REINFORCEMENT Check List-QF and

1. PURPOSE: To establish a uniform, predetermined and controlled methodology for various activities related to Reinforcement Steel works Minimise errors while executing the works. Control of nonconformance and provide proper guidelines while executing the job. 2. SCOPE : This section deals with reinforcement for all reinforced concrete works and covers the requirement of materials, their properties, storage, handling, furnishing of bar-bending schedules and the cleaning, bending, binding and placing of reinforcement with suitable cover blocks. It also includes supply of reinforcement unless specified other wise. The procedure is subject to revision depending upon the actual practical requirement while executing the particular job at site. This procedure also includes the methods of record keeping. 3. 4. REFERENCE DOCUMENTS: As per Technical Specifications at Contract Documents and GENERAL

Client Specifications, if any.

4.1 All works are to be carried out as per approved drawings issued and to complete satisfaction of Site and Client Engineers. Quality and Safety aspects are to be ensured till completion of works. 4.2 Methodology of measurements and acceptance criteria(with tolerances), extra rates as applicable to unspecified working operations are to be arrived with Client for all essential operations of specific Concreting works prior to commencing. 4.3. Methodology adopted and materials deployed for carrying out works are to be conforming to approved standards 4.4. Maintenance of Project Records: Check Lists as per QF 116, and QF 117 site records are to be recorded and maintained for office reference and Project record. 5.0 5.1 DETAIL ACTION PLAN: General Requirement Bar-bending schedules for all RCC works are to be prepared and approvals of Engineer is obtained prior to commencing the works.

5.1.2 Written approvals from Engineer, is obtained for deviations to the drawings regarding any adjustments in diameter or spacing of reinforcement. Due approvals of Engineers to Bar bending schedule shall be taken and modified , when a particular type and size of reinforcement is not available and reinforcement / fabrication works are commenced. 5.1.3 Reinforcing bars are to l be stored consignmentwise and size wise off the ground & with proper covers to protected from rusting, oil, grease and distortions. The stacks shall be easily measurable. Steel needed for immediate use shall only be removed from storage. 5.2 5.2.1 Materials All steel for reinforced concrete works shall be in accordance with technical specification Common Civil Construction Material and conform to IS: 1786 (for High Strength deformed steel bars and wires for concrete reinforcement) & IS: 13620 (for Fusion bonded Epoxy coated reinforcing bars). All mild steel bars shall conform to IS: 432.

a) Prior to commencing concreting works all the materials as specified above are to be to be tested either at field or at approved lab. b) Layout of structure is to be marked as per drawing and bottom level of Concrete is recorded. c) Concrete Mix is to be laid as per specification and Top Level of Specific Concreting work is recorded in the QF-Format. d) As Mixing of concrete is generally done in the Batching plant, The mixing duration should be ensured for thorough mixing of all ingredients for getting a proper mix and transported immediately on transit mixers and placed at required locations. e) All resources(Technical, Skilled and unskilled personnel, Materials, Plant and Equipment etc., ) for executing the works to approved drawings/ specifications and as directed by, to satisfaction of the Engineer and shall be utilized/deployed. f) Provision of IS: 456 shall be followed as general guidance, along with all other relevant Indian Standards, unless otherwise specifically mentioned. g) Site Engineer, is responsible for adequacy, correctness, completeness, safety, strength, quality, workmanship etc to respective structural scope of concreting works being executed by him. 5.2.2 Fusion Bonded Epoxy Coated Reinforcement Bars

