreed mutually between Contractor and Consultant.
Extent of Coverage of Non-destructive Tests - Non-destructive tests of
welded joints shall be carried out as per approved drawings and
procedures. The extent to which non-destructive tests are to be carried
out shall be mutually discussed and agreed between the Contractor and
Consultant.
The following documents shall be maintained by the Contractor and
produced as and when asked for by the Consultant :
The quality of electrodes and accessories to be used.
List of certificates on qualification of welders who will carry out or
have carried out welding and also their identification stamps on
welding done by them.
Documents on approved deviations, if any.
Radiography films and their interpretation joint wise, if udertaken.
Ultrasonic test reports, if undertaken.
Details of joints checked by liquid dye-penetration examination, if
undertaken.
Details of joints checked by magnetic particle inspection.
Acceptance Norms - Acceptance norms for welds shall generally be as
per relevant IS, however in absence of suitable guidelines in IS, the
contractor shall follow the welding norms of consultant which shall be
handed over to contractor during execution of job.
1.10.0 REVISIONING, ASSEMBLY, ALIGNMENT & GROUTING OF
EQUIPMENT
1.10.1 The Contractor, where necessary, shall dismantle equipment and revision
the parts if required before placement on foundation. All gear drives and
pinion stands shall be dismantled if required, the gear casing shall be
levelled and aligned and the gear elements assembled with casing and
box up with lubrication pipes etc and grouted. However, the gearboxes,
which are proprietary in nature shall not be opened.
1.10.2 The Contractor shall clean thoroughly all the parts to be assembled,
lubricate and reassemble. All doweling wherever necessary shall be done
by the Contractor. Site assembly envisages certain amount of drilling &
reaming of dowel holes of various sizes. The Contractor shall arrange to
carry out the above jobs including supply of drills and reamers upto 20
dia holes.
1.10.3 Installation of all electrical equipment to be coupled to the mechanical

equipment including all DC and AC motors along with motor mounted
ventilation units, tacho-generators, tacho-combination units, brakes, limit
switches, position encoders etc as specified.
1.10.4 The Contractor shall align all the equipment to the accuracy as indicated
in the drawings. On completion of the final alignment prior to grouting of
the equipment, a certificate indicating alignment/levels with reference to
the drawing and actual dimensions achieved shall be prepared by the
Contractor for consultant’s/Customer' s certification.
1.10.5 The Contractor shall carry out certain amount of gas cutting and grinding
on components as required to maintain the working clearance.
1.10.6 Minor rectification on equipment/component during erection/ assembly/
trials shall be carried out by the Contractor at site by gas cutting, welding,
grinding, drilling and tapping new holes etc as a part of erection work.
1.10.7 Limit switches/proximity switch bases, strikers etc shall be mounted on
to the equipment either by drilling and tapping holes or by welding as per
drawing. Modification of the base frames/support frame of mounted
electrics to the extent of enlarging/plugging and drilling and tapping of
new holes below dia 20 mm only shall be carried out by the Contractor.
1.10.8.1 The Contractor shall carry out grouting of the equipment with anti-shrink
grouting material or as specified by the consultant/customer including
supply of grout materials.
1.10.9 The Contractor shall align, level & grout the AC & DC motors and also
align & level electrical equipment mounted on mechanical equipment.
The Contractor shall couple the electrical motors to the mechanical drives
after getting clearance from Purchaser. The Contractor shall fit the
couplings on both gear box shaft and motor shaft. Further decoupling and
coupling shall also be done as may be necessary at site.
1.10.10 Certain electrical items shall be received at site duly assembled with
mechanical equipment. The Contractor shall arrange for their erection,
testing and commissioning. All motors and driven equipment shall be
accurately leveled and aligned to required tolerances. Equipment shipped
with motor mounted, shall be rechecked and realigned, if necessary.
Laser alignment kits to be used to the extent possible to achieve higher
accuracy level.
1.10.11 Flushing, first filling and subsequent topping up of oils, and lubricants
shall be carried out by the Contractor.
1.10.12 The Contractor shall erect all auxiliary equipment, steel work, piping and
instruments, ventilation equipment etc. complete in all respects to the
stage of commissioning in accordance with contract and as per relevant
drawings/instructions.

