SUB-HEAD 1.

(SPECIFICATION IN GENERAL)

S P E C I F I C A T I O N

1.0

GENERAL :

1.1

The detailed specifications given hereafter are for the items of works described in the
schedule of quantities attached herein, and shall be guidance for proper execution of work to
the required standards.

1.2

It may also be noted that the specification are of generalized nature and these shall be read in
conjunction with the description of item in schedule of quantities and drawings.

1.3

The work also includes all minor details of construction which are obviously and fairly intended
and which may not have been referred to in these documents but are essential for the entire
completion in accordance with standard engineering practice.

1.4

The Chief Engineer, A&CED, shall be the sole deciding authority as to the meaning,
interpretations and implication for various provisions of the specifications and his decision in
writing shall be final and binding on all concerned.

1.5

In case any difference or discrepancy between the specifications and the description in the
schedule of quantities, the schedule of quantities shall take precedence.

1.6

In case any difference or discrepancy between the specifications and the drawing, the
specification shall take precedence.

1.7

Unless specifically otherwise mentioned, all the applicable latest codes and standards
published by the Bureau of Indian Standards and all other standards, shall govern in all
respects of design, workmanship, quality, properties of materials, method of testing and
method of measurements.

*****

CONTENTS
Clause No.

Brief Description

Page No.

List of Bureau of Indian Standard Codes

General
Responsibility for Loss or Damage
Mode of Carriage
Lead
General Consideration for Stacking and Storage
Protection against Atmospheric Agencies
Protection against fire and other Hazards
Stacking and Storage of Materials
Measurements
Rate
Storage and Stacking Check List
Typical Sketch for Cement Godown

1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7 to 1.26
1.27
1.28
Table 1.1
Fig. 1.1

LIST OF BUREAU OF INDIAN STANDARD CODES

S. No.

I. S. No.

Subject

1.

IS 4082

2.

IS 1141

Stacking & storage of construction materials and

components at site Recommendations
Seasoning of Timber Code of Practice

1.0 CARRIAGE OF MATERIALS

1.0 GENERAL
The carriage and stacking of materials shall be done as directed by the Engineer-in-Charge. Any tools
and plants, required for the work shall be arranged by the Contractor. The carriage of materials
includes loading within a lead of 50 metres, unloading and stacking within a lead of 50 metres.
1.1 RESPONSIBILITY FOR LOSS OR DAMAGE
Loading, carriage, unloading and stacking shall be done carefully to avoid loss or damage to the
materials. In case of any loss or damage, recovery shall be effected from the Contractor at twice the
issue rates of the materials. If the issue rates of the materials are not available then the recovery shall
be effected at twice the prevailing market rates as determined by the Engineer-in-Charge.
1.2 MODE OF CARRIAGE
Depending upon the feasibility and economy, the Engineer-in-Charge shall determine the mode of
carriage viz. whether by mechanical or manual labour.
1.3 LEAD
1.3.1 All distances shall be measured over the shortest practical route and not necessarily the route
actually taken. Route other than shortest practical route may be considered in cases of unavoidable
circumstances and as approved by Engineer-in-Charge alongwith reasons in writing.
1.3.2 Carriage by manual labour shall be reckoned in units of 50 metres or part thereof.
1.3.3 Carriage by mechanical transport shall be reckoned in one km unit. Distances of 0.5 km or more
shall be taken as 1 km and distance of less than 0.5 km shall be ignored. However, when the total
lead is less than 0.5 km, it will not be ignored but paid for separately in successive stages of 50 metres
subject to the condition that the rate worked on this basis does not exceed the rate for initial lead of 1
km by mechanical/ manual transport.
1.4 GENERAL CONSIDERATION FOR STACKING AND STORAGE
1.4.1 Planning of Storage Layout
For any site, there should be proper planning of the layout for stacking and storage of different
materials, components and equipments with proper access and proper manoeuvrability of the vehicles
carrying the material. While planning the layout, the requirements of various materials, components
and equipments at different stages of construction shall be considered. The storage & stacking check
list is given in Table 1.1. For further details refer IS- 4082.
1.4.2 Material shall be stored in such a manner as to prevent deterioration or intrusion of foreign
matter and to ensure the preservation of their quality and fitness for the work.
1.5 PROTECTION AGAINST ATMOSPHERIC AGENCIES
Materials stored at site, depending upon the individual characteristics, shall be protected from
atmospheric actions, such as rain, sun, winds and moisture to avoid deterioration.
1.6 PROTECTION AGAINST FIRE AND OTHER HAZARDS
1.6.1 Materials like timber, coal, paints, etc. shall be stored in such a way that there may not be any
possibility of fire hazards. Inflammable materials like kerosene and petrol, shall be stored in
accordance with the relevant rules and regulations so as to ensure the desired safety during storage.
Stacks shall not be piled so high as to make them unstable under fire fighting conditions and in
general they shall not be more than 4.5 m in height. The provisions given in IS 13416 (part 5) shall be
followed.

1.7 STACKING AND STORAGE OF MATERIALS

1.7.1 Cement
1.7.1.1 In case cement is received in bags. Cement shall be stored at the work site in a building or a
shed which is dry, leakproof and as moisture proof as possible. The building or shed for storage
should have minimum number of windows and close fitting doors and these should be kept closed as
far as possible.
1.7.1.2 Cement shall be stored and stacked in bags and shall be kept free from the possibility of any
dampness or moisture coming in contact with them. Cement bags shall be stacked off the floor on
wooden planks in such a way as to keep about 150 mm to 200 mm clear above the floor. The floor
may comprise of lean cement concrete or two layers of dry bricks laid on well consolidated earth. A
space of 600 mm minimum shall be left alround between the exterior walls and the stacks (see Fig.
1.1) In the stacks the cement bags shall be kept close together to reduce circulation of air as much as
possible. Owing to pressure on the bottom layer of bags sometimes warehouse pack is developed in
these bags. This can be removed easily by rolling the bags when the cement is taken out for use.
Lumbed bags, if any should be removed and disposed off.
1.7.1.3 The height of stack shall not be more than 10 bags to prevent the possibility of lumping up
under pressure. The width of the stack shall be not more than four bags length or 3 metres. In stacks
more than 8 bags high, the cement bags shall be arranged alternately length-wise and cross-wise so
as to tie the stacks together and minimize the danger of topping over. Cement bags shall be stacked
in a manner to facilitate their removal and use in the order in which they are received; a lable showing
date of receipt of cement shall be put on each stack to know the age of cement.
1.7.1.4 For extra safety during the monsoon, or when it is expected to store for an unusually long
period, the stack shall be completely enclosed by a water proofing membrane such as polyethylene,
which shall close on the top of the stack. Care shall be taken to see that the waterproofing membrane
is not damaged any time during use.
1.7.1.5 Cement in gunny bags, paper bags and polyethylene bags shall be stored separately.
1.7.2 In case cement is received in drums
These shall be stored on plane level ground, as far as possible near the concrete mixing place. After
taking out the required quantity of cement, the lid of the drum shall be securely tied to prevent ingress
of moisture.
1.7.3 In case cement is received in silos
The silos shall be placed near the concrete batching plant. Proper access shall be provided for the
replacement of silos.
1.7.4 Different types of cements shall be stacked and stored separately.
1.8 BRICKS
1.8.1 Bricks shall be stacked in regular tiers as and when they are unloaded to minimize breakage and
defacement. These shall not be dumped at site.
1.8.2 Bricks stacks shall be placed close to the site of work so that least effort is required to unload
and transport the bricks again by loading on pallets or in barrows. Building bricks shall be loaded or
unloaded a pair at a time unless palletized. Unloading of building bricks or handling in any other way
likely to damage the corners or edges or other parts of bricks shall not be permitted.
1.8.3 Bricks shall be stacked on dry firm ground. For proper inspection of quality and ease in counting
the stacks shall be 50 bricks long, 10 bricks high and not more than 4 bricks in width, the bricks being
placed on edge, two at a time along the width of the stack. Clear distance between adjacent stacks
shall not be less than 0.8 m. Bricks of each truck load shall be put in one stack.
5

1.8.4 Bricks of different types, such as clay bricks, clay fly ash bricks, fly ash lime bricks, sand lime
(calcium silicate) bricks, auto-clave bricks etc. shall be stacked separately. Bricks of different
classification and size consideration (such as, conventional and modular) shall be stacked separately.
Also bricks of different types, such as, solid, hollow and perforated shall be stacked separately.
1.9 BLOCKS
1.9.1 Blocks are available as hollow and solid concrete blocks, hollow and solid light weight concrete
blocks, autoclaved aerated concrete blocks, concrete stone masonry blocks and soil based blocks.
1.9.2 Blocks shall be unloaded one at a time and stacked in regular tiers to minimize breakage and
defacement. These shall not be dumped at site. The height of the stack shall not be more than 1.2 m.
The length of the stack shall not be more than 3.0 m, as far as possible and the width shall be of two
or three blocks.
1.9.3 Normally blocks cured for 28 days only should be received at site. In case blocks cured for less
than 28 days are received, these shall be stacked separately. All blocks should be water cured for 10
to 14 days and air cured for another 15 days; thus no blocks with less than 28 days curing shall be
used in building construction.
1.9.4 Blocks shall be placed close to the site of work so that least effort is required for their
transportation.
1.9.5 Blocks manufactured at site shall be stacked at least for required minimum curing period as
given in 1.9.3.
1.9.6 The date of manufacture of the blocks shall be suitably marked on the stacks of blocks
manufactured at factory or site.
1.10 FLOOR, WALL AND ROOF TILES
1.10.1 Floor, wall and clay roof tiles of different types, such as, cement concrete tiles (plain, coloured
and terrazzo) and ceramic tiles (glazed and unglazed) shall be stacked on regular platform as far as
possible under cover in proper layers and in tiers and they shall not be dumped in heaps. In the stack,
the tiles shall be so placed that the mould surface of one faces that of another. Height of the stack
shall not be more than one metre. During unloading, these shall be handled carefully so as to avoid
breakage.
1.10.2 Tiles of different quality, size and thickness shall be stacked separately to facilitate easy
removal for use in work. Tiles when supplied by manufacturers packed in wooden crates, shall be
stored in crates. The crates shall be opened one at a time as and when required for use.
1.10.3 Ceramic tiles and clay roof tiles are generally supplied in cartons which shall be handled with
care. It is preferable to transport these at the site on platform trolleys.
1.11 AGGREGATES
1.11.1 Aggregates shall be stored at site on a hard dry and level patch of ground. If such a surface is
not available, a platform of planks or old corrugated iron sheets, or a floor of bricks, or a thin layer of
lean concrete shall be made so as to prevent contamination with clay, dust, vegetable and other
foreign matter.
1.11.2 Stacks of fine and coarse aggregates shall be kept in separate stock piles sufficiently removed
from each other to prevent the material at the edges of the piles from getting intermixed. On a large
job, it is desirable to construct dividing walls to give each type of aggregates its own compartment.
Fine aggregates shall be stacked in a place where loss due to the effect of wind is minimum.
1.11.3 Unless specified otherwise or necessitated by site conditions stacking of the aggregates should
be carried out in regular stacks. The suggested sizes for stacks are as follows :

Sl. no.

(i)
(ii)

(iii)

Material

Soling stone
Or
Coarse aggregates
Or
Or
Fine aggregates
Or
Or

Size of Stack (in m)

Length
5.0
5.0
2.0
5.0
5.0
2.0
5.0
5.0

Breadth
2.0
1.0
2.0
5.0
1.0
2.0
5.0
1.0

Height
0.50
0.50
0.50
1.00
0.50
0.50
1.00
0.50

1.12 FLY ASH

Fly ash shall be stored in such a manner as to permit easy access for proper inspection and
identification of each consignment. Fly ash in bulk quantities shall be stored in stack similar to fine
aggregates as specified in 1.11 to avoid any intrusion of foreign matter. Fly ash in bags shall be stored
in stacks not more than 10 bags high.
1.13 STEEL
1.13.1 For each classification of steel, separate areas shall be earmarked. It is desirable that ends of
bars and sections of each class be painted in distinct separate colours.
1.13.2 Steel reinforcement shall ordinarily be stored in such a way as to avoid distortion and to prevent
deterioration and corrosion. It is desirable to coat reinforcement with cement wash before stacking to
prevent scaling and rusting.
1.13.3 Bars of different classification, sizes and lengths shall be stored separately to facilitate issues in
such sizes and lengths so as to minimize wastage in cutting from standard lengths.
1.13.4 In case of long storage, reinforcement bars shall be stacked above ground level by at lest 150
mm. Also in coastal areas or in case of long storage a coat of cement wash shall be given to prevent
scaling and rusting.
1.13.5 Structural steel of different classification, sizes and lengths shall be stored separately. It shall
be stored above ground level by at least 150 mm upon platforms, skids or any other suitable supports
to avoid distortion of sections. In coastal areas or in case of long storage suitable protective coating of
primer paint shall be given to prevent scaling and rusting.
1.14 ALUMINIUM SECTIONS
Aluminium sections of different classification, sizes and lengths shall be stored separately, on a level
platform under cover. The aluminium sections shall not be pulled or pushed from the stack nor shall
be slided over each other, to protect the anodizing layer.
1.15 DOORS, WINDOWS AND VENTILATORS
1.15.1 General
While unloading, shifting handling and stacking timber or other lignocellulosic material based, metal
and plastic door and window frames and shutters, care shall be taken that the material is not dragged
one over the other as it may cause damage to the surface of the material particularly in the case of
decorative shutters. The material should be lifted and carried preferably flat avoiding damage of
corners or sides.
1.15.2 Metal and plastic doors, windows and ventilators shall be stacked upright (on their sills) on level
ground preferably on wooden battens and shall not come in contact with dirt and ashes. If received in

crates they shall be stacked according to manufacturers instructions and removed from the crates as
and when required for the work.
1.15.3 Metal and plastic frames of doors, windows and ventilators shall be stacked upside down with
the kick plates at the top. These shall not be allowed to stand for long in this manner before being
fixed so as to avoid the door frames getting out of shape and hinges being strained and shutters
drooping.
1.15.4 During the period of storage all metal doors, windows and ventilators shall be protected from
loose cement and mortar by suitable covering such as tarpauline. The tarpauline shall be hung loosely
on temporary framing to permit circulation of air to prevent condensation.
1.15.5 All timber and other lignocellulosic material based frames and shutters shall be stored in a dry
and clean covered space away from any infestation and dampness. The storage shall preferably be in
well ventilated dry rooms. The frames shall be stacked one over the other in vertical stacks with cross
battens at regular distances to keep the stack vertical and straight. These cross battens should be of
uniform thickness and placed vertically one above the other. The door shutters shall be stacked in the
form of clean vertical stacks over the other and at least 80 mm above ground on pallets or suitable
beams or rafters. The top of the stack shall be covered by a protecting cover and weighted down by
means of scantlings or other suitable weights. The shutter stack shall rest on hard and level ground.
1.15.6 If any timber or other lignocellulosic material based frame or shutter becomes wet during
transit, it shall be kept separate from the undamaged material. The wet material may be dried by
stacking in shade with battens in between adjacent boards with free access of dry air generally
following the guidance laid down in IS 1141.
1.15.7 Separate stacks shall be built up for each size, each grade and each type of material. When
materials of different sizes grades and types are to be stacked in one stack due to shortage of space,
the bigger size shall be stacked in the lower portion of the stacks. Suitable pallets or separating
battens shall be kept in between the two types of material.
1.16 ROOFING SHEETS
1.16.1 Roofing sheets shall be stored and handled in such a manner as not do damage them in any
way.
1.16.1 Plain and corrugated asbestos cement sheets shall be stacked horizontally to a height of not
more than one meter on a firm and level ground, with timber or other packing beneath them. If stacked
in exposed position, they shall be protected from damage by the winds.
Asbestos cement sheets of same variety and size shall be stacked together. Damage sheets shall not
be stacked with sound materials. All damaged sheets shall be salvaged as early as possible.
1.16.2 Corrugated galvanized iron sheets and aluminium sheets shall be stacked horizontally to a
height of not more than 0.5 m on a firm and level ground, with timber or other packing beneath them.
To protect them from dust and rain water, these shall be covered with tarpaulin or polyethylene sheets.
1.16.3 Plastic sheets and glass reinforced plastic (GRP) sheets shall be stacked under a shed to a
height of not more than 0.5 m on a firm and level ground with timber or other packing beneath them.
1.17 GYPSUM BOARDS, PLYWOOD, FIBREBOARD, PARTICLE BOARD, BLOCK BOARD, ETC.
1.17.1 These boards shall be stored flat in a covered clean and dry place. Different sizes and types of
each of these boards shall be stacked separately.
The board shall be stacked on a flat platform on which a wooden frame shall be constructed with 50
mm x 25 mm battens in such a way that it will give support to all four edges and corners of the boards
with intermediate battens placed at suitable intervals to avoid warping.
The boards shall be stacked in a solid block in a clear vertical alignment. The top sheet of each stack
8

shall be suitably weighed down to prevent warping wherever necessary.