The reinforcement bars to be provided with Fusion Bonded Epoxy Coating shall conform to tender specifications, IS:13620 and other relevant IS specifications. In spite of producing test certificates by the Sub-contractor for the proper quality of reinforcement

bar, the quality of steel should also be tested by the FBE coating firm at plant site for bend test before doing coating Reinforcement bars to be coated shall be fresh from rolling mills as far as possible. The Fusion Bonded Epoxy Coating shall be got done from an authorized FBE coating agency approved by Client. The coating process shall conform to IS: 13620. Patch up material shall be procured in sealed containers with certificates from the coating agency for the sources; quality and quantity patch up materials. Annealed soft iron PVC Coated wires of 18G binding wires are to be used. For bars larger than 25 mm dia bars at crossing points, 20G annealed soft iron PVC coated wires shall be used.. 5.2.2.1 Tests for FBE Coating on Reinforcing Bars The Painting certificate from the FBE coating agency is to be submitted indicating the quality of powder epoxy material and other components of FBEC conform to relevant IS Standards. Such certificates shall accompany each lot of coated bars leaving the plant for work site. The coated reinforcing bars shall be tested at plant site by and test results signed jointly by authorized representatives of Site/GDCL and the coating agency. The tests on coated bars shall be as per relevant IS: 13620 for the following tests. i) Thickness ii) Continuity iii) Adhesion Tests for the thickness of coating shall be carried out on minimum two bars of each size from each production shift. Random tests shall be made for continuity of coating. In spite of above tests and test certificates produced by the coating agency, the Client reserves the rights of carry out independent tests of Plant site as a cross checking. GDCLs agreement with coating agency shall include the provisions of Clients cross checking and that if the coating quality is not approved by Client the decision of Client as to reject or repair the coating shall be final and binding on all parties. 5.2.2.2 Handling The coated bars are to be carefully handled in order not to drop them, not to rub /drag against any hard surface or against other coated bars in all handling situations such as conveying, stacking, placing or stacking of fabricated barsetc., For this purpose wooden packing batons are to be used. PVC binding material used to tie the coated bars into bundles shall be in order not to damage the coating of bars. The coated bars are to be stacked with separation gap between ground and bars with wooden member between rows of bars or bundles of such tied bars. The cut ends of bars shall be touched up with special touch up Materials of specifications as provided by coating agency. There shall be minimum tie gap to repair the cut ends and damaged portions with touch up materials and that failure to do so may cause complete rejection of the coated bars. The cut ends and damaged portions are to be touched up with repair touch

up material within one hour cutting or damage. While bending the bars, the pins of work benches shall be provided with PVC or plastic sleeves. It is preferable to install bar bending machines suitable for FBE coated bars and that each bending operation is done in a time of not less than 90 sec. The coated steel is to be avoided for directly getting exposed to sun rays and rains and shall be protected with opaque polyethylene sheets or such any other similar approved materials. While undertaking concreting works , the workmen or trolleys shall not directly move on coated bars movement on wooden planks placed on the bars may be done cautiously. FBE coated reinforcement bars quantity sufficient for 3 months at site only shall be stacked/stored properly at site. Despite all test certificates, if the coated bars are handled roughly during the course of operations causing damage to coating over area or portion and the damage is if unreasonably high Engineer-in-charge reserves the right to reject the FBE coated bars, such rejected bars are to be removed from site. within three days of rejection. The decision of Engineer-in-charge will be final as to their use post rejections and the bars with damaged coatings or to allow repairing the coating, or to get it recoated entirely at GDCLs cost. The supply of coated Reinforcement bars are to be as per Project planning maintaining 3 months inventory. 5.3 Bending and Placing

5.3.1 Bending a) Reinforcing bars supplied bent or in coils, shall be straightened before these are cut to size. Straightening of bars shall be done in cold and without damaging the bars. b) Reinforcing steel shall be bent in accordance with procedure specified in IS: 2502 and / or as approved by the Engineer. Bends and shapes shall comply strictly with the dimensions shown on the approved bar bending schedules and they shall be rechecked by the GDCL Engineers before bending and he shall be entirely responsible for their correctness. Bars correctly bent shall only be used. Unless specified otherwise or directed by the Engineer, the detailing of reinforcement shall be in accordance with IS: 5525 and SP: 34. c) No reinforcement shall be bent when in position in the work without approval of the Engineer, whether or not it is partially embedded in concrete. Where reinforcement bars are bent aside at construction joints and afterwards bent back into their original positions, care shall be taken to ensure that, at no time, the radius of the bend is less than 4 bar diameters for deformed bars. Care shall also be taken while bending back bars to ensure that the concrete around the bar is not damaged. d) Welding of bars to obtain continuity shall not be allowed, particularly for cold twisted bars, unless specifically approved by the Engineer. If welding is approved, the work shall be carried out as per IS: 2751, IS: 456 and IS: 9417, according to the best practice and as directed by the Engineer. Welded mesh fabrics shall conform to IS: 1566 & as per drawings.