2.0.0 LIST OF TOOLS AND TACKLES.

The following is the indicative list of tools & tackles required for erection
of the equipment. Contractor has to prepare and submit a detailed list of
tools and tackles prior to start of erection :
1. Hardened and ground parallel blocks (pairs of various sizes).
2. Piano wire 0.3 mm dia and 0.5 mm dia.
3. 300 mm and 500 mm combination squares.
4. Protractor head for use with combination squares.
5. Plumb bobs.
6. Nylon fishing wire.
7. Hydraulic jack - 25 T, 10 T, 5 T
8. Screw jacks - 25 T, 10 T, 5 T
9. Welding machines - Adequate no.
10. Welding generator.
11. Gas cutting sets with torches, hoses and gauges.
12. Woven wire slings - pairs of various lengths and diameters from
10 mm to 25 mm.
13. Open-end wrenches for all sizes of bolts.
14. Light duty and heavy duty socket sets.
15. Pneumatic drilling machine.
16. Pneumatic grinding machine.
17. Electric sander and buffer.
18. High-speed electric drilling machine with magnetic base with
capacity up to 32 mm dia .
19. HSS twist drills & reamers.
20. Slip gauges.
21. Filler gauge
22. Sledge hammers - various weights.
23. Pneumatic chipping hammers with full complements of flat,
gauge, cope chisels.
24. Flexible grinders with stone wheels.
25. Angle grinders.
26. Straight grinders.
27. Torque wrenches from 100 NM to 3000 NM .
28. Cold rolled steel and brass shims of different thickness.
29. Eyebolts of various sizes from M8 and above.
30. Clevises for slings.
31. Compressed air hose and cleaning equipment.
32. Complete sets of machinist' s hand tools.
33. Files, emery cloth, cleaning cloth and wire brushes.
34. Hand greasing equipment .
35. Wire ropes of various diameters and lengths.
36. Manila rope of various diameters and lengths.
37. Chain pulley blocks 20 T, 10 T, 5 T .
38. Different sizes of drills, taps, threading dies.
39. Box type square precision level of 0.01mm/m
40. Magnetic base micrometer with electronic attachment or with
potentiometer attachment.
41. Welding cable
42. Pipe bending machine.
43 Laser Alignment Kit

3.0.0 COLD TRIAL, PRELIMINARY ACCEPTANCE TEST,

COMMISSIONING & FINAL ACCEPTANCE TEST
Contractor shall deploy necessary resources during Cold trial, PAT,
Commissioning & FAT and extend necessary assistance for successful
completion of above activities and shall perform following activities.
• Attending to points for rectification / modification mentioned in
Preliminary Acceptance test.
• Deployment of manpower round the clock, if necessary.
• Minor rework, if necessary, to ensure required performance of the
equipment.
• Inspecting gearboxes drives for oil flow and cleaning nozzles etc.
• Coupling / decoupling motors with drives.
• Adjustment / relocation of limit switches / sensors / strikers /
proximity switches etc.
• Fitting, refitting, removing and fitting of splines, coupling guards
wherever required.
• Check oil leakage and rectify.
• Removal and refitting of chains / ropes etc.
• Lubricating / greasing of equipment as per instruction manuals
• Overall cleaning, check for tightness of bolts / fasteners etc.
• Checking all connections / joints, priming connections etc.
• Gearboxes to be cleaned, washed and filled up as per the instruction
manuals. Replace gaskets and oil seals etc., if necessary.
• Preparation of check list and protocols for the safety of men &
machineries.
4.0.0 WEIGHT SCHEDULE
Detail of weight schedule shall be furnished during finalization of
contract.
5.0.0 TIME SCHEDULE
The time required for erection and commissioning will be as per contract.
A schedule shall be prepared by Contractor and submitted to the
consultant/Purchaser for actual work plan based upon the realistic site
conditions. The date of start of erection job will be intimated to the
Purchaser.
The Contractor shall reschedule the work and work overtime at his own
cost with the prior approval of the Purchaser as may be necessary to meet
the required erection schedule.
6.0.0 RESOURCE PLAN
6.1.1 The Contractor shall deploy all labour - skilled, semi-skilled and
unskilled, riggers, mill wrights, certified welders, pipe fitters, instrument
fitters, mechanics, licensed electricians, supervisors, foremen, erection
and testing engineers etc. needed for proper erection and commissioning
of plant and equipment.
6.1.2 The Contractor shall arrange management of erection work with proper
and adequate supervision by qualified personnel for ensuring progress of
erection work and quality of workmanship.
7.0.0 OBLIGATION OF THE PURCHASER