The boards shall be unloaded and stacked with utmost care avoiding damage to the corners and
surface. In case of decorative plywood and decorative boards, the surfaces of which are likely to get
damaged by dragging one sheet over another it is advisable that these are lifted as far as possible in
pairs facing each other.
1.18 GLASS SHEETS
1.18.1 It is important that all glass sheets whether stored in crates or not shall be kept dry. Suitable
covered storage space shall be provided for the safe storage of the glass sheets. In removing glass
sheets from crates, great care shall be taken to avoid damages. The glass sheets shall be lifted and
stored on its long edges against a vertical wall or other support with the first sheet so placed that its
bottom edge is 25 mm from the vertical support. The stacks shall be of not more than 25 panes and
shall be supported at two points by fillets of wood at 300 mm from each end. The whole stack shall be
as close and as upright as possible.
The glass sheets of different sizes, thickness and type shall be stacked separately. The distance
between any two stacks shall be of the order of 400 mm.
1.19 CAST IRON, GALVANIZED IRON AND ASBESTOS CEMENT PIPES AND FITTINGS
1.19.1 The pipes shall be unloaded where they are required when the trenches are ready to receive
them.
1.19.2 Storage shall be done on firm, level and clear ground and wedges shall be provided at the
bottom layer to keep the stack stable.
1.19.3 The stack shall be in pyramid shape or the pipes length-wise and cross-wise in alternate layers.
The pyramid stack is advisable in smaller diameter pipes for conserving space in storing them. The
height of the stack shall not exceed 1.5 m.
1.19.4 Each stack shall contain only pipes of same class and size, with consignment or batch number
marked on it with particulars of suppliers wherever possible.
1.19.5 Cast iron detachable joints and fittings shall be stacked under cover separately from the
asbestos cement pipes and fittings.
1.19.6 Rubber rings shall be kept clean, away from grease, oil heat and light.
1.20 POLYETHYLENE PIPES
1.20.1 Natural polyethylene pipe should be stored under cover and protected from direct sunlight.
However, black polyethylene pipes may be stored either under cover or in the open.
1.20.2 Coils may be stored either on edges or stacked flat one on top of the other, but in either case
they should not be allowed to come into contact with hot water or steam pipes and should be kept
away from hot surface.
1.20.3 Straight lengths should be stored on horizontal racks giving continuous support to prevent the
pipe taking on a permanent set.
1.20.4 Storage of pipes in heated areas exceeding 27o C should be avoided.
1.21 UNPLASTICIZED PVC PIPES
1.21.1 The pipe should be given adequate support at all times. Pipes should be stored on a
reasonably flat surface free from stones and sharp projections so that the pipe is supported throughout

its length. In storage, pipe racks should be avoided. Pipe should not be stacked in large piles,
especially under warm temperature conditions as the bottom pipes may distort, thus giving rise to
difficulty in jointing. Socket and spigot pipes should be stacked in layers with sockets placed at
alternate ends of the stacks to avoid lopsided stacks.
1.21.1.1 It is recommended not to store pipe inside another pipe.
1.21.1.2 On no account should pipes be stored in a stressed or bent condition or near the sources of
heat.
1.21.1.3 Pipes should not be stacked more than 1.5 m high. Pipes of different sizes and classes
should be stacked separately.
1.21.2 The ends of pipe should be protected from abrasion particularly those specially prepared for
jointing either spigot or socket solvent welded joints or shouldered for use with couplings.
1.21.3 In tropical conditions, pipes should be stored in shade. In very cold weather, the impact strength
of PVC is reduced making it brittle and more care in handling shall be exercised in wintry condition.
1.21.4 If due to unsatisfactory storage of handling a pipe becomes kinked, the damaged portion
should be cut out completely. Kinking is likely to occur only on very thin walled pipes.
1.22 BITUMEN, ROAD TAR, ASPHALT, ETC.
1.22.1 All types of bitumen, road tar, asphalt, etc, in drums or containers shall be stacked vertically on
their bottoms in up to 3 tiers. Leaky drums shall be segregated. Empty drums shall be stored in
pyramidal stacks neatly in rows.
1.23 WATER
1.23.1 Wherever water is to be stored for construction purposes this shall be done in proper storage
tanks to prevent any organic impurities getting mixed up with it.
1.24 OIL PAINTS
1.24.1 All containers of paints, thinners and allied materials shall preferably be stored in a separate
room on floors with sand cushions. The room shall be well-ventilated and free from excessive heat,
sparks of flame and direct rays of sun. The containers of paint shall be kept covered or properly fitted
with lid and shall not be kept open except while using. The containers of paints have expiry date
marked by the manufacturers, which should be highlighted so as to facilitate use of paint within due
period.
1.25 SANITARY APPLIANCES
1.25.1 All sanitary appliances shall be carefully stored under cover to prevent damage. When
accepting and storing appliances, advance planning shall be made regarding the sequence of removal
from the store to the assembly positions. Supporting brackets shall be so stored as to be readily
accessible for use with the appliances.
1.26 OTHER MATERIALS
1.26.1 Small articles like nails, screws, nuts and bolts, door and window fittings, polishing stones,
protective clothing, spare parts of machinery, linings, packing, water supply and sanitary fittings,
electrical fittings, insulation board, etc, shall be kept in suitable and properly protected store rooms.
Valuable small material such as, copper pipes and fittings shall be kept under lock and key.
1.27 MEASUREMENTS
Length, breadth and height of stacks shall be measured correct to a cm. The quantity shall be worked
out in cubic metre correct to two place of decimal. The volume of stacks shall be reduced by

10

percentages as shown against each for looseness in stacking to arrive at the net quantity for payment.
No reduction shall be made in respect of articles or materials for which mode of payment is by length
or weight or number.
1.27.1 Earth
In loose stacks such as cart loads, lorry loads, etc. 20%
In fills consolidated by light mechanical machinery 10%
In fills consolidated by heavy mechanical machinery but not under OMC (Optimum Moisture
Content) 5%
In fills consolidated by heavy mechanical machinery at OMC Nil
Consolidated fills in confined situation such as under floors. etc. Nil
Other Materials
Manure or sludge 8%
Moorum, building rubbish Lime and sand Nil
Stone metal, 40 mm nominal size and above 7.5%
Coarse aggregate/ stone metal below 40 mm nominal size Nil
Soling stone/ Boulder 100 mm and above 15%
Excavated rocks 50%
1.28 RATE
The rate for carriage of materials is inclusive of all the operations described above.
TABLE 1.1
Storage and Stacking Check List (Clause 1.4.1)
Sl.
N
o.

Material /
Component

1
2

Cement
Stone and
Aggregates
Stones,
aggregates, fly
ash and cinder
Veneering
stones
Bricks
and
Blocks
Tiles
Clay and
concrete floor,
wall and roof
tiles
Ceramic tiles
Steel
Aluminum
Sections
Door, windows
and Ventilators
Roofing Sheets
AC
GI
and
Aluminum

b
3
4
a

b
5
6
7
8
a
b

Firm
Level
Groun
d

Base
Har
d
Flo
or

Off
Flo
or

Heap
s

Stack
Tier Fla
s
t

Vertic
al

Type of cover
Ope Open
Und
n
but
er
covere shed
d

11

Sheets

Plastic Sheets
Boards like
Plywood,
Particle
Boards, Fibre

Boards,
Blockboards
and
Gypsum Board

10 Glass Sheets
11 CI, GI and AC
Pipes & fittings

a Pipes
b CI
and
GI

fittings

c AC Fittings
12 Polyethlylene

Pipes
13 Unplasticized

PVC Pipes
14 Bitumen, Road

Tar, Asphalt, etc

in Drums

15 Oil Paints
16 Sanitary

Appliances
TYPICAL SKETCH FOR CEMENT GODOWN
c
9

Figure 1
Fig. 1.1 : Typical Arrangement in Cement Godown

12

SUB-HEAD 2.0

(SPECIFICATION EARTH WORK EXCAVATION)

13

CONTENTS
Clause No.

Brief Description
List of Bureau of Indian Standard Codes

Page No.

2.0

Definitions

2.1

Classification of Soils

2.2

Antiquities and Useful Materials

2.3

Protections

2.4

Site Clearance

2.5

Setting out and Making profiles

2.6

Blasting

2.7

Excavation in All kinds of soils

2.8

Excavation in Ordinary/ Hard rock

2.9

Earth work by mechanical means

2.10

Filling

2.11

Measurements

2.12

Rates

2.13

Surface Excavation

2.14

Rough Excavation and Filling

2.15

Excavation over Area (All kinds of Soil)

2.16

Excavation over Area (Ordinary/Hard rock)

2.17

Excavation in Trenches for Foundations & drains (All kinds of Soil)

2.18

Excavation in Trenches for Foundation & Drains (Ordinary/ Hard rock)

2.19

Excavation in Trenches for Pipes, Cables etc. and Refilling

2.20

Planking and Strutting

2.21

Excavation in Water, Mud or Foul position

2.22

Earth work for major works

2.23

Filling in Trenches, Plinth, under Floor etc.

2.24

Sand Filling in Plinth

2.25

Surface Dressing

2.26

Jungle Clearance

2.27

Felling Trees

14

LIST OF BUREAU OF INDIAN STANDARD CODES

S. No. I.S. No.

Subject

IS 632

Gamma BHC (Lindane) emulsifiable concentrates

IS 1200 (Pt 1)

Method of measurement of earth work

IS 1200 (Pt-27)

Method of measurement of earth work (by Mechanical

Appliances )

IS 4081

Safety code for Blasting and related drilling operation

IS 4988 (Part IV)

Excavators

IS 6313 (pt-II)

Anti Termite measures in buildings (pre -constructional)

IS 6313(pt.-III)

Anti Termite Measures in Buildings for existing buildings

IS 6940

Methods of test for pesticides and their formulations

IS 8944

Chlorpyrifos emulsifiable concentrates

10

IS 8963 Chlorpyrifos

Technical specifications

11

IS 12138

Earth moving Equipments

15

2.0 EARTH WORK

2.0 DEFINITIONS
Dead men or Tell Tales: Mounds of earth left undisturbed in pits dug out for borrowing earth
Burjis: Short pillars of brick/ stone having top surface finished with cement plaster for marking etc.
Formation or Profile: Final shape of the ground after excavation or filling up.
Foul condition: Filthy and unhygienic conditions where physical movements are hampered such as
soil mixed with sewage or night soil.
Lead : All distances shall be measured over the shortest practical route and not necessarily the route
actually taken. Route other than shortest practical route may be considered in cases of unavoidable
circumstances and approved by Architect / Engineer-in-Charge along with reasons in writing. Carriage
by manual labour shall be reckoned in units of 50 meters or part thereof. Carriage by animal and
mechanical transport shall be reckoned in one km. unit. Distances of 0.5 km. or more shall be taken
as 1 km. and distance of less than 0.5 km. shall be ignored. However, when the total lead is less than
0.5 km., it will not be ignored but paid for separately in successive stages of 50 meters subject to the
condition that the rate worked on this basis does not exceed the rate for initial lead of 1 km. by
mechanical/animal transport.
Lift: The vertical distance for removal with reference to the ground level. The excavation up to 1.5
meters depth below the ground level and depositing the excavated materials upto 1.5 meters above
the ground level are included in the rate of earth work. Lifts inherent in the lead due to ground slope
shall not be paid for.
Safety rules: Safety rules as laid down by the statutory authority and as provided in National Building
Code (NBC) shall be followed.
2.1 CLASSIFICATION OF SOILS
2.1.0 The earthwork shall be classified under the following categories and measured separately for
each category:
(a) All kind of soils: Generally any strata, such as sand, gravel, loam, clay, mud, black cotton
moorum, shingle, river or nallah bed boulders, siding of roads, paths etc. and hard core,
macadam surface of any description (water bound, grouted tarmac etc.), lime concrete mud
concrete and their mixtures which for excavation yields to application of picks, showels,
jumper, sacrifiers, ripper and other manual digging implements.
(b) Ordinary rock: Generally any rock which can be excavated by splitting with crow bars or
picks and does not require blasting, wedging or similar means for excavation such as lime
stone, sand stone, hard laterite, hard conglomerate and un-reinforced cement concrete below
ground level. If required light blasting may be resorted to for loosening the materials but this
will not in any way entitle the material to be classified as Hard rock.
(c) Hard rock: Generally any rock or boulder for the excavation of which blasting is required such
as quartzite, granite, basalt, reinforced cement concrete (reinforcement to be cut through but
not separated from concrete) below ground level and the like.
(d) Hard rock (blasting prohibited): Hard rock requiring blasting as described under (c) but
where the blasting is prohibited for any reason and excavation has to be carried out by
chiseling, wedging, use of rock hammers and cutters or any other agreed method.
2.2 ANTIQUITIES AND USEFUL MATERIALS
2.2.1 Any finds of archaeological interest such as relics of antiquity, coins, fossils or other articles of
value shall be delivered to the Architect / Engineer-in-Charge and shall be the property of the
Government.
16