5.3.2

Placing in Position a) All reinforcement shall be accurately fixed and maintained in position asshown on the drawings by such approved means as steel chairs and / or concrete spacer blocks as per IS: 2502. Bars intended to be in contact at crossing points shall be securely bound together at all such points by two annealed steel wire of 1.6 mm diameter conforming to IS: 280 in such a manner that they do not slip over each other at the time of fixing & concreting. The tying of bars shall be in criss-cross manner. The vertical distance between successive layers of bars shall be maintained with mild steel spacer bars. They should be spaced such that the main bars do not sag perceptibly between adjacent spacers. Before actual placing, Site Engineerr shall study the drawings thoroughly and inform the Engineer in case he feels that placement of certain bars is not possible due to congestion. In such cases, he should not start placing any bar before obtaining clearance from the Engineer. b) Binders shall tightly embrace the bars with which these 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 spacer bars. Bars shall be so spaced that the main bars do not sag perceptively between adjacent spacers. Bundled bars shall be provided wherever shown on the drawing to facilitate concreting. Location of laps and development lengths shall be as indicated on the drawings. c) The placing of reinforcement shall be completed well in advance of concrete pouring. Reinforcement shall be checked by the Engineer for accuracy of placement and cleanliness prior to concrete pouring. Necessary correction as directed by the Engineer shall be carried out. Care shall be taken to ensure that projecting ends of ties and other embedded metal do not encroach into the concrete cover. Concrete blocks used for cover and positioning of reinforcement shall be made of mortar 1:2 (1 cement: 2 sand) by volume and cured for at least seven days before use. The Engineer shall approve the sizes and locations of these cover blocks. The 28 days crushing strength of cover blocks shall be at least equal to the specified strength of concrete in which the blocks are to be embedded. d) Reinforcement bars shall not be lapped unless the length required exceeds the maximum available lengths of bars at site. Laps and anchorage length of reinforcing bars shall be in accordance with IS:456, unless otherwise specified. If the bars in a lap are not of the same diameter, the smaller diameter will guide the lap length. Laps shall be staggered as far as practicable and as directed by the Engineer and not more than 50% of bars shall be lapped at a particular section. Mechanical connections for splicing reinforcement bars in congested locations may be used by the Subcontractor, only if approved by the Engineer.

5.4

Cover to Reinforcement Minimum cover to reinforcement shall be as indicated in construction drawings. However, following are for general guidelines.

5.4.1

Nominal Cover based on Exposure Condition: Unless shown otherwise on the drawings, clear concrete cover for reinforcement (exclusive of plaster or other finishes) depending on the condition of exposure as described in IS:456 and shall be as given in Table 5. However, nominal cover shall in no case be less than 40mm or the diameter of the bar for longitudinal reinforcement in columns. In case of columns with minimum dimension of 200mm or less whose reinforcing bars do not exceed 12mm, a nominal cover of 25mm may be used. Minimum nominal cover for footings shall be 50mm. Table 5 Nominal Cover to meet Durability Requirements Exposure Min. Nominal Concrete Cover (mm) 20 30 45 50 75

Mild Moderate Severe Very Severe Extreme

a) b)

Nominal cover may be reduced by 5mm for main reinforcement with diameter of less than or equal to 12mm for mild exposure. Nominal cover may be reduced by 5mm for concrete grade of M35 and above used for Severe and Very Severe exposure conditions.

5.4.2

Nominal Cover based on Fire Resistance: Minimum nominal cover to be provided to all reinforcement including links to meet specified period of Fire Resistance shall be as given in Table 6.