7.1.0 Obligations of the Purchaser for Erection
7.1.1 Roads / accesses as per permanent plant layout capable of carrying heavy
and oversized equipment by trucks / trailers.
7.1.2 Complete storm water and sanitary drainage for the covered buildings
used as premises ( excluding turnkey projects ).
7.1.3 To allow the contractor’s (including his major sub-contractor) workers
and staff to avail the Purchaser’s first aid facilities at site ad Purchaser’s
hospital facilities if available on chargeable basis.
7.1.4 Other facilities :
a) Facilities for free call on Purchaser’s fire service as required.
b) Sufficient levelled space for construction of temporary site stores,
site office, fabrication yard etc.
c) Adequate water for erection and drinking purpose and for use at
assembly, stores office, erection site etc at battery limit. The quantum
of requirement shall be specified by the contractor.
d) Supply of power as per availability from 415V 3 phase AC with
tapping points for assembly, piping, cabling and erection purpose at
battery limit. The quantum of requirement of construction power
shall be specified by the contractor.
e) Assist in issue of gate passes for entry of the contractor including his
sub-contractor’s personnel, removal / entry of materials, tools and
tackles etc. belonging to the contractor or his subcontractors and
permission to engage female labour for working inside the plant as
per labour laws.
f) Plant security force in position for overall security of plant as and
when available.
7.1.5 The Purchaser shall only forward the application to statutory authorities
as principal employer for obtaining licences, permits, statutory consents
etc. which the Contractor may need to obtain in the interest of the work.
7.2.0 Obligations of the Purchaser for Storage & Transportation.
7.2.1 Area for covered stores / sheds of required area within a distance of
maximum 2000 m from the erection site. The above covered areas shall
not preferably be in more than three separate buildings. For turnkey
projects, the contractor has to make space for storage of equipment in
their own area.
7.2.2 Area for open space for storage of equipment adjacent to the covered
storage building.
7.2.3 Electricity at the nearest CPSS and water at construction water main.
7.2.4 Access to central fire brigades as and when available.

7.2.5 Railway tracks and siding adjacent to the storage area as and when
available.
7.2.6 Approximate area required for stores. The actual requirement shall,
however, be discussed and finalised later.
8.0.0 LIST OF EXCLUSIONS FROM CONTRACTOR’S SCOPE OF
WORK AND SERVICES
,
8.1.0 Operating personnel for commissioning purpose and for running the plant
for production purpose.


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NMDC LIMITED

3.0 MTPY STEEL PLANT AT NAGARNAR

GENERAL TECHNICAL SPECIFICATION

No. MEC/GTS/11/R2/Q6QZ/REV 2 MAR’ 2010

3.0 MTPY STEEL PLANT AT NAGARNAR

GENERAL TECHNICAL SPECIFICATION

No. MEC/GTS/11/R2/Q6QZ/REV 2 MAR’ 2010

LIST OF CONTENTS FOR GS-06

SNo Chapter Chapter No No of Pages

Chapter 06 Material handling equipment Page 1 of 152

01.00 CONVEYOR SYSTEM & RELATED EQUIPMENT

Chapter 06 Material handling equipment Page 2 of 152

01.02 Design Basis & Hierarchy of Specifications

The equipment shall be designed as per design criteria given below:

Material characteristics (Tentative – Final in Technical Specification)

Material Size Bulk Density

Coke (Uncut) 0-300mm 0.5t/m3

− Utilisation of cross sectional area - 80 % of theoretical cross sectional area

− Design capacity of belt conveyors- 20% more than rated capacity to be

− Motor kW shall be selected with a minimum 10% margin over calculated

− Troughing angle - 35o

− Friction factor (for kW calculation) of belt conveyors- 0.03

− Friction factor between belt and drive pulley : 0.275

− Idlers (Carrying, Self Aligning Carrying)

− Return idler spacing - 3000 mm

− Training Idler spacing

− Impact idler spacing - 500 mm or less - (min. 6 Nos.)

− Deck plate - 3.15 mm thick wherever specified

− Drive pulley –12 mm thk. vulcanized natural rubber lagging, minimum

− Tail/ Bend/take-up pulley – 10 mm thk vulcanized natural rubber lagging,

− Pulley face width - As per IS 8531-1986, Reaffirmed in 1993.

− Bearing / Pillow blocks

a) Service rating of 1.8 times the calculated shaft kW and thermal

b) Casing Material - fabricated or cast steel

d) No worm gear / open gears unless otherwise mentioned for gates

− Low speed coupling - gear or resilient.

V shaped, mounted on carrier assemblies with elasto-mount and non metallic

Chapter 06 Material handling equipment Page 6 of 152

All equipment shall be designed, manufactured, supplied, erected, tested and

Standardisation of components and assemblies shall be carried out to the maximum

Chapter 06 Material handling equipment Page 7 of 152

a) Manufacturer’s name and trade mark, if any.

Before dispatch, the finished material shall be subject to inspection by the

a) Full thickness belt test

i) Breaking load, Kg/sq. cm for wrap and weft.

b) Rubber cover test (Top/Bottom)

Chapter 06 Material handling equipment Page 8 of 152

i) Tensile strength of cover , Kg/sq. cm

c) Physical dimension check

Chapter 06 Material handling equipment Page 9 of 152

Training idlers shall not be used close to belt-weighing scales.

Chapter 06 Material handling equipment Page 10 of 152

Minimum Idler shaft diameter shall be as following:

Carrying / SACI : 20mm upto 1000mm BW

Impact Idlers : 30 mm upto 1000mm BW

a) Friction factor test

a) External belt cleaners

Chapter 06 Material handling equipment Page 11 of 152

8. Hold Back and Brakes with panel

Chapter 06 Material handling equipment Page 12 of 152

10. Discharge Hood

- Coal : 6thk SS-409M

Chapter 06 Material handling equipment Page 13 of 152