2.2.2 Any material obtained from the excavation which in the opinion of the Architect / Engineer-inCharge is useful shall be stacked separately in regular stacks as directed by the Architect / Engineerin-Charge and shall be the property of the Government.
2.3 PROTECTIONS
2.3.1 Excavation where directed by the Architect / Engineer-in-Charge shall be securely barricaded
and provided with proper caution signs, conspicuously displayed during the day and properly
illuminated with red lights and/or written using fluorescent reflective paint as directed by engineer in
charge during the night to avoid accident.
2.3.2 The Contractor shall take adequate protective measures to see that the excavation operations
do not damage the adjoining structures or dislocate the services. Water supply pipes, sluice valve
chambers, sewerage pipes, manholes, drainage pipes and chambers, communication cables, power
supply cables etc. met within the course of excavation shall be properly supported and adequately
protected, so that these services remain functional. However, if any service is damaged during
excavation shall be restored in reasonable time.
2.3.3 Excavation shall not be carried out below the foundation level of the adjacent buildings until
under-pinning, shoring etc. is done as per the directions of the Architect / Engineer-in-Charge for
which payment shall be made separately.
2.3.4 Any damages done by the contractor to any existing work shall be made good by him at his own
cost. Existing drains pipes, culverts, over head wires, water supply lines and similar services
encountered during the course of execution shall be protected against damage by the contractor. The
contractor shall not store material or otherwise occupy any part of the site in manner likely to hinder
the operations of such services.
2.4 SITE CLEARANCE
2.4.1 Before the earth work is started, the area coming under cutting and filling shall be cleared of
shrubs, rank vegetation, grass, brushwood, trees and saplings of girth up to 30cm measured at a
height of one meter above ground level and rubbish removed up to a distance of 50 meters outside
the periphery of the area under clearance. The roots of trees and saplings shall be removed to a depth
of 60cm below ground level or 30 cm below formation level or 15 cm below sub grade level, whichever
is lower, and the holes or hollows filled up with the earth, rammed and leveled.
2.4.2 The trees of girth above 30 cm measured at a height of one meter above ground shall be cut
only after permission of the Architect / Engineer-in-Charge is obtained in writing. The roots of trees
shall also be removed as specified in 2.4.1. Payment for cutting such trees and removing the roots
shall be made separately.
2.4.3 Existing structures and services such as old buildings, culverts, fencing, water supply pipe lines,
sewers, power cables, communication cables, drainage pipes etc. within or adjacent to the area if
required to be diverted/removed, shall be diverted/dismantled as per directions of the Engineer-inCharge and payment for such diversion/dismantling works shall be made separately.
2.4.4 In case of archaeological monuments within or adjacent to the area, the contractor shall provide
necessary fencing al round such monuments as per the directions of the Architect / Engineer-inCharge and protect the same properly during execution of works. Payment for providing fencing shall
be made separately.
2.4.5 Lead of 50 m mentioned in the Schedule of Quantities is the average lead for the disposal of
excavated earth within the site of work. The actual lead for the lead for the disposal of earth may be
more or less than the 50 m for which no cost adjustment shall be made in the rates.
2.4.6 Disposal of Earth shall be disposed off at the specified location or as decided by the Engineer-inCharge. The contractor has to take written permission about place of disposal of earth before the earth
is disposed off, from Engineer-in-Charge.
17

2.5 SETTING OUT AND MAKING PROFILES

2.5.1 A masonry pillar to serve as a bench mark will be erected at a suitable point in the area, which is
visible from the largest area. This bench mark shall be constructed as per Fig. 2.1 and connected with
the standard bench mark as approved by the Engineer-in-Charge. Necessary profiles with strings
stretched on pegs, bamboos or Burjis shall be made to indicate the correct formation levels before
the work is started. The contractor shall supply labour and material for constructing bench mark,
setting out and making profiles and connecting bench mark with the standard bench mark at his own
cost. The pegs, bamboos or Burjis and the bench mark shall be maintained by the contractor at his
own cost during the excavation to check the profiles.
2.5.2 The ground levels shall be taken at 5 to 15 meters intervals (as directed by the Engineer-inCharge) in uniformly sloping ground and at closer intervals where local mounds, pits or undulations
are met with. The ground levels shall be recorded in field books and plotted on plans. The plans shall
be drawn to a scale of 5 meters to one cm or any other suitable scale decided by the Engineer-inCharge. North direction line and position of bench mark shall invariable be shown on the plans. These
plans shall be signed by the contractor and the Architect / Engineer-in-Charge or their authorized
representatives before the earth work is started. The labour required for taking levels shall be supplied
by the contractor at his own cost.
2.6 BLASTING
2.6.0 Where hard rock is met with and blasting operations are considered necessary, the contractor
shall obtain the approval of the Architect / Engineer-in-Charge in writing for resorting to blasting
operation.
Note: In ordinary rock blasting operations shall not be generally adopted. However, the contractor may
resort to blasting with the permission of the Engineer-in-charge, but nothing extra shall be paid for
such blasting operations.
The contractor shall obtain license from the competent authority for undertaking blasting work as well
as for obtaining and storing the explosive as per the Explosive Act, 1884 as amended up to date and
the Explosive Rules, 1983. The contractor shall purchase the explosives fuses, detonators, etc. only
from a licensed dealer. The contractor shall be responsible for the safe transportation, storage and
custody as per explosive rules and proper accounting of the explosive materials. Fuses and
detonators shall be stored separately and away from the explosives. The Architect / Engineer-inCharge or his authorized representative shall have the right to check the contractors store and
account of explosives. The contractor shall provide necessary facilities for this. The contractor shall be
responsible for any damage arising out of accident to workmen, public or property due to storage,
transportation and use of explosive during blasting operation.
2.6.1 Blasting operations shall be carried out under the supervision of a responsible authorized agent
of the contractor (referred subsequently as agent only), during specified hours as approved in writing
by the Engineer-in-Charge. The agent shall be conversant with the rules of blasting. In case of blasting
with dynamite or any other high explosive, the position of all the bore holes to be drilled shall be
marked in circles with white paint. These shall be inspected by the contractors agent. Bore holes shall
be of a size that the cartridge can easily pass down. After the drilling operation, the agent shall inspect
the holes to ensure that drilling has been done only at the marked locations and no extra hole has
been drilled. The agent shall then prepare the necessary charge separately for each bore hole. The
bore holes shall be thoroughly cleaned before a cartridge is inserted. Only cylindrical wooden tamping
rods shall be used for tamping. Metal rods or rods having pointed ends shall never be used for
tamping. One cartridge shall be placed in the bore hole and gently pressed but not rammed down.
Other cartridges shall then be added as may be required to make up the necessary charge for the
bore hole. The top most cartridges shall be connected to the detonator which shall in turn be
connected to the safety fuses of required length. All fuses shall be cut to the length required before
being inserted into the holes. Joints in fuses shall be avoided. Where joints are unavoidable a semicircular nitch shall be cut in one piece of fuse about 2 cm deep from the end and the end of other
piece inserted into the nitch. The two pieces shall then be wrapped together with string. All joints
exposed to dampness shall be wrapped with rubber tape.

18

The maximum of eight bore holes shall be loaded and fired at one occasion. The charges shall be
fired successively and not simultaneously. Immediately before firing, warning shall be given and the
agent shall see that all persons have retired to a place of safety. The safety fuses of the charged holes
shall be ignited in the presence of the agent, who shall see that all the fuses are properly ignited.
Careful count shall be kept by the agent and others of each blast as it explodes. In case all the
charged bore holes have exploded, the agent shall inspect the site soon after the blast but in case of
misfire the agent shall inspect the site after half an hour and mark red crosses (X) over the holes
which have not exploded. During this interval of half an hour, nobody shall approach the misfired
holes. No driller shall work near such bore until either of the following operations have been done by
the agent for the misfired boreholes.
(a) The contractors agent shall very carefully (when the tamping is of damp clay) extract the
tamping with a wooden scraper and withdraw the fuse, primer and detonator. After this a fresh
detonator, primer and fuse shall be placed in the misfired holes and fired, or
(b) The holes shall be cleaned for 30 cm of tamping and its direction ascertained by placing a
stick in the hole. Another hole shall then be drilled 15 cm away and parallel to it. This hole
shall be charged and fired. The misfired holes shall also explode along with the new one.
Before leaving the site of work, the agent of one shift shall inform the other agent relieving him
for the next shift, of any case of misfire and each such location shall be jointly inspected and
the action to be taken in the matter shall be explained to the relieving agent. The Architect /
Engineer-in-Charge shall also be informed by the agent of all cases of misfires, their causes
and steps taken in that connection.
2.6.2 General Precautions
For the safety of persons red flags shall be prominently displayed around the area where blasting
operations are to be carried out. All the workers at site, except those who actually ignite the fuse, shall
withdraw to a safe distance of at least 200 meters from the blasting site. Audio warning by blowing
whistle shall be given before igniting the fuse. Blasting work shall be done under careful supervision
and trained personnel shall be employed. Blasting shall not be done with in 200 meters of an existing
structure, unless specifically permitted by the Architect / Engineer-in-Charge in writing.
All procedures and safety precautions for the use of explosives drilling and loading of explosives
drilling and loading of explosives before and after shot firing and disposal of explosives shall be taken
by the contractor as detailed in IS 4081, safety code for blasting and related drilling operation.
2.6.3 Precautions against Misfire
The safety fuse shall be cut in an oblique direction with a knife. All saw dust shall be cleared from
inside of the detonator. This can be done by blowing down the detonator and tapping the open end. No
tools shall be inserted into the detonator for this purpose. If there is water present or if the bore hole is
damp, the junction of the fuse and detonator shall be made water tight by means of tough grease or
any other suitable material.
The detonator shall be inserted into the cartridge so that about one third of the copper tube is left
exposed outside the explosive. The safety fuse just above the detonator shall be securely tied in
position in the cartridge. Water proof fuse only shall be used in the damp bore hole or when water is
present in the bore hole.
If a misfire has been found to be due to defective fuse, detonator or dynamite, the entire consignment
from which the fuse detonator or dynamite was taken shall be got inspected by the Architect /
Engineer-in-Charge or his authorized representative before resuming the blasting or returning the
consignment.
2.7 EXCAVATION IN ALL KINDS OF SOILS
2.7.1 All excavation operations manually or by mechanical means shall include excavation and getting
out the excavated materials. In case of excavation for trenches, basements, water tanks etc. getting
out shall include throwing the excavated materials at a distance of at least one meter or half the depth

19

of excavation, whichever is more, clear off the edge of excavation. In all other cases getting out shall
include depositing the excavated materials as specified. The subsequent disposal of the excavated
material shall be either stated as a separate item or included with the items of excavation stating lead.
2.7.2 During the excavation the natural drainage of the area shall be maintained. Excavation shall be
done from top to bottom. Undermining or undercutting shall not be done.
2.7.3 In firm soils, the sides of the trenches shall be kept vertical upto a depth of 2 meters from the
bottom. For greater depths, the excavation profiles shall be widened by allowing steps of 50 cms on
either side after every 2 meters from the bottom. Alternatively, the excavation can be done so as to
give slope of 1:4 (1 horizontal : 4 vertical). Where the soil is soft, loose or slushy, the width of steps
shall be suitably increased or sides sloped or the soil shored up as directed by the Engineer-inCharge. It shall be the responsibility of the contractor to take complete instructions in writing from the
Architect / Engineer-in-Charge regarding the stepping , sloping or shoring to be done for excavation
deeper than 2 meters.
2.7.4 The excavation shall be done true to levels, slope, shape and pattern indicated by the Engineerin-Charge. Only the excavation shown on the drawings with additional allowances for centering and
shuttering or as required by the Architect / Engineer-in-Charge shall be measured and recorded for
payment.
2.7.5 In case of excavation for foundation in trenches or over areas, the bed of excavation shall be to
the correct level or slope and consolidated by watering and ramming. If the excavation for foundation
is done to a depth greater than that shown in the drawings or as required by the Engineer-in-Charge,
the excess depth shall be made good by the contractor at his own cost with the concrete of the mix
used for leveling/ bed concrete for foundations. Soft/defective spots at the bed of the foundations shall
be dug out and filled with concrete (to be paid separately) as directed by the Engineer-in-Charge.
2.7.6 While carrying out the excavation for drain work care shall be taken to cut the side and bottom to
the required shape, slope and gradient. The surface shall then be properly dressed. If the excavation
is done to a depth greater than that shown on the drawing or as required by the Engineer-in-Charge,
the excess depth shall be made good by the contractor at his own cost with stiff clay puddle at places
where the drains are required to be pitched and with ordinary earth, properly watered and rammed,
where the drains are not required to be pitched. In case the drain is required is to be pitched, the back
filling with clay puddle, if required, shall be done simultaneously as the pitching work proceeds. The
brick pitched storm water drains should be avoided as far as possible in filled-up areas and loose
soils.
2.7.7 In all other cases where the excavation is taken deeper by the contractor, it shall be brought to
the required level by the contractor at his own cost by filling in with earth duly watered, consolidated
and rammed.
2.7.8 In case the excavation is done wider than that shown on the drawings or as required by the
Engineer-in-Charge, additional filling wherever required on the account shall be done by the contractor
at his own cost.
2.7.9 The excavation shall be done manually or by mechanical means as directed by Architect /
Engineer-in-Charge considering feasibility, urgency of work, availability of labour /mechanical
equipments and other factors involved. Contractor shall ensure every safety measures for the workers.
Neither any deduction will be made nor any extra payment will be made on this account.
2.8 EXCAVATION IN ORDINARY/HARD ROCK
2.8.1 All excavation operations shall include excavation and getting out the excavated matter. In case
of excavation for trenches, basements, water tanks etc. getting out shall include throwing the
excavated materials at a distance of at least one meter or half the depth of excavation, whichever is
more, clear off the edge or excavation. In all other cases getting out shall include depositing the
excavated materials as specified. The subsequent disposal of the excavated material shall be either
stated as a separate item or included with the item of excavation stating lead.

20

2.8.2 During the excavation, the natural drainage of the area shall be maintained. Excavation shall be
done from top to bottom. Undermining or under cutting shall not be done.
2.8.3 Where hard rock is met with and blasting operations are considered necessary, the contractor
shall obtain the approval of the Architect / Engineer-in-Charge in writing for resorting to the blasting
operations. Blasting operations shall be done as specified in Para 2.6 and chiseling shall be done to
obtain correct levels, slopes, shape and pattern of excavation as per the drawings or as required by
the Architect / Engineer-in-Charge and nothing extra shall be payable for chiseling.
2.8.4 Where blasting operations are prohibited or are not practicable, excavation in hard rock shall be
done by chiseling.
2.8.5 In ordinary rock excavation shall be carried out by crowbars, pick axes or pneumatic drills and
blasting operation shall not be generally adopted. Where blasting operations are not prohibited and it
is practicable to resort to blasting for excavation in ordinary rock, contractor may do so with the
permission of the Architect / Engineer-in-Charge in writing but nothing extra shall be paid for this
blasting. Blasting shall be done as specified in Para 2.6.
2.8.6 If the excavation for foundations or drains is done to a depth greater than that shown in the
drawings or as required by the Engineer-in-Charge. The excess depth shall be made good by the
contractor at his own cost with the concrete of the mix used for leveling/ bed concrete for foundations.
Soft/ defective spots at the bed of foundations shall be dug out and filled with concrete (to be paid
separately) as directed by the Architect / Engineer-in-Charge.
2.8.7 In all other cases where the excavation is taken deeper by the contractor, it shall be brought to
the required level by the contractor at his own cost by filling with earth duly watered, consolidated and
rammed.
2.8.8 In case the excavation is done wider than that shown on the drawings or as required by the
Engineer-in-Charge, filling wherever required on this account shall be done by the contractor at his
own cost.
2.8.9 Only the excavation shown on the drawings or as required by the Architect / Engineer-in-Charge
shall be measured and recorded for payment except in case of hard rock, where blasting operations
have been resorted to, excavation shall be measured to the actual levels, provided the Architect /
Engineer-in-Charge is satisfied that the contractor has not gone deeper than what was unavoidable.
2.8.10 The excavation shall be done manually or by mechanical means as desired by Architect /
Engineer-in-Charge considering feasibility, urgency of work, availability of labour /mechanical
equipments and other factors involved Contractor shall ensure every safety measures for the workers.
Neither any deduction will be made nor any extra payment will be made on this account.
2.9 EARTH WORK BY MECHANICAL MEANS
Earth work by mechanical means involves careful planning keeping in view site conditions i.e. type of
soil, nature of excavation, distances through which excavated soil is to be transported and working
space available for employing these machines. The earth moving equipment should be accordingly
selected.
The earth moving equipment consists of excavating and transporting equipment. Excavating
equipments may be further classified as excavators and tractor based equipments.
2.9.1 Excavators
Excavators generally used at site are as follows:
(i) Dippershovel : It is used for excavating against a face or bank consisting of open-top
bucket or dipper with a bottom opening door, fixed to an arm or dipper stick which slides and
pivots on the jib of the crane. It is suitable for excavating all clay chalk and friable materials
and for handling rock and stone. However, it is not suitable for surface excavation for which a
skimmer is used.