Table 6 Nominal Cover to meet Durability Requirements Fire Resistance (hours) Beams Slabs Ribs Column s 40 40 40 40 40 40 Simply Continuos Simply Continuos Simply Continuos Supported Supported Supported 20 20 20 20 20 20 20 20 20 20 20 20 20 20 25 20 35 20 40 30 35 25 45 35 60 40 45 35 55 45 70 50 55 45 65 55 Nominal Cover (mm)

0.5 1 1.5 2. 3 4

5.4.3

Clear distance between reinforcing bars shall be in accordance with IS:456 or as shown on drawings. Sampling and Testing General Sample bent bars shall be checked to ensure that they conform to the bar bending schedules. Reinforcement in position shall be checked for proper positioning, and rigidity, cover, spacing of bars, placement of chairs and spacers etc. Also, it shall be checked that all bars at crossings are properly tied.

5.5 5.5.1

5.6 5.6.1

Acceptance Criteria: Unless otherwise specified by Engineer, the reinforcement shall be placed within the following tolerances: For Effective depth 200mm For Effective depth > 200mm 10mm 15mm

5.6.2 Unless specified otherwise, actual concrete cover shall be within the following tolerances: Tolerance for nominal cover (+)10mm / ( -) 0mm

6.0

FOUNDATION BOLT ASSEMBLY This section of the specification deals with the requirements of supply, fabrication and erection of foundation bolt assembly etc.

6.1

General Requirements Supply, fabrication, erection and installation of foundation bolt assembly shall comprise of foundation bolts, stiffener plates, washers, nuts, lock nuts, pipe sleeves etc.

6.2

Materials The materials shall be in accordance with technical specification Common Civil Construction Material.

6.3

Workmanship

6.3.1 The fabrication and erection of bolt assemblies shall include threading, cutting, grinding, drilling, welding etc. all complete. All bolts, bolt assemblies etc. shall be fabricated by the Sub-contractor to the correct dimensions and shapes as shown on drawings. The bolts shall have coarse pitch screw thread in the diameter range, 8 mm to 64 mm and 6 mm pitch screw for diameter greater than 64 mm. 6.3.2 For fabrication of any particular size of bolt indicated on the drawing, the diameter of the threaded portion of the bolt shall be considered as the diameter of the bolt. Fabrication & erection shall be carried out as per IS: 800. Welding shall conform to IS: 816 and IS: 9595. Every bolt shall be provided with a steel washer under the nut. The washer shall be flat and minimum diameter of outside inscribed circle shall be 2.5 times that of the bolt. The washer shall be of suitable thickness. All nuts shall be of steel with well formed hexagonal heads, unless specified otherwise, forged from solid metal and shall be dipped in hot boiled linseed oil as soon as these are made. The nuts shall fit properly on the bolts.

6.3.3

6.3.4

6.3.5 Necessary template, temporary bracings, supports etc. are provided to ensure proper positioning of the assemblies and holding these firmly until these are cast/ grouted and the grout has set. All materials erected shall be in plumb and in level (unless otherwise specified) and at exact locations indicated in the drawings. Threads shall be protected with PVC tape or polythene sheets or hessian cloth.

7.0

METHODS OF MEASUREMENT Measurement shall be taken as per IS: 1200 (Relevant Part).

8.0 8.1

CODES AND STANDARDS All standards, acts & codes of practice referred to shall be the latest editions including all applicable official amendments & revisions. In case of conflict between this specification & those of standards, codes etc. referred to, this specification shall prevail.
IS: 73 - 1992 IS: 216 - 1961 IS: 277 - 1992 IS: 280 1978 IS: 456 2000 IS: 457 1957 Paving bitumen - Specification Specification for Coal Tar pitch Galvanized steel sheets (plain and corrugated) - Specification Mild steel wire for general engineering purposes