21

(ii) Backhoe : It is similar to face shovel except that the dipper stick pivots on the end of the jib
and the dipper or bucket works towards the chassis and normally has no bottom door but is
emptied by swinging away from the chassis to invert the bucket. It may be designed to carry
both a front mounted bucket loading mechanism and a rear mounted backhoe. It is mainly
used to excavate trenches and occasionally used for the excavation of open areas such as
small basements. In the backhoe mode the bucket lifts, swings and discharges materials while
the undercarriage is stationary. When used in the loader mode, the machine loads or
excavated through forward motion of the machine, and lifts, transports and discharges
materials.
(iii) Skimmer : This arrangement is similar to the face shovel except that in this case the bucket
slides on rollers directly along the jib and thus has a more restricted movement. It is used for
surface excavation and leveling in conjunction with transport to haul away the excavated
material.
(iv) Dragline : It is usually fitted with a long slender boom or jib and the bucket, which in operation
faces towards the machine and has no door, is supported by cable only as on a crane. It
works from the side of the excavation at normal ground level and is used for excavating large
open excavations such as basements when the depth is beyond the limit of the boom of a
backhoe. It is commonly used for open cast mining operations.
(v) Clamshell : It consists of two hinged half-buckets or jaws pivoted to a frame which is
suspended by cable from a long jib of an excavation. The grab is used for deep excavations of
limited area on all types of soil except rock. Crane and Grab is a variant of this type of
equipment.
2.9.2 Tractorbased Equipment
It is a selfpropelled crawler or wheeled machine used to exert a push or pull force through mounted
equipment. It is designed either as attachments to normal tracked or wheeled tractors or as machines
in which the earth moving attachments and the tractor are designed as a single integrated unit. A
tractor, which is hydraulically operated, can be rigged as :
(i) Loaders : It is used for loading, light dozing, scraping and grabbing operations, lifting and
transporting the materials (loose earth, rubble, sand, gravel aggregate etc) at various sites
through forward motion of the machine.
(ii) Tractor Shovel : This consists of a tipping bucket at the front attached by strong pivoted arms
or booms to the frame of the machine. It is used for stripping top soil, excavating against a
face, bulldozing and for loading spoil or loose materials. It is similar to crawler dipper-shovel.
(iii) Trench Digger : It operates on the same principle as a backhoe excavator except that the
bucket is controlled by hydraulic rams instead of cables and pulleys.
(iv) Scraper : Scrapers provide unique capability to excavate, load, haul and dump materials.
Scrapers are available in various capacities by a number of manufacturers with options such
as self loading with elevators, twin engines or push-pull capability. They are cost effective
where the haul distance is too long for bulldozers, yet too short for trucks. This distance
typically ranges from 120 m to 1200 m; however, the economics should be evaluated for each
project. Scraper has an open bowl with a cutting edge positioned between the axles, which
cuts, loads, transports, discharges and spreads through forward motion of the machine.
Loading through forward motion of the machine can be assisted by a powered mechanism
(elevator) fixed to the scraper bowl.
(v) Bulldozer and Angle-dozer : The most common equipment used for clearing and leveling
activities is a bulldozer. The terms bulldozer is used to define a tractor mounted with a dozing
blade. The bulldozer consists of a rectangular steel blade with renewable cutting edge set at
right angles (capable of only tilting but not angling) to the direction of travel and attached by
steel arms to the side frames of a crawler tractor. It may be used for excavating natural soil or
for moving loose soil or debris, which is pushed forward as the tractor forces it ahead.

22

(vi) Angle dozer is capable of both tilting and angling

2.9.3 Transporting Equipment
This implies horizontal movement primarily but it can involve some vertical movement too.
(i) Dumpers : These are self-propelled wheeled machines, having an open body. It is designed
for the transport of excavated materials and consists of a shallow tipping hopper or skip
mounted on a wheeled chassis, such as, power barrow, dumper, multi-skip dumpers, high
discharge dumpers, dump truck, etc. These can be rear dump, side dump or bottom dump.
(ii) Vibratory Roller : It is a single Drum Vibratory Roller for compaction of embankments, etc.
The smooth drum version is for compaction of granular and mixed soil. The sheep foot Roller
consists of a hallow cylindrical steel drum or drums on which projecting feet are mounted.
These feet penetrate into the fill as a roller moves forward and cause compaction. The
geometry of the foot may be sheep, club pyramid, and cone or cylinder foot. Such rollers are
employed for compaction (densification) of cohesive and semi-cohesive soils.
2.10 FILLING
2.10.1 The earth used for filling shall be free from all roots, grass, shrubs, rank vegetation, brushwood,
tress, sapling and rubbish.
2.10.2 Filling with excavated earth shall be done in regular horizontal layers each not exceeding 20 cm
in depth. All lumps and clods exceeding 8 cm in any direction shall be broken. Each layer shall be
watered and consolidated with steel rammer or tonne roller. Where specified, every third and top
must layer shall also be consolidated with power roller of minimum 8 tones. Wherever depth of filling
exceeds 1.5 meter vibratory power roller shall be used to consolidate the filing unless otherwise
directed by Engineer-in-charge. The top and sides of filling shall be neatly dressed. The contractor
shall make good all subsidence and shrinkage in earth fillings, embankments, traverses etc. during
execution and till the completion of work unless otherwise specified.
2.11 MEASUREMENTS
2.11.1 The length and breadth of excavation or filling shall be measured with a steel tape correct to the
nearest cm. The depth of cutting or height of filling shall be measured, correct to 5 mm, by recording
levels before the start of the work and after the completion of the work. The cubical contents shall be
worked out to the nearest two places of decimal in cubic meters.
2.11.1.1 In case of open footings up to the depth of 1.5 meters, al round excavation of 30 cm. beyond
the outer dimension of footing shall be measured for payment to make allowances for centering and
shuttering. Any additional excavation beyond this limit shall be at the risk and cost of the contractor
and shall not be measured for payment.
2.11.1.2 In case of open footings/Rafts at a depth of more than 1.5 meter, all-round excavation of 75
cm shall be measured for payment to make allowance for centering and shuttering. Additional
excavation beyond this limit shall be at the risk and cost of the contractor and shall not be measured
for payment.
2.11.2 In case the ground is fairly uniform and where the site is not required to be leveled, the
Architect / Engineer-in-Charge may permit the measurements of depth of cutting or height of filling
with steel tape, correct to the nearest cm. In case of borrow pits, diagonal ridges, cross ridges or
dead-men, the position of which shall be fixed by the Engineer-in-Charge, shall be left by the
contractor to permit accurate measurements being taken with steel tape on the completion of the work
Deduction of such ridges and dead men shall be made from the measurements unless the same are
required to be removed later on and the earth so removed is utilized in the work. In the latter case
nothing extra will be paid for their removal as subsequent operation.
2.11.3 Where ordinary rock and hard rock is mixed. The measurement of the excavation shall be
made as specified in 2.11.1 and 2.11.2 the two kinds of rock shall be stacked separately and
measured in stacks. The net quantity of the two kinds of rocks shall be arrived at by applying
23

deduction of 50% to allow for voids in stacks. If the sum of net quantity of two kinds of rocks exceeds
the total quantity of the excavated material, then the quantity for each type of rock shall be worked out
from the total quantity in the ratio of net quantities in stack measurements of the two types of rocks. If
in the opinion of the Engineering-in-charge stacking is not feasible, the quantity of ordinary and hard
rock shall be worked out by means of cross-sectional measurements.
2.11.4 Where soil, ordinary rock and hard rock are mixed, the measurements for the entire excavation
shall be made as specified in 2.11.1 and 2.11.2 Excavated materials comprising hard rock and
ordinary rock shall be stacked separately, measured, and each reduced by 50% to allow for voids to
arrive at the quantity payable under hard rock and ordinary rock. The difference between the entire
excavation and the sum of the quantities payable under hard rock and ordinary rock shall be paid for
as excavation in ordinary soil or hard soil as the case may be.
2.11.5 Where it is not possible or convenient to measure the depth of cutting by recording levels as
specified in 2.11.1 quantity of excavation shall be worked out from filling. The actual measurements of
the fill shall be calculated by taking levels of the original ground before start of the work after site
clearance and after compaction of the fill as specified and the quantity of earth work so computed shall
be reduced by 10% in case of consolidated fills and by 5% in case the consolidation is done by heavy
mechanical machinery to arrive at the net quantity of excavation for payment. No such deduction shall,
however, be made in case of consolidation by heavy mechanical machinery at optimum moisture
content, or when the consolidated filling is in confined situations such as under floors.
2.11.6. Recording Measurements for Earth Leveling Work
2.11.6.1 Level Books: In case of leveling operations and earthwork, measurements are required to be
recorded in level books in addition to Measurement Books. The Level Books should be numbered,
accounted for and handled like Measurement Books.
2.11.6.2 Preparatory Works: Before starting the earth work, following steps should be taken :
(1) Original ground levels should be recorded in the Level Book in the presence of the contractor
or his authorized representative, and should be signed by him and the Department Officer who
records the levels. All the local mounds and depressions should be indicated clearly in the
drawing and the field Level Book and should be checked by the Assistant Engineer/Executive
Engineer before the leveling work is started.
(2) A suitable baseline should be fixed with permanent masonry pillars at distances not exceeding
150 meters to provide a permanent reference line for facilitating check work. The base line (s)
should be entered in the Level Book with co-ordinates. These baselines should be maintained
till the final payment for the work has been made.
(3) While recording the levels, it should be ensured that the circuit is closed by taking final levels
of the starting point or any other point, the R.L. of which was previously determined.
(4) Plans showing initial levels, location of bench marks and reduced levels, should be prepared
and signed by both the parties and attached to the agreement before commencement of the
work.
2.11.6.3 Test Check of the Levels
(1) The Assistant Engineer should exercise test check at least to the extent of 50%, and the
Executive Engineer at least to the extent of 10% where the value of this item of work exceeds
10% of the tender acceptance power of the Assistant Engineer.
(2) The test check of the levels should be carried out independently by each officer, and the
readings should be recorded in the prescribed Level Book in red ink against the old levels
which should be neatly scored out wherever necessary. If the test check carried out reveals
serious mistakes in the original levels, these should be taken or re-taken and re-checked.

24

(3) The test check carried out by an officer should be as representative as possible for the entire
work done.
(4) On completion of work, the levels should again be recorded in the Level Book and the
contractors signatures obtained. These levels should also be test checked by the Assistant
Engineer/Executive Engineer to the same extent as indicated in (1) within one month of the
date of completion of the earth work, and according to the procedure as laid down in the case
of initial levels as indicated above.
(5) The formation levels as per final execution of the work should be compared with the proposed
formation levels and the work got rectified within permissible tolerance.
2.11.6.4 Payment of Leveling Work
(1) Every fourth running bill and the final bill should be paid on the basis of levels.
(2) Intermediate payments can, however, be made on the basis of borrow pit measurements. The
Executive Engineer should take care that the quantities thus assessed are not in any case
more than the actual work done.
2.11.6.5 Large Scale Leveling Work
(1) In case of large scale leveling work involving both cutting and filling, an accurate site plan
should be prepared before the work is commenced. The portions requiring cutting and filling
shall then be divided into squares and corresponding squares into filling, which are
complementary to the squares in cutting given the same number.
(2) A table may be written upon the plan showing leads involved between the various
complementary squares. This would form a lead chart for the work to be done.
(3) Before the work of leveling is commenced, the lead chart shall be checked by the Assistant
Engineer in the presence of the contractor or his authorized representative, and his signatures
shall be obtained on the same. This should form an integral part of the contract and should be
duly signed by both the integral parties before commencement of the work.
(4) The quantity payable for earthwork shall be lower of the quantity derived from cutting or filling.
The payment for lead shall be based on lead chart prepared in the aforesaid manner.
2.11.6.6 Import of Earth: In case of earth to be imported, the area from where the earth is to be
imported, should be pre-determined wherever possible before the start of the work, and wherever
feasible, the average lead should be worked out and stipulated in the tender. After this is determined,
initial levels of the area to be filled should be recorded. The levels should be properly checked during
the progress of work and on completion.
2.12 RATES
2.12.1 Rates for Earthwork shall include the following:
(a)
(b)
(c)
(d)
(e)
(f)

Excavation and depositing excavated material as specified.

Handing of antiquities and useful material as specified on 2.2.
Protection as specified in 2.3.
Site clearance as specified in 2.4.
Setting out and making profiles as specified in 2.5.
Forming (or leaving) dead men or Tell Tales in borrow pits and their removal after
measurements.
(g) Bailing out or pumping of rain water from excavations.
(h) Initial lead of 50 m and lift of 1.5 m.
(i) Blasting operations for hard rock as specified in 2.6.
2.12.2 No deduction shall be made from the rate if in the opinion of the Engineer- in-charge,
operations specified in 2.12.1 (b) to (h) are not required to be carried out on any account whatsoever.
25

2.13 SURFACE EXCAVATION

2.13.1 Excavations exceeding 1.5 m in width and 10 Sqm. on plan but not exceeding 30 cm. in depth
in all types of soils and rocks shall be described as surface excavation and shall be done as specified
in 2.7 and 2.8.
2.13.2 Measurements
The length and breadth shall be measured with a steel tape correct to the nearest cm. and the area
worked out to the nearest two places of decimal in square meters.
2.13.3 Rate shall be as specified in 2.12.
2.14. ROUGH EXCAVATION AND FILLING
2.14.1 Excavation for earth from borrow pits, cutting hill side slopes etc. shall be described as rough
excavation and shall be done as specified in 2.7, 2.8 and 2.9.
2.14.2 Wherever filling is to be done, the earth from excavation shall be directly used for filling and no
payment for double handling of earth shall be admissible. Filling of excavated earth shall be done as
specified in 2.10. In case of hill side cutting, where the excavated materials is thrown down the hill
slopes, payment for filling excavated earth shall not be admissible.
2.14.3 Measurements shall be as specified in 2.11.
2.14.4 Rates shall be as specified in 2.12.
2.15 EXCAVATION OVER AREA (ALL KINDS OF SOIL)
2.15.1 This shall comprise:
(a) Excavation exceeding 1.5 m in width and 10 Sqm on plan and exceeding 30 cm in depth.
(b) Excavation for basements, water tanks etc.
(c) Excavation in trenches exceeding 1.5 m in width and 10 Sqm on plan.
2.15.2 Excavation shall be done as specified in 2.7.
2.15.3 Measurements shall be as specified in 2.11.
2.15.4 Rates shall be as specified in 2.12.
2.16 EXCAVATION OVER AREA (ORDINARY/ HARD ROCK)
2.16.1 This shall comprise:
(a) Excavation exceeding 1.5 m in width and 10 Sqm on plan and exceeding 30 cm in depth.
(b) Excavation for basements, water tanks etc.
(c) Excavation in trenches exceeding 1.5 m in width and 10 Sqm on plan.
2.16.2 Excavation shall be done as specified in 2.8 and 2.9.
2.16.3 Measurements shall be done as specified in 2.11.
2.16.4 Rates shall be as specified in 2.12.
2.17 EXCAVATION IN TRENCHES FOR FOUNDATIONS AND DRAINS (ALL KINDS OF SOIL)
2.17.1 This shall comprise excavation not exceeding 1.5 m in width or 10 Sqm on plan and to any
depth in trenches (excluding trenches for pipes, cables, conduits etc.)
26

2.17.2 Excavation shall be done as specified in 2.7.

2.17.3 Measurements shall be as specified in 2.11.
2.17.4 Rates shall be as specified in 2.12.
2.18 EXCAVATION IN TRENCHES FOR FOUNDATION AND DRAINS (ORDINARY/ HARD ROCK)
2.18.1 This shall comprise excavation not exceeding 1.5m in width or 10 Sqm. On plan and to any
depth in trenches (excluding trenches for pipes, cables, conduits etc.)
2.18.2 Excavation shall be done as specified in 2.8. and 2.9.
2.18.3 Measurements shall be as specified in 2.11.
2.18.4 Rates shall be as specified in 2.12.

2.19 EXCAVATION IN TRENCHES FOR PIPES, CABLES ETC. AND REFILLING

2.19.1 This shall comprise excavation not exceeding 1.5 mts in width or 10 Sqm in plan and to any
depth trenches for pipes. Cables etc. and returning the excavated material to fill the trenches after
pipes, cables etc. are laid and their joints tested and passed and disposal of surplus excavated
material upto 50 m lead.
2.19.2 Width of Trench
(a) Upto one meter depth the authorized width of trench for excavation shall be arrived at by
adding 25 cm to the external diameter of pipe (not socket/ collar) cable, conduit etc. Where a
pipe is laid on concrete bed/ cushioning layer, the authorized width shall be the external
diameter of pipe (not socket/ collar) plus 25 cm or the width of concrete bed/ cushioning layer
whichever is more.
(b) For depths exceeding one meter, an allowance of 5 cm per meter of depth for each side of the
trench shall be added to the authorized width (that is external diameter of pipe plus 25 cm) for
excavation. This allowance shall apply to the entire depth of the trench. In firm soils the sides
of the trenches shall be kept vertical upto depth of 2 meters from the bottom. For depths
greater than 2 meters, the excavation profiles shall be widened by allowing steps of 50 cm on
either side after every two meters from bottom.
(c) Where more than one pipe, cable, conduit etc, are laid, the diameter shall be reckoned as the
horizontal distance from outside to outside of the outermost pipes, cable, conduit etc.
(d) Where the soil is soft, loose or slushy, width of trench shall be suitably increased or side
sloped or the soil shored up as directed by the Engineer-in-Charge. It shall be the
responsibility of the contractor to take complete instructions in writing from the Architect /
Engineer-in-Charge regarding increase in the width of trench. Sloping or shoring to be done
for excavation in soft, loose or slushy soils.
2.19.3 Excavation : Shall be done as specified in 2.7, 2.8 and 2.9.
2.19.4 Refilling
Filling in trenches shall be commenced soon after the joints of pipes, cables, conduits etc. have been
tested and passed. The space all-round the pipes, cables conduits etc. shall be cleared of all debris,
brick bats etc. Where the trenches are excavated in hard/ soft soil, the filling shall be done with earth
on the side and top of pipes in layers not exceeding 20 cm in depth. Each layer shall be watered,
rammed and consolidated. All clods and lumps of earth exceeding 8 cm in any direction shall be
broken or removed before the excavated earth is used for filling. In case of excavation trenches in
ordinary/ hard rock, the filling upto a depth of 30cm above the crown of pipe, cable, conduits etc. shall
be done with fine material like earth, moorum or pulverized/ decomposed rock according to the
availability at site. The remaining filling shall be done with boulders of size not exceeding 15cm mixed
with fine material like decomposed rock, moorum or earth as available to fill up the voids, watered,
27

rammed and consolidated in layers not exceeding 30cm. Excavated material containing deleterious
material, salt peter earth etc. shall not be used for filling. Ramming shall be done with iron rammers
where feasible and with blunt ends of crow bars where rammers cannot be used. Special care shall be
taken to ensure that no damage is caused to the pipes, Cables, Conduits etc. laid in the trenches.
2.19.5 Measurements
2.19.5.1 Trenches for pipes, cables, conduits etc. shall be measured in running meter correct to the
nearest cm in stages of 1.5 m depth and described separately as under:
(a) Pipes, cables, conduits, etc. not exceeding 80 mm dia.
(b) Pipes, cables, conduits etc. exceeding 80 mm dia but not exceeding 300mm dia.
(c) Pipes, cables, conduits etc. exceeding 300 mm dia.
2.19.5.2 Where two or more categories of each work are involved due to different classification of soil
within the same stage of trench depth or where the soil is soft loose or slushy requiring increase in the
width of trench or sloping sides or shoring, trenches for pipes, cables, conduits, etc. shall be measured
in cubic meters as specified in 2.10. Extra excavation, if any, on account of collar/ socket of pipes shall
neither be measured nor paid for separately.
2.19.6 Rates
The rate shall be as specified in 2.12 and shall also include the cost of refilling and all other operations
described above.
2.20 PLANKING AND STRUTTING
2.20.1 When the depth of trench in soft/loose soil exceeds 2 meters, stepping, sloping and/ or
planking and strutting of sides shall be done. In case of loose and slushy soils, the depths at which
these precautions are to be taken, shall be determined by the Architect / Engineer-in-Charge
according to the nature of soil.
Planking and strutting shall be close or open depending on the nature of soil and the depth of trench.
The type of planking and strutting shall be determined by the Engineer-in-Charge. It shall be the
responsibility of the contractor to take all necessary steps to prevent the sides of trenches from
collapse. Architect / Engineer-in-Charge should take guidance from IS: 3764 for designing the shoring
and strutting arrangements and specifying the profile of excavation.
2.20.2 Close Planking and Strutting
Close planking and strutting shall be done by completely covering the sides of the trench generally
with short upright, members called poling boards. These shall be 250x38 mm in section or as
directed by the Engineer-in-Charge.
The boards shall generally be placed in position vertically in pairs. One boards on either side of cutting.
These shall be kept apart by horizontal walling of strong wood at a maximum spacing of 1.2 meters
cross strutted with ballies, or as directed by Engineer-in-Charge. The length and diameter of the
ballies strut shall depend upon the width of the trench. Typical sketch of close timbering is given in Fig.
2.2.
Where the soil is very soft and loose, the boards shall be placed horizontally against the sides of the
excavation and supported by vertical walling which shall be strutted to similar timber pieces on the
opposite face of the trench. The lowest boards supporting the sides shall be taken in the ground for a
minimum depth of 75 mm. No portion of the vertical side of the trench shall remain exposed. The
withdrawal of the timber members shall be done very carefully to prevent collapse of the trench. It shall
be started at one end and proceeded systematically to the other end. Concrete or masonry shall not
be damaged while removing the planks. No claim shall be entertained for any timber which cannot be
withdrawn and is lost or buried, unless required by the Architect / Engineer-in-Charge to be left
permanently in position.

28

2.20.3 Open Planking and Strutting

In case of open planking and strutting, the entire surface of the side of the trench is not required to
be covered. The vertical boards 250 mm wide & 38 mm thick, shall be spaced sufficiency apart to
leave unsupported strips of 50 cm average width. The detailed arrangement, sizes of the timber and
the distance apart shall be subject to the approval of the Engineer-in-Charge. In all other respect,
specifications for close planking and strutting shall apply to open planking and strutting. Typical sketch
of open planking and strutting is given in fig. 2.2.
2.20.4 Measurements
The dimensions shall be measured correct to the nearest cm and the area of the face supported
shall be worked out in square meters correct to two places of decimal.
2.20.4.1 Works shall be grouped according to the following:
(a) Depth not exceeding 1.5 m.
(b) Depth exceeding 1.5m in stages of 1.5 m.
2.20.4.2 Planking and strutting to the following shall be measured separately:
(a)
(b)
(c)
(d)

Trenches.
Areas- The description shall include use and waste of raking shores.
Shafts, walls, cesspits, manholes and the like
Where tightly driven close but jointed sheeting is necessary as in case of running sheeting is
necessary as in case of running sand the item shall be measured separately and packing of
cavities behind sheeting with suitable materials included with the item.
(e) Planking and strutting required to be left permanently in position shall be measured
separately.
2.20.5 Rates
Rates shall include use and waste of all necessary timber work as mentioned above including fixing
and subsequent removal.
2.21 EXCAVATION IN WATER. MUD OR FOUL POSITION
2.21.1 All water that may accumulate in excavations during the progress of the work from springs, tidal
or river seepage, broken water mains or drains (not due to the negligence of the contractor), and
seepage from subsoil aquifer shall be bailed, pumped out or otherwise removed. The contractor shall
take adequate measures for bailing and/or pumping out water from excavations and/or pumping out
water from excavations and construct diversion channels, bunds, sumps, coffer dams etc. as may be
required. Pumping shall be done directly from the foundation trenches or from a sump out side the
excavation in such a manner as to preclude the possibility of movement of water through any fresh
concrete or masonry and washing away parts of concrete or mortar. During laying of concrete or
masonry and for a period of at least 24 hours thereafter, pumping shall be done from a suitable sump
separated from concrete or masonry by effective means.
Capacity and number of pumps, location at which the pumps are to be installed, pumping hours etc.
shall be decided from time to time in consultation with the Engineer-in-Charge. Pumping shall be done
in such a way as not to cause damage to the work or adjoining property by subsidence etc. Disposal of
water shall not cause inconvenience or nuisance in the area or cause damage to the property and
structure nearby.
To prevent slipping of sides, planking and strutting may also be done with the approval of the
Engineer-in-Charge.
2.21.2 Classification
The earth work for various classification of soil shall be categorized as under:
(a) Work in or under water and/or liquid mud: Excavation, where water is met with from any of
the sources specified in 2.21.1 shall fall in this category. Steady water level in the trial pits

29

before the commencement of bailing or pumping operations shall be the sub-soil water level in
that area.
(b) Work in or under foul position: Excavation, where sewage, sewage gases or foul conditions
are met with from any source, shall fall in this category. Decision of the Architect / Engineer-inCharge whether the work is in foul position or not shall be final.
2.21.3 Measurements
2.21.3.1 The unit, namely, meter depth shall be the depth measured from the level of foul position/
subsoil water level and upto the centre of gravity of the cross sectional area of excavation actually
done in the conditions classified in 2.21.2. Meter depth shall be reckoned correct to 0.1 m, 0.05 m or
more shall be taken as 0.1 m and less than 0.05 m ignored. The extra percentage rate is applicable in
respect of each item but the measurements shall be limited only to the quantities of earth work actually
executed in the conditions classified in 2.21.2.
2.21.3.2 In case earth work in or under foul position is also in or under water and/or liquid mud, extra
payment shall be admissible only for the earth work actually executed in or under foul position.
2.21.3.3 Pumping or bailing out water met within excavations from the sources specified in 2.21.1
where envisaged and specifically ordered in writing by the Architect / Engineer-in-Charge shall be
measured separately and paid. Quantity of water shall be recorded in kilolitres correct to two places of
decimal. This payment shall be in addition to the payment under respective items of earthwork and
shall be admissible only when pumping or bailing out water has been specifically ordered by the
Architect / Engineer-in-Charge in writing.
2.21.3.4 Planking and strutting or any other protection work done with the approval of the Engineer-inCharge to keep the trenches dry and/or to save the foundations against damage by corrosion of rise in
water levels shall be measured and paid for separately.
2.21.3.5 Bailing or pumping out water, accumulated in excavation, due to rains is included under
respective items of earthwork and is not to be paid separately.
2.21.4 Rates
The rates for respective items described above shall include cost of all the operations as may be
applicable.
2.22 EARTH WORK FOR MAJOR WORKS
2.22.1 Excavation shall be undertaken to the width of the Basement/Retaining wall footing including
necessary margins for construction operation as per drawing or directed otherwise. Where the nature
of soil or the depth of the trench and season of the year, do not permit vertical sides, the contractor at
his own expense shall put up the necessary shoring, strutting and planking or cut slopes with or
without steps, to a safer angle or both with due regard to the safety of personnel and works and to the
satisfaction of the Engineer. Measurement of plan area of excavation for payment shall be permitted
only.
2.22.2 All the major excavation shall be carried out by mechanical excavator. No extra payment shall
be made for that.
2.22.3 The contractor shall make at his own cost all necessary arrangements for maintaining water
level, in the area where works are under execution low enough so as not to cause any harm to the
work shall be considered as inclusive of pumping out or bailing out water, if required, for which no
extra payment shall be made. This will include water coming from any source, such as rains,
accumulated rain water, floods, leakages from sewer and water mains, subsoil water table being high
or due to any other cause whatsoever. The contractor shall make necessary provision of pumping,
dredging bailing out water coming from all above sources and excavation and other works shall be
kept free of water by providing suitable system approved by the Engineer-in-charge.
Sub-soil water table at work site is reported to be about approx. 6.5 m. below the general ground level
30

as observed in the month of April. The water level is likely to rise up to 1 to 2 m. during rainy season.
In order to avoid possibility of basement floor of main building being getting uplifted / damaged due to
water pressure, the contractor shall lower the ground water table below the proposed foundation level
by boring tube wells all around the proposed building using well point sinking method or any suitable
method as approved by Engineer-in-charge. Sub soil water table shall be maintained at least 50 cm.
below the P.C.C. level during laying of P.C.C. water proofing treatment, laying of basement raft and
beams including filling of earth/sand under the basement floor. The water table shall not be allowed to
rise above base of raft level until completion of outer retaining walls including water proofing of vertical
surface of walls and back filling along the walls upto ground level and until the structure attains such
height to counter balance the uplift pressure. However, the contractor should inspect the site and
make his own assessment about sub-soil water level likely to be encountered at the time of execution
and quote his rates accordingly. Rate of all items are inclusive of pumping out or bailing out water, if
required. Nothing extra on this account whatsoever shall be paid to him. The sequence of construction
shall be got approved by the Engineer-in-charge.
2.22.4 The contractor shall take all necessary measures for the safety of traffic during construction
and provide, erect and maintain such barricades including signs, markings, flags, lights and flagman,
as necessary at either end of the excavation/embankment and at such intermediate points as directed
by the Architect / Engineer-in-Charge for the proper identification of construction area. He shall be
responsible for all damages and accidents caused due to negligence on his part.
2.22.5 The contractor shall provide suitable barricading with suitably painted single row of G.I. Sheets
about 3- 0 wide (90 cms.) nailed or bolted with wooden poles spaced 2 to 3 meter apart and each
pole 1.6 m to 2 m long 8 cm. to 10 cm. dia. The poles will be embedded in mobile iron pedestal rings
suitably framed for giving stable support as per direction of the Engineer-in-charge. All management
(including watch and ward) of barricades shall be the full responsibility of the contractor. The
barricades shall be removed only after completion of the work or part of the work. The contractors rate
shall include all above items of work and nothing extra shall be paid to the contractor over and above
his quoted rates.
2.23 FILLING IN TRENCHES, PLINTH, UNDER FLOOR ETC.
2.23.1 Earth
Normally excavated earth from same area shall be used for filling. Earth used for filling shall be free
from shrubs, rank, vegetation, grass, brushwood, stone shingle and boulders (larger than 75mm in any
direction), organic or any other foreign matter. Earth containing deleterious materials, salt peter earth
etc. shall not be used for filling. All clods and lumps of earth exceeding 8 cm in any direction shall be
broken or removed before the earth is used for filling.
2.23.2 Filling
The space around the foundations and drains in trenches shall be cleared of all debris, brick bats etc.
The filling shall be done in layers not exceeding 20 cm in depth. Each layer shall be watered, rammed
and consolidated. Ramming shall be done with iron rammers where possible and with blunt end of
crow bars where rammers cannot be used. Special care shall be taken to ensure that no damage is
caused to the pipes, drains, masonry or concrete in the trenches. In case of filling under floor, the
finished level of filling shall be kept to the slope intended to be given to the floor.
2.23.3 Measurements
2.23.3.1 Filling Side of Foundations: The cubical contents of bed concrete leveling course and
masonry/ concrete in foundations upto the ground level shall be worked out and the same deducted
from the cubical contents of earthwork in excavation for foundations already measured under the
respective item of earth work to arrive at the quantity for filling sides of foundation. The quantity shall
be calculated correct to two places of decimal.
2.23.3.2 Filling in Plinth and under Floors: Depth of filling shall be the consolidated depth. The
dimensions of filling shall be on the basis of pre-measurement correct to the nearest cm and cubical
content worked out in cubic meters correct to two places of decimal.