Code of practice for plain and reinforced concrete Code of practice for general construction of plain & reinforced concrete for dams & other massive structures IS: 516 1959 Method of test for strength of concrete IS: 702 - 1988 Specification for Industrial bitumen IS: 800 - 1984 Code of Practice for General Construction in Steel. IS: 816 - 1969 Code of practice for use of metal arc welding for general construction in mild steel IS: 883 - 1994 Design of structural timber in building Code of Practice IS: 1161 - 1998 Steel Tubes for Structural Purposes. IS: 1199 1959 Methods of sampling and analysis of concrete Method of measurement of Building and Civil Engineering works IS: 1200 (Part 2) - 1974 Concrete Method of measurement of Building and Civil Engineering works IS: 1200 (Part 5) - 1982 Formwork Method of measurement of Building and Civil Engineering works IS: 1200 (Part 8) 1993 Steel & Iron work Bitumen Felt for Water-Proofing and Damp-Proofing Specification IS: 1322 - 1993 Specification for Hard-drawn steel wire fabric for concrete IS: 1566 - 1982 reinforcement Bituminous compounds for Waterproofing and caulking purposes IS: 1580 - 1991 specification. Damp proofing treatment using bitumen felts - Code of practice IS: 1609 1991 Batch type concrete mixers IS: 1791 1985 IS: 1838 (Part I) - 1983 Specification for Preformed fillers for expansion joints in concrete pavements and structures (non-extruding and resilient type) Bitumen Impregnated Fiber Low Tensile Structural Steels Specification IS: 1977 1996 Steel for General Structural Purposes Specification IS: 2062 1999 IS: 2386 (Part IV) 1963 Methods of test for aggregates for concrete Mechanical

IS: 2204 1962 IS: 2210 1988 IS: 2386 (Part I) - 1963 IS: 2386 (Part II) - 1963 IS: 2386 (Part III) - 1963 IS: 2386 (Part V) 1963 IS: 2386 (Part VI) 1963 IS: 2386 Part VII -1963 IS: 2386 (Part VIII) 1963 IS: 2438 - 1963 IS: 2502 - 1963 IS: 2505 - 1992 IS: 2506 - 1985 IS: 2514 - 1963 IS: 2645 - 1975 IS: 2722 - 1964 IS: 2750 - 1964 IS: 2751 - 1979 IS: 2812 - 1993 IS: 3067 - 1988 IS: 3150 - 1982 IS: 3201 - 1988 IS: 3370 (Part I) 1965 IS: 3370 (Part II) 1965 IS: 3370 (Part IV) 1967 IS: 3384 - 1986 IS: 3414 - 1968 IS: 3558 - 1983 IS: 3696 Part I - 1987

Properties. Code of practice for construction of reinforced concrete shell roof Criteria for design of reinforced concrete shell structures and folded plates Methods of test for aggregates for concrete Particle Size & Shape. Methods of test for aggregates for concrete Estimation of Deleterious Materials and Organic Impurities. Methods of test for aggregates for concrete Specific Gravity, Density, Voids, Absorption and Bulking Methods of test for aggregates for concrete Soundness Methods of test for aggregates for concrete Measuring Mortar Making Properties of Fine Aggregate Methods of test for aggregates for concrete Alkali Aggregate Reactivity Methods of test for aggregates for concrete Petrographic Examination Roller pan mixer Code of practice for bending and fixing of bars for concrete reinforcement Concrete vibrators immersion type general requirements General requirements for concrete vibrators, screed board Type Specification for Concrete vibrating tables Specification for Integral cement water proofing compounds Portable swings weigh batchers for concrete. (Single and double bucket type) Specification for Steel scaffoldings Recommended practice for welding of mild steel plain and deformed bars for reinforced concrete construction Recommendations for Manual Tungsten Inert-Gas Arc welding of Aluminium and Aluminium Alloys. Code of practice for general design details and preparatory work for damp proofing & water proofing of buildings Specification for Hexagonal Wire Netting for General Purposes Criteria for design and construction of precast concrete trusses and purlins Code of practice for concrete structures for the storage of liquids Part I : General Requirements Code of practice for concrete structures for the storage of liquids Part II : Reinforced Concrete Structures Code of practice for concrete structures for the storage of liquids Part IV : Design Tables Specification for bitumen primer for use in waterproofing & damp proofing Code of practice for design and installation of joints in buildings Code of practice for use of immersion vibrators for consolidating concrete Safety code for scaffolds and ladders - Scaffolds