31

2.23.4 Rates
The rates include cost of all the operations described above.
2.24 SAND FILLING IN PLINTH
2.24.1 Sand : Sand shall be clean and free from dust organic and foreign matter and its grading shall
be within the limits of grading zone IV or V specified in Section 3 Mortars.
2.24.2 Filling: Sand filling shall be done in a manner similar to earth filling in plinth specified in
2.23.3.2. except that consolidation shall be done by flooding with water. The surface of the
consolidated sand filling shall be dressed to the required level or slope and shall not be covered till the
Architect / Engineer-in-Charge has inspected and approved the sand filling.
2.24.3 Measurements
The length, breadth and depth of consolidated sand shall be measured with steel tape correct to the
nearest cm and cubical contents worked out in cubic meters correct to two places of decimal.
2.24.4 Rates
The rates include the cost of material and labour involved in all the operations described above.
2.25 SURFACE DRESSING.
2.25.1 Surface dressing shall include cutting and filling upto a depth of 15 cm and clearing of shrubs,
rank vegetation, grass, brushwood, trees and saplings of girth upto 30 cm measured at a height of one
meter above the ground level and removal of rubbish and other excavated material upto a distance of
50 meters outside the periphery of the area under surface dressing. High portions of the ground shall
be cut down and hollows depression filled upto the required level with the excavated earth so as to
give an even, neat and tidy look.
2.25.2 Measurements
Length and breadth of the dressed ground shall be measured correct to the nearest cm and the area
worked out in square meters correct to two places of decimal.
2.25.3 Rates
The rates shall include cost of labour involved in all the operations described above.
2.26 JUNGLE CLEARANCE
2.26.0 Jungle clearance shall comprise uprooting of rank vegetation, grass, brushwood, shrubs,
stumps, trees and saplings of girth upto 30 cm measured at a height of one meter above the ground
level. Where only clearance of grass is involved it shall be measured and paid for separately.
2.26.1 Uprooting of Vegetations
The roots of trees and saplings shall be removed to a depth of 60 cm below ground level or 30 cm
below formation level or 15 cm below sub-grade level, whichever is lower. All holes or hollows formed
due to removal of roots shall be filled up with earth rammed and leveled. Trees, shrubs, poles, fences,
signs, monuments, pipe lines, cable etc., within or adjacent to the area which are not required to be
disturbed during jungle clearance shall be properly protected by the contractor at his own cost and
nothing extra shall be payable.
2.26.2 Stacking and Disposal
All useful materials obtained from clearing and grubbing operation shall be stacked in the manner as
directed by the Engineer-in-Charge. Trunks and branches of trees shall be cleared of limbs and tops
and stacked neatly at places indicated by the Engineer-in-Charge. The materials shall be the property
of the Government. All unserviceable materials which in the opinion of the Architect / Engineer-inCharge cannot be used or auctioned shall be removed up to a distance of 50 m outside the periphery
of the area under clearance. It shall be ensured by the contractor that unserviceable materials are
disposed off in such a manner that there is no likelihood of getting mixed up with the materials meant
32

for construction.
2.26.3 Clearance of Grass
Clearing and grubbing operation involving only the clearance of grass shall be measured and paid for
separately and shall include removal of rubbish upto a distance of 50 m outside the periphery of the
area under clearance.
2.26.4 Measurements
The length and breadth shall be measured correct to the nearest cm and area worked out in square
meters correct to two places of decimal.
2.26.5 Rates
The rate includes cost of all the operation described above.
Note: Jungle clearance and clearance of grass are not payable separately for the earth work specified
in 2.13 to 2.19.
2.27 FELLING TREES
2.27.1 Felling
While clearing jungle, growth trees above 30 cm girth (measured at a height of one meter above
ground level) to be cut, shall be approved by the Architect / Engineer-in-Charge and then marked at
site. Felling trees shall include taking out roots upto 60 cm below ground level or 30 cm below
formation level or 15 cm below sub-grade level, whichever is lower.
All excavation below general ground level arising out of the removal of trees, stumps etc. shall be filled
with suitable material in 20 cm layers and compacted thoroughly so that the surfaces at these points
conform to the surrounding area. The trunks and branches of trees shall be cleared of limbs and tops
and cut into suitable pieces as directed by the Engineer-in-Charge.
2.27.2 Stacking and Disposal
Wood, branches, twigs of trees and other useful material shall be the property of the Government. The
serviceable materials shall be stacked in the manner as directed by the Architect / Engineer-in-Charge
upto a lead of 50m.
All unserviceable material, which in the opinion of Architect / Engineer-in-Charge cannot be used or
auctioned
shall be removed from the area and disposed off as per the directions of the Engineer-in-Charge. Care
shall be taken to see that unsuitable waste materials are disposed off in such a manner that there is
no likelihood of these getting mixed up with the materials meant for construction.
2.27.3 Measurements
Cutting of trees above 30 cm in girth (measured at a height of one meter above level) shall be
measured in numbers according to the sizes given below:
(a)
(b)
(c)
(d)

Beyond 30 cm girth, upto and including 60cm girth.

Beyond 60 cm girth, upto and including 120 cm girth.
Beyond 120 cm girth, upto and including 240 cm girth.
Above 240 cm girth.

2.27.4 Rate
The rate includes the cost involved in all the operations described above. The contract unit rate for
cutting trees above 30 cm in girth shall include removal of stumps as well.

33

SUB-HEAD 3.0

(SPECIFICATION FOR ANTI-TERMITE TREATMENT)

34

CONTENTS
Clause No.

Brief Description

Page No.

3.1

Definitions

3.2

Constructional Measures

3.3

Post Constructional Treatment

3.4

Figure Site Bench Mark

3.5

Figure Close and Open Planking and Strutting

3.6

Figure Anti-Termite Treatment Construction Stage 1

3.7

Figure Anti-Termite Treatment Construction Stage 3

3.8

Figure Anti-Termite Treatment Construction Stage 5

3.9

Figure Anti-Termite Treatment Construction Stage 7

3.10

Figure Anti-Termite Treatment Final Recommendations

35

3.1.0 ANTI-TERMITE TREATMENT

3.1.1 Sub-terrain termites are responsible for most of the termite damage in buildings. Typically, they
form nests or colonies underground. In the soil near ground level in a stump or other suitable piece of
timber in a conical or dome shaped mound. The termites find access to the super-structure of the
building either through the timber buried in the ground or by means of mud shelter tubes constructed
over unprotected foundations.
Termite control in existing as well as new building structures is very important as the damage likely to
be caused by the termites to wooden members of building and other household article like furniture,
clothing, stationery etc. is considerable. Anti-termite treatment can be either during the time of
construction i.e. pre-constructional chemical treatment or after the building has been constructed i.e.
treatment for existing building.
Prevention of the termite from reaching the super-structure of the building and its contents can be
achieved by creating a chemical barrier between the ground, from where the termites come and other
contents of the building which may form food for the termites. This is achieved by treating the soil
beneath the building and around the foundation with a suitable insecticide.
3,1,2 Materials
3.1.2.1 Chemicals: Any one of the following chemicals in water emulsion to achieve the percentage
concentration specified against each chemical shall be used:
(a) Chlorpyrifos emulsifiable concentrate of 20%
(b) Lindane emulsifiable concentrate of 20%
Anti-termite treatment chemical is available in concentrated form in the market and concentration is
indicated on the sealed containers. To achieve the specified percentage of concentration, Chemical
should be diluted with water in required quantity before it is used. Graduated containers shall be used
for dilution of chemical with water in the required proportion to achieve the desired percentage of
concentration. For example, to dilute chemical of 20% concentration. 19 parts of water shall be added
to one part of chemical for achieving 1% concentration.
Architect / Engineer-in-Charge shall procure the chemical of required concentration in sealed original
containers directly from the reputed and authorized dealers, chemical shall be kept in the custody of
the Engineer in-Charge or his authorized representatives and issued for use to meet the days
requirements. Empty containers after washing and concentrated chemical left unused at the end of the
days work shall be returned to the Architect / Engineer-in-Charge or his authorized representative.
3.1.2.2 Measurements: Concentrated chemical in sealed containers shall be measured in liters.
Chemicals of different types and concentration shall be measured separately.
3.1.2.3 Rate: The Rate for the concentrated chemical shall include the cost of material, containers and
all the operations involved in transportation and delivery at the place specified.
3.1.2.4 Safety Precautions
Chemical used for anti-termite treatment are insecticides with a persistent action and are highly
poisonous. This chemical can have an adverse effect upon health when absorbed through the skin,
inhaled as vapors or spray mists or swallowed. The containers having emulsifiable concentrates shall
be clearly labeled and kept securely closed in stores so that children or pet cannot get at them.
Storage and mixing of concentrates shall not be done near any fire source or flame. Persons using
these chemical shall be warned that absorption though skin is the most likely source of accidental
poisoning. Particular care shall be taken to prevent skin contact with concentrates and prolonged
exposure to dilute emulsion shall also be avoided. After handling the concentrates or dilute emulsion.
Workers shall wash themselves with soap and water and wear clean clothing, especially before eating.
In the event of severe contamination, clothing shall be removed at once and the skin washed with
soap and water. If chemical has splashed into the eyes, they shall be flushed with plenty of soap and
water and immediate medical attention shall be sought.
36

Care should be taken in the application of chemicals to see that they are not allowed to contaminate
wells or springs which serve as source of drinking water.
3.2.0 Anti-Termite Treatment: Constructional Measures
The construction measures specified below should be adopted for protection against subterranean
termites originating both internally from within the plinth and externally from the area surrounding the
building.
(a) Earth free from roots, dead leaves, or other organic matter shall be placed and compacted in
successive horizontal layers of loose material not more than 200 mm thick. Dry brick shall be
inserted at last 50 mm in brick masonry for providing apron floor around the periphery. [See
Fig. 2.3(i)]
(b) Brick on edge masonry in cement mortar shall be laid on the plinth wall. Dry brick shall be
placed on the inner side of plinth wall for getting anticipated offset space for coarse sand and
on the other side for installing anti-termite masonry groove. In the case of intermediate walls,
dry bricks are placed on either side of the brick on edge masonry for getting offset space for
coarse sand layer. [See Fig. 2.3(ii)]
(c) The dry brick for the anti-termite groove shall be taken out and dense cement concrete 1:3:6
(1 cement : 3 sand : 6 coarse aggregate by volume) sub-floor carpet shall be laid casting the
anti-termite groove in position. In case of internal partition walls, the cement concrete sub-floor
shall be laid on either side over the dry bricks to sufficient extent for getting staggered vertical
joints over the joint of plinth wall and earth filling. [See Fig. 2.3(iii)]
(d) Superstructure masonry shall be raised over the dense cement concrete sub floor carpet and
over-head jobs completed. [See Fig. 2.3)(iv)]
(e) The dry brick for coarse sand layer shall be removed and graded sand (of size 3 to 5 mm)
layer at least 100 mm thick shall be compacted over the earth filling and underneath the
partially laid dense cement concrete sub-floor carpet [See Fig. 2.3)(v)]
(f) Dense cement concrete (1:3:6 mix.) sub-floor at least 75 mm thick shall be laid over the sand
filling. Necessary finish may be provided to the cement concrete sub-floor carpet. [See Fig.
2.3)(vi)]
(g) Dry brick provided for apron floor shall be taken out and 600 mm wide formation of earth in
1:30 slope shall be made. Over the formation, 75 mm thick lime concrete 1:3:6 (1 lime:3
sand:6 coarse aggregate, by volume) shall be laid. [See Fig. 2.3)(vii)]
(h) Over the 75 mm thick like concrete bed at least 25 mm thick cement concrete topping 1:2:4 (1
cement: 2 sand: 4 fine aggregate, by volume) shall be laid and 12 mm thick cement plaster
shall be applied on foundation and plinth. [See Fig. 2.3)(viii)] The final recommendations
incorporating the constructional details given above (i to viii) are shown in Fig. 2.4.
3.3.0 Anti Termite Treatment : Treatment for Existing Building: Post Construction Treatment
3.3.1 Material
(a) Chemicals : Any one of the following chemicals conforming to relevant Indian Standards in
water emulsion may be used for soil treatment in order to protect a building from termite
attack.

Chemical with Percent Relevant Indian Standards Concentration by weight (Active

ingredient)

Chlorpyrifos 20EC IS 8944 1.0

Lindane 20EC IS 632 1.0

These chemicals are available in concentrated form in the market and concentration is
indicated on the sealed containers. To achieve the specified percentage of concentration,
chemicals should be diluted with water in required quantity before it is used. Graduated
37

containers shall be used for dilution of chemicals with water in the required proportion to
achieve the desired percentage of concentration. For example, to dilute chemical of 20%
concentration, 19 parts of water shall be added to one part of chemical for achieving 1%
concentration. Oil or kerosene based solution of chlorpyrifos 20 EC or Lindane 20 EC, 1.0
percent (by weight) concentration is useful for treatment of wood. Architect / Engineer-inCharge shall procure the chemical of required concentration in sealed original containers
directly from the reputed and authorized representative. Chemical shall be kept in the custody
of the Architect / Engineer-in-Charge or his authorized representatives and issued for use to
meet the days requirements. Empty containers after washing and concentrated chemical left
unused at the end of the days work shall be returned to the Architect / Engineer-in-Charge or
his authorized representative.
(b) Measurements : Concentrated chemical in sealed containers shall be measured in liters.
Chemicals of different types and concentration shall be measured separately.
(c) Rate : The rate for the concentrated chemical shall include the cost of material, containers and
all the operations involved in transportation and delivery at the place specified.
(d) Safety Precautions : Chemical used for anti-termite treatment are insecticides with a
persistent action and are highly poisonous. This chemical can have an adverse effect upon
health when absorbed through the skin, inhaled as vapors or spray mists or swallowed. The
containers having emulsifiable concentrates shall be clearly labeled and kept securely closed
in stores so that children or pet cannot get at them. Storage and mixing of concentrates shall
not be done near any fire source or flame. Persons carrying out chemical soil treatments
should familiarize themselves and exercise due care when handling the chemicals whether in
concentrated or in diluted form. After handling the concentrates or dilute emulsion, worker
shall wash themselves with soap and water and wear clean clothing especially before eating
and smoking. In the event of severe contamination, clothing shall be removed at once and the
skin washed with soap and water. If chemical has splashed into the eyes, they shall be flushed
with plenty of soap and water and immediate medical attention shall be sought. The use of
chemical shall be avoided where there is any risk of wells or other water supplies becoming
contaminated.
3.3.2 Treatment
(a) Once the termites have an ingress into the building, they keep on multiplying and destroy the
wooden and cellulosic materials, and as such it becomes essential to take measures for
protection against termites. Anti termite measures described below are necessary for the
eradication and control of termites in existing building. To facilitate proper penetrations of
chemical in to the surface to be treated, hand operated pressure pump shall be used. To have
proper check for uniform penetration of chemical, graduated containers shall be used. Proper
check should be kept so that the specified quantity of chemical is used for the required area
during the operation. Chemical treatment for the eradication and control of sub-terrain termites
in existing building shall be done as per IS 6313 (Part III). Treatment shall be got done only
from the approved specialized agencies using the chemical procured directly by the Architect /
Engineer-in-Charge from reputed and authorized dealers.
(b) Treatment along outside of foundations: The soil in contact with the external wall of the
building shall be treated with chemical emulsion at the rate of 7.5 liters per square meter of
vertical surface of the sub-structure to a depth of 300 mm. To facilitate this treatment, a
shallow channel shall be excavated along and close to the wall face. The chemical emulsion
shall be directed towards the wall at 1.75 liters per running meter of the channel. Rodding with
12 mm diameter mild steel rods at 150 mm apart shall be done in the channel. If necessary,
for uniform dispersal of the chemical to 300 mm depth from the ground level. The balance
chemical of 0.5 liter per running meter shall then be used to treat the backfill earth as it is
returned to the channel directing the spray towards the wall surface. If there is a concrete or
masonry apron around the building, approximately 12 mm diameter holes shall be drilled as
close as possible to the plinth wall about 300 mm apart, deep enough to reach the soil below
and the chemical emulsion pumped into these holes to soak the soil below at the rate of 2.25
liters per linear meter. In soils which do not allow percolation of chemicals to desired depth,
the uniform disposal of the chemical to a depth of 300 mm shall be obtained by suitably
38

modifying the mode of treatment depending on site condition In case of RCC foundations the
soil (backfill) in contact with the column sides and plinth beams along with external perimeter
of the building shall be treated with chemical emulsion at the rate of 7.5 litres/sqm. of the
vertical surface of the structure. To facilitate this treatment, trenches shall be excavated equal
to the width of the shovel exposing the sides of the column and plinth beams upto a depth of
300 mm or upto the bottom of the plinth beams, if this level is less than 300 mm. The
chemical emulsion shall be sprayed on the backfill earth as it is returned into the trench
directing the spray against the concrete surface of the beam or column as the case may be.
(c) Treatment of Soil under Floors : The points where the termites are likely to seek entry
through the floor are the cracks at the following locations:

At the junction of the floor and walls as result of shrinkage of the concrete;
On the floor surface owing to construction defects;
At construction joints in a concrete floor, cracks in sections; and
Expansion joints in the floor.

Chemical treatment shall be provided in the plinth area of ground floor of the structure,
wherever such cracks are noticed by drilling 12 mm holes at the junction of floor and walls
along the cracks on the floor and along the construction and expansion joints at the interval of
300 mm to reach the soil below. Chemical emulsion shall be squirted into these holes using a
hand operated pressure pump to soak the soil below until refusal or upto a maximum of one
liter per hole. The holes shall then be sealed properly with cement mortar 1:2 (1 cement: 2
coarse sand) finished to match the existing floors. The cement mortar applied shall be cured
for at least 10 days as per instruction of Engineer-in-charge.
(d) Treatment of Voids in Masonry : The movement of termites through the masonry wall may
be arrested by drilling holes in masonry wall at plinth level and squirting chemical emulsions
into the holes to soak the masonry. The holes shall be drilled at an angle of 45 degree from
both sides of the plinth wall at 300 mm intervals and emulsion squirted through these holes to
soak the masonry using a hand operated pump. This treatment shall also be extended to
internal walls having foundations in the soil. Holes shall also be drilled at wall corners and
where door and window frames are embedded in the masonry or floor at ground. Emulsion
shall be squirted through the holes till refusal or to a maximum of one liter per hole. Care shall
be taken to seal the holes after the treatment.
(e) Treatment at Points of Contact of Wood Work : The wood work which has already been
damaged beyond repairs by termites shall be replaced. The new timber shall be dipped or
liberally brushed at least twice with chemical in oil or kerosene. All existing wood work in the
building which is in contact with the floor or walls and which is infested by termites, shall be
treated by spraying at the points of contacts with the adjoining masonry with the chemical
emulsion by drilling 6 mm holes at a downward angle of about 45 degree at junction of wood
work and masonry and squirting chemical emulsion into these holes till refusal or to a
maximum of half a liter per hole. The treated holes shall then be sealed. Infested wood work in
chaukhat, shelves, joints, purlins etc., in contact with the floor or the walls shall be provided
with protective treatment by drilling holes of about 3 mm diameter with a downward slant to the
core of the wood work on the inconspicuous surface of the frame. These holes should be at
least 150 mm centre to centre and should cover in entire frame work. Chemicals shall be
liberally infused in these holes. If the wood is not protected by paint or varnish two coats of the
chemicals shall be given on all the surfaces and crevices adjoining the masonry.
3.3.3 Measurements : All dimensions shall be measured correct to a cm. The measurements shall be
made of the surface actually provided with anti termite treatment. Measurements shall be done
separately for treatment of foundations, soils under floors, voids in masonry and wood work as
detailed below:
(a) Treatment along outside of foundations : The measurements shall be made in running meters
taking length along the plinth of the building.
(b) Treatment of soil under floors : The measurements shall be made in square meters, inside
clear dimensions of rooms, verandah etc. shall be taken.

39

(c) Treatment of voids in masonry : The measurements shall be made in running meters along
the plinth of the building.
(d) Treatment of wood work : The measurements shall be made in running meters for chowkhats,
joints, purlins, beams etc.
3.3.4 Rates
The rate shall include the cost of labour and all other inputs (except concentrated chemical) involved in
all the operations described above including drilling, refilling and making good the holes.
3.3.5 Treatment of Electrical Fixtures
If infestation in electrical fixture (like switch boxes in the wall) is noticed, covers of the switch boxes
shall be removed and inside of such boxes shall be treated liberally with 5 per cent Malathion dusting
powder. The covers of the switch boxes shall be re-fixed after dusting.
THE DESIGN FOR TEMPORARY SITE BENCH MARK

40

CLOSE AND OPEN PLANKING AND STRUTTING

41

ANTI-TERMITE CONSTRUCTION STAGE -1

42

ANTI-TERMITE CONSTRUCTION STAGE -3

43

ANTI-TERMITE CONSTRUCTION STAGE -5

44

ANTI-TERMITE CONSTRUCTION STAGE -7

45

ANTI-TERMITE CONSTRUCTION FINAL RECOMMENDATIONS

46

SUB HEAD : 4.0

CONCRETE WORK
CONTENTS
Clause No.

4.1
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
4.2.12
4.2.13
4.2.14
4.2.15
4.2.16
4.3
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6

4.5.0
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
4.5.8
4.5.9
4.5.10
4.5.11
4.5.12

Brief Description

Page No.

List of Mandatory Tests

List of Bureau of Indian Standard Codes
Material
Coarse Aggregate
Chemical Admixtures
Cement Concrete
Grades of Cement Concrete
Workability of Concrete
Concrete Mix Proportioning
Batching
Mixing
Placing
Compaction
Construction Joints
Concreting under Special Conditions
Curing
Testing of Concrete
Form Work
Finishes
Durability of Concrete
Measurements
Rate
Cement Fly Ash Concrete
Damp Proof Course
Cement Concrete Layer
Curing
Application of Hot Bitumen
Water Proofing Materials
Measurements
Rate
Appendix A Determination of Particle Size
Appendix B Test for Surface Moisture
Appendix C Determination of Ten Per cent Fine Value
Appendix D Slump Test
Ready Mixed Concrete
Terminology
Types of Mixing
Truck Mixed Concrete
Materials
Basis of Supply
General Requirements
Sampling and Testing
Concrete Manufactured and Supplied on the Basis of Specified
Strength
Placing of Ready Mixed Concrete
Precast Concrete
General
Concrete Pavements

47

LIST OF MANDATORY TESTS

Material

Clause

Test

Field/
Laboratory

Test
procedure

Min. qty
Material
Carrying
test

Stone
aggregate

4.1.2.2

(a) Percentage of soft

or
deleterious
material

Field
or
LaboratoryTest
as
required

IS
Part
II

4.1.2.3

Particle size

Field/ Lab

Appendix A

45 cum

For every 45 cum or

part thereof for RCC
Work only. For rest of
items as decided by
Architect / Engineer-inCharge

4.1.2.5

(a)

Estimation
organic
impurities

Field/ Lab

IS
Part
II

10 cum

For every 40 cum or

part thereof

(b)

Surface
moisture

Field/ Lab

IS 2386

10 cum

-do-

(c)

Determination
of 10% fine
value

Field/ Lab

IS 2386

10 cum

-do-

(d) Specific gravity

Field/ Lab

IS 2386

10 cum

-do-

(e) Bulk density

Field/ Lab

IS 2386

10 cum

-do-

(f)

Aggregate
crushing
strength

Field/ Lab

IS 2386

10 cum

-do-

(g) Aggregate impact

value

Field/ Lab

IS 2386

10 cum

-do-

Slump test

Field

Appendix D

10 cum

15 cum or part thereof

Concrete

4.2.2

of

2386-

2386-

As required
Architect
Engineer-inCharge

of
for
out

Frequency of Testing

7
by
/

For quantities

all

48

LIST OF BUREAU OF INDIAN STANDARDS CODES

S No.

IS. No.

Subject

1.

IS 383

Specification for coarse and fine aggregate from natural sources for
concrete.

2.

IS 456

Plain and reinforced concrete - Code of practice

3.

IS 516

Method of test for strength of concrete

4.

IS 1199

Method of sampling and analysis of concrete

5.

IS 1200
(Part II)

Method of measurement of building and civil engineering work (concrete

work)

6.

IS 1322

Specification for bitumen felt for water proofing and damp proofing.

7.

IS 1791

General requirements for batch type concrete mixers

8.

IS 2386

Method of test for aggregates for concrete

(a)

Part I -Particle size and shape

(b)

Part II -Estimation of deleterious materials and organic impurities

(c)

Part III -Specific gravity, density, voids absorption and bulking.

(d)

Part IV -Mechanical properties.

(e)

Part V Soundness

9.

IS 2505

General requirements for concrete vibrators - immersion type.

10.

IS 2506

General requirements for concrete vibrators - screed board concrete

vibrators

11.

IS 2645

Specification for integral water proofing compounds for cement mortar and
concrete

12.

IS 3068

Specification for broken brick (burnt clay) coarse aggregate for use in
concrete.

13.

IS 3812

Specification for fly ash for use as Pozzolana and admixture in cement
mortar and concrete.

14.

IS 4656

Specification for form vibrators for concrete.

15.

IS 7861
(Part-I)

Code of practice for extreme weather concreting (Part-I) recommended

practice for hot weather concreting.

16.

IS 7861
(Part
II)
IS 9103

Code of practice for extreme weather concreting (Part-II) recommended.

17.

Specification for concrete admixtures

49

4.0 CONCRETE WORK

4.1. MATERIAL
Water, cement, fine aggregate or sand, surkhi, and fly ash shall be as specified in Chapter 3.0 Mortar.
4.1.1 Coarse Aggregate
4.1.1.1 General: Aggregate most of which is retained on 4.75 mm IS Sieve and contains only as much
fine material as is permitted in IS 383 for various sizes and grading is known as coarse aggregate.
Coarse aggregate shall be specified as stone aggregate, gravel or brick aggregate and it shall be
obtained from approved/ authorized sources.
(a) Stone Aggregate: It shall consist of naturally occurring (uncrushed, crushed or broken) stones.
It shall be hard, strong, dense, durable and clean. It shall be free from veins, adherent coating,
and injurious amounts of disintegrated pieces, alkali, vegetable matter and other deleterious
substances. It shall be roughly cubical in shape. Flaky and elongated pieces shall be avoided.
It shall conform to IS 383 unless otherwise specified.
(b) Gravel: It shall consist of naturally occurring (uncrushed, crushed or broken) river bed shingle
or pit gravel. It shall be sound, hard and clean. It shall be free from flat particles of shale or
similar laminated material, powdered clay, silt, loam, adherent coating, alkali, vegetable matter
and other deleterious substances. Pit gravel shall be washed if it contains soil materials
adhering to it. These shall conform to IS 383 unless otherwise specified.
(c) Brick Aggregate: Brick aggregate shall be obtained by breaking well burnt or over burnt dense
brick/ brick bats. They shall be homogeneous in texture, roughly cubical in shape and clean.
They shall be free from un-burnt clay particles. Soluble salt, silt, adherent coating of soil,
vegetable matter and other deleterious substances. Such aggregate should not contain more
than one percent of sulphates and should not absorb more than 10% of their own mass of
water, when used in cement concrete. It shall conform to IS 306 unless otherwise specified.
(d) Light weight aggregate such as sintered fly ash aggregate may also be used provided the
Architect / Engineer-in-Charge is satisfied with the data on the proportion of concrete made
with them.
4.1.1.2 Deleterious Material: Coarse aggregate shall not contain any deleterious material, such as
pyrites, coal, lignite, mica, 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 the concrete. Coarse
aggregate to be used for reinforced cement concrete. Coarse aggregate to be used for reinforced
cement concrete shall not contain any material liable to attack the steel reinforcement. Aggregates
which are chemically reactive with alkalis of cement shall not be used. The maximum quantity of
deleterious material shall not be more than five percent of the weight of coarse aggregate when
determined in accordance with IS 2386.
4.1.1.3 Size and Grading
(i) Stone aggregate and gravel: It shall be either graded or single sized as specified. Nominal
size
and grading shall be as under:a. Nominal sizes of graded stone aggregate or gravel shall be 40, 20, 16, or 12.5 mm as
specified. For any one of the nominal sizes, the proportion of other sizes as determined by
the method prescribed in Appendix A of Chapter 4 shall be in accordance with Table 4.1.