IS: 3696 Part II - 1991 IS: 3935 - 1966 IS: 4014 Part I - 1967 IS: 4014 Part II - 1967 IS: 4082 - 1996

IS: 4130 - 1991 IS: 4326 - 1993 IS: 4461 - 1998 IS: 4656 - 1968 IS: 4925 - 1968 IS: 4990 - 1993 IS: 5121 - 1969 IS: 5525 - 1969 IS: 5624 - 1993 IS: 6494 - 1988 IS: 6509 - 1985 IS: 7193 - 1994 IS: 7293 - 1974 IS: 7861 (P art I) 1975 IS : 7 86 1 (P a rt II) 1981 IS: 7634 (Part III) 1975 IS:12118 (Part I) 1987 IS: 7969 - 1975 IS: 8500 - 1991 IS: 9012 - 1978 IS : 9 077 - 1979 IS: 9103 - 1999 IS: 9417 -1989 IS: 9595 - 1996 IS: 10262 - 1982 IS: 10297 - 1982

Safety code for scaffolds and ladders - Ladders Code of practice for composite construction Code of practice for steel tubular scaffolding Definitions and Materials Code of practice for steel tubular scaffolding Safety Regulations for Scaffolding Stacking and storage of construction materials and components at Site Recommendations Demolition of buildings Code of safety Earthquake resistant design and construction of buildings Code of Practice Code of practice for joints in surface hydro-electric power stations Specification for Form vibrators for concrete Specification for Concrete batching and Mixing plant Plywood for concrete shuttering work Specification Safety code for piling and other deep foundations Recommendations for detailing of reinforcement in reinforced concrete work Foundation bolts - Specification Code of practice for water proofing of underground water reservoirs and swimming pools Code of practice for installation of joints in concrete pavements Glass fibre base bitumen felts Specification Safety code for working with construction machinery Code of practice for extreme weather concreting Recommended Practice for Hot Weather Concreting C od e o f p ractice for ex treme weather co n creting Recommended Practice for Cold Weather Concreting Code of Practice for Plastics Pipe Work for Potable water supplies : Laying and Jointing of Unplasticized PVC pipes. Specification for Two parts poly sulphide based sealants General Requirements Safety code for handling and storage of building materials Structural Steel Micro alloyed (Medium and High Strength Qualities ) - Specification Recommended practice for shotcreting Code of p ractice fo r co rrosion pro tectio n of steel reinforcement in RB and RCC construction Specification for admixtures for concrete Recommendations for welding cold-worked bars for reinforced concrete construction Recommendations for metal-arc welding of carbon and carbon manganese steels Recommended guidelines for concrete mix design Code of practice for design and construction of floors and roofs using

IS: 10505 - 1983 IS: 11384 - 1985 IS: 11447 - 1985 IS: 12118 (Part II) - 1987 IS: 13311 (Part I) - 1992 IS: 13311 (Part II) - 1992 IS: 13620 - 1993 IS: 14687 - 1999 SP: 23 - 1982 SP: 34 - 1987

precast reinforced / prestresed concrete ribbed or cored slab unit Code of practice for construction of floors and roofs using precast concrete waffle units Code of practice for composite construction in structural steel and concrete Code of practice for construction with large panel prefabricates Specification for Two parts poly sulphide based sealants Methods of Test Non destructive testing of concrete Methods of test Ultrasonic Pulse Velocity Non destructive testing of concrete Methods of test Rebound hammer Fusion bonded epoxy coated reinforcing bars - Specification False work for Concrete structures Guidelines Handbook on concrete mixes Handbook of concrete reinforcement and detailing