50

TABLE 4.1
Graded Stone Aggregate or Gravel
IS Sieve
Designation
80 mm

Percentage passing (by weight) for nominal size of

40
12.5
20 mm
16 mm
mm
mm
100
-

63
40
20
16

95 to 100
30 to 70
-

100
95 to 100
-

100
90 to 100

12.5 mm

10 mm
4.75 mm

10 to 35
0 to 5

25 to 55
0 to 10

30 to 70
0 to 10

mm
mm
mm
mm

100
90 to
100
40 to 85
0 to 10

b. Nominal sizes of single sized stone aggregate or gravel shall be 63, 40, 20, 16, 12.5 or 10
mm as specified. For any one of the nominal size, the proportion of other sizes as
determined by the method prescribed in Appendix A of Chapter 4 shall be in accordance
with Table 4.2.
TABLE 4.2
Single Sized (Un-graded) Stone Aggregate or Gravel
IS Sieve
Designation

10 mm

80 mm

Percentage passing (by weight) for nominal size of

12.5
63 mm
40 mm
20 mm
16 mm
mm
100
-

63 mm

85-100

100

40 mm

0-30

85-100

100

20 mm

0- 5

0-20

85-100

100

16 mm

85-100

100

12.5 mm

85-100

100

10 mm

0-5

0-5

0-20

0-30

0-45

85-100

4.75 mm

0-5

0-5

0-10

0-20

2.36 mm

0-5

c.

When stone aggregate or gravel brought to site is single sized (un-graded), it shall be
mixed with single sized aggregate of different sizes in the proportion to be determined by
field tests to obtain graded aggregate of specified nominal size. For the required nominal
size, the proportion of other sizes in mixed aggregate as determined by method
prescribed in Appendix A of Chapter 4 shall be in accordance with Table 4.1.
Recommended proportions by volume for mixing of different sizes of single size (ungraded) aggregate to obtain the required nominal size of graded aggregate are given in
Table 4.3.

51

TABLE 4.3
Single Sized (Ungraded) Stone Aggregate or Gravel
Cement
concrete

Nominal size
of graded
aggregate
required

(1)

(2)

Parts of single size aggregate of size

50 mm
40 mm
20 mm
12.5
10
mm
mm

(3)

(4)

(5)

(6)

(7)

1:6:12

63

1:6:12

40

1:5:10

63

7.5

2.5

1:5:10

40

7.5

2.5

1:4:8

63

1:4:8

40

1:3:6

63

4.5

1.5

1:3:6

40

4.5

1.5

1:3:6

20

4.5

1.5

1:2:4

40

2.5

1.5

20

1:2:4
1:2:4
1: 11/2 :3

12.5
20

Note:
(i) The proportions indicated in Table 4.3 above are by volume when considered necessary,
these proportions may be varied marginally by Architect / Engineer-in-Charge after making
sieve analysis of aggregate brought to site for obtaining required graded aggregate. No
adjustments in rate shall be made for any variation in the proportions so ordered by the
Architect / Engineer-in-Charge. If single size coarse aggregate are not premixed at site to
obtain the graded coarse aggregate required for the mix, the volume of single size
aggregates required for the mix shall be suitably increased to account for reduction in total
volume at the site of mixing.
(ii) Brick Aggregate: Nominal size of brick aggregate shall be 40 mm and its grading shall
be as specified in Table 4.4 when tested for sieve analysis for the method prescribed in
Appendix A of Chapter 4.0.
TABLE 4.4
Brick Aggregate
IS Sieve Designation
75 mm
37.5 mm
20.0 mm
4.75 mm

Percentage passing (by weight)

100
95-100
45-100
0.50

4.1.1.4 Stacking: Aggregate shall be stacked on a hard, dry and level patch of ground. When stack
piling, the aggregate shall not form pyramids resulting in segregation of different sized materials. It
shall be stacked separately according to nominal size of coarse aggregates. Stacking shall be done in
regular stacks, of height not exceeding 100 cm.
4.1.1.5 Testing: Coarse aggregate shall be tested for the followings (as per IS 2386)

52

(a)
(b)
(c)
(d)

Determination of particle size and shape (Appendix A of Chapter 4)

Estimation of organic impurities (as per IS 2386 - Part II)
Surface moisture (Appendix B of Chapter 4)
Determination of 10% fine value (Appendix C of Chapter 4)

4.1.1.6 Measurements: The aggregates shall be measured in stacks and paid for after making a
deduction of 7.5% of the gross measurements of stacks in respect of aggregates of nominal size 40
mm and above. No deduction from the gross measurements of the stacks is to be made in respect of
aggregate of nominal size below 40 mm.
4.1.2 Chemical Admixtures
When required, admixtures of approved quality shall be mixed with concrete, as specified. The
admixtures shall conform to IS 9103 and as specified in Chapter 5 - R.C.C.
4.1.2.1 Admixtures may be any one of the following classes for use in concrete:a.
b.
c.
d.
e.
f.

Water Reducing Admixtures

Retarding Admixtures
Accelerating Admixtures.
Water Reducing and Retarding Admixtures.
Water Reducing and Accelerating Admixtures.
Permeability Reducing (water proofing) Admixtures.

4.1.2.2 Liquid Admixtures: Admixtures introduced into the concrete as liquids generally fall into the
following categories.
a.
b.
c.
d.
e.
f.

Air Entraining.
Water Reducing
Water Reducing Retarders.
Retarders.
Water Reducing Accelerators.
Accelerators.

4.1.2.3 Dosage of these admixtures may vary according to manufacturers specification.

4.1.2.4 Two or more admixtures may not be compatible in the same solution. It is therefore mandatory
that when two admixtures manufactured by the same manufacturers is being used simultaneously, the
manufacturer shall certify their compatibility. In case the two or more admixtures are produces by
different manufacturers, then, before their use in concrete, test shall be performed by the
manufacturer to establish their compatibility, all such test reports shall be furnished to the Architect /
Engineer-in-Charge for his approval before their use in concrete.
4.1.2.5 Some admixture may be in the form of powder, particle or high concentration liquids which may
require mixing with water prior to dosing. Under these conditions water in solution shall be considered
as part of total water content in the batch in order to maintain the water-cement ratio.
4.1.2.6 Admixture manufacturers recommendation shall be carefully followed so as to ensure
complete solution of the product or to prepare a standard solution of uniform strength for easier use.
4.1.2.7 Certain admixtures may contain significant amounts of finely divided insoluble materials or
active ingredients which may or may not be readily soluble. It is essential for such admixtures that
precautions be taken to ensure that these constituents be kept in a state of uniform suspension before
actual batching. When relatively small amounts of powered admixtures are to be used directly, these
shall be pre-blended with cement.
4.1.2.8 Admixtures are sold under various trade names and may be in the form of liquids or powders.
The proprietary name and the net quantity of content shall be clearly indicated in each package or
container of admixtures. The admixtures shall be uniform within each batch and uniform between all
batches.
53

4.1.2.9 No admixtures shall be accepted for use in concrete unless these are tested in accordance
with IS 9103 and the test results are approved by the Architect / Engineer-in-Charge.
4.2. CEMENT CONCRETE
4.2.1 Grades of Cement Concrete: The concrete shall be in grade designated as under:
TABLE 4.5
Grades of Concrete
Group

Grade Designation

(1)
Ordinary Concrete

M10

10

M15

15

M20

20

M25

25

M30

30

M35

35

M40

40

M45

45

M50

50

M55

55

M60

60

M65

65

M70

70

M75

75

M80

80

Standard Concrete

High Strength Concrete

(2)

Specified characteristic
compressive strength of 150
mm Cube at 28 Days in
N/mm2
(3)

Notes :
1. In the designation of concrete mix M refers to the mix and the number to the specified
compressive strength of 150 mm size cube at 28 days, expressed in N/mm2.
2. For concrete of compressive strength greater than M55, design parameters given in the
standard may not be applicable and the values may be obtained from specialized literatures
and experimental results.

4.2.1.1 The characteristic strength is defined as the strength of material below which not more than 5
percent of the test results are expected to fall.

54

TABLE 4.6
Minimum Cement Content, Maximum Water-Cement Ratio and Minimum Grade of Concrete for
Different Exposures with Normal Weight Aggregates of 20 mm Nominal; Maximum Size
Sl.
No.

Exposure

Plain Concrete

Reinforced Concrete

Minimum

Maximum

Minimum

Minimum

Maximum

Minimum

Cement

Free Water

Grade of

Cement

Free

Grade of

Content
kg/m3

Cement
Ratio

Concrete

Content
kg/m3

WaterCement
Ratio

Concrete

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(i)
(ii)
(iii)
(iv)
(v)

Mild
Moderate
Severe
Very Severe
Extreme

220
240
250
260
280

0.60
0.60
0.50
0.45
0.40

M15
M20
M20
M25

300
300
320
340
360

0.55
0.50
0.45
0.45
0.40

M20
M25
M30
M35
M40

Notes:
1. Cement content prescribed in this Table is irrespective of the grades of cement. The additions
such as fly or ground granulated blast furnace slag may be taken into account in the concrete
composition with respect to the cement content and water-cement ratio, if the suitability is
established and as long as the maximum amounts taken into account do not exceed the limit
of Pozzolana and slag specified in IS 1489 (Part 1) and IS 455 respectively.
2. Minimum grade for plain concrete under mild exposure condition is not specified.
3. The above minimum cement content and maximum water cement ratio apply only to 20 mm
nominal maximum size aggregate. For other sizes of aggregate, these should be changed as
per Table 6 of IS 456.
The minimum grade of concrete for plain and reinforced concrete shall be as per Table 4.6.
4.2.1.2 Concrete of grades lower than those given in Table 4.6 may be used for lean concrete,
foundation for masonry walls or temporary reinforced concrete construction.
4.2.2 Workability of Concrete
4.2.2.1 The concrete mix proportion chosen should be such that the concrete is of adequate
workability for the placing conditions of the concrete and can properly be compacted with the means
available. Suggested ranges of workability of concrete measured in accordance with IS 1199 are given
below:
Placing Conditions

Degree of Workability

Slump (mm)

(1)

(2)

Blinding concrete: shallow

sections: Pavements using pavers

Very low

See 4.2.2.2

Mass concrete: Lightly reinforced

sections in slabs, beams, wall,
columns, : floors

Low

25-75

Medium

50-100

Hand placed pavements: canal

lining; Strip footing
Heavily reinforced sections in
slabs, beams, walls, columns:

(3)

55

Slip form work: Pumped concrete

Medium

75-100

Trench fill

High

100-150

Tremie concrete

Very High

See 4.2.2.3

Note:- For most of the placing conditions, internal vibrators (needle vibrators) are suitable. The
diameter of the needle shall be determined based on the density and spacing of reinforcement bars
and thickness of sections. For tremie concrete, vibrators are not required to be used (see also 4.2.7)
4.2.2.2 In the very low category of workability where strict control is necessary, for example,
pavement quality concrete, measurement of workability be determination of compacting factor will be
more appropriate than slump ( see IS 1199) and a value of compacting factor of 0.75 to 0.80 is
suggested.
4.2.2.3 In the very high category of workability, measurement of workability by determination of flow
will be appropriate (see IS 9103).
4.2.3 Concrete Mix Proportioning
4.2.3.1 The determination of the proportion of cement, aggregate and water to attain the required
strength shall be made as follows:
(a) By designing the concrete mix: such concrete shall be called Design mix concrete, for details
reference may be made to RCC Chapter.
(b) By adopting nominal concrete mix: such concrete shall be called Nominal mix concrete.
Design mix concrete is preferred to nominal mix. If design mix concrete cannot be used for
any reason on the work for grades of M20 or lower, nominal mixes may be used with the
permission of Architect / Engineer-in-Charge, which, however, is likely to involve a higher
cement content.
4.2.3.2 Nominal Mix Concrete: Nominal Mix Concrete may be used for concrete of M20 or lower. The
proportions of materials for nominal mix concrete shall be in accordance with Table 4.7.
The cement content of the mix specified in Table 4.7 for any nominal mix shall be proportionately
increased if the quantity of water in the mix has to be increased to overcome the difficulty or placement
and compaction, so that the water cement ratio as specified is not exceeded.

Grade of
Concrete

TABLE 4.7
Proportions for Nominal Mix Concrete
Total Quantity of
Proportion of Fine
Dry Aggregates by
Aggregate to
Mass per 50 kg of
Coarse Aggregate
cement, to be taken as the
(by Mass)
Sum of the Individual
Masses of Fine and Coarse
Aggregates, Kg.
Max

Quantity of
Water
per 50 kg of
Cement, max
Ltr.

(1)

(2)

(3)

(4)

M5
M7.5
M10
M15
M20

800
625
480
330
250

Generally 1:2 but subject

to an upper limit of 1: 1
and
a lower limit of
1:2

60
45
34
32
30

Note : - The proportion of the fine to coarse aggregate should be adjusted from upper limit
progressively as the grading of fine aggregate becomes finer and the maximum size of coarse

56

aggregate becomes larger. Graded coarse aggregate shall be used.

Note : - Quantity of water required from durability point of view may be less than the value given
above.
Example
For an average grading of fine aggregate (that is, Zone II of Table 4 of IS 383), the proportions shall
be 1:1 , 1:2 and 1:2 for maximum size of aggregates 10 mm, 20 mm and 40 mm respectively.
4.2.4 Batching
To avoid confusion and error in batching, consideration should be given to using the smallest practical
number of different concrete mixed on any site or in any one plant. In batching concrete, the quantity
of both cement and aggregate shall be determined by mass; admixture, if solid, by mass: liquid
admixture may however be measured in volume or mass: water shall be weighed or measured by
volume in a calibrated tank (see also IS 4925).
Ready-mixed concrete supplied by ready-mixed concrete plant shall be preferred. For large and
medium project sites the concrete shall be sourced from ready-mixed concrete plants or from on site
or off site batching and mixing plants (see IS 4926).
4.2.4.1 Except where it can be shown to the satisfaction of the Architect / Engineer-in-Charge that
supply of properly graded aggregate of uniform quality can be maintained over a period of work, the
grading aggregate should be controlled by obtaining the coarse aggregate in different sizes and
blending them in the right proportions when required, the different sizes being stocked in separate
stock-piles. The material should be stock-piled for several hours preferably a day before use. The
grading of coarse and fine aggregate should be checked as frequently as possible, the frequency for a
given job being determined by the Architect / Engineer-in-Charge to ensure that the specified grading
is maintained.
4.2.4.2 The accuracy of the measuring equipment shall be within + 2 percent of the quantity of cement
being measured and within + 3 percent of the quantity of aggregate, admixtures and water being
measured.
4.2.4.3 Proportion/Type and grading of aggregates shall be made by trial in such a way so as to obtain
densest possible concrete. All ingredients of the concrete should be used by mass only.
4.2.4.4 Volume batching may be allowed only where weigh-batching is not practicable and provided
accurate used in concrete have earlier been established. Allowance for bulking shall be made in
accordance with IS 2386 (Part 3). The mass volume relationship should be checked as frequently as
necessary, the frequency for the given job being determined by Architect / Engineer-in-Charge to
ensure that the specified grading is maintained.
4.2.4.5 It is important to maintain the water cement ratio constant at its correct value. To this end,
determination of moisture contents in both fine and coarse aggregates shall be made as frequently as
possible, the frequency for a given job being determined by the Architect / Engineer-in-Charge
according to weather conditions. The amount of the added water shall be adjusted to compensate for
any observed variations in the moisture contents. For the determination of moisture content in the
aggregates, IS 2386 (Part 3) may be referred to. To allow for the variation in mass for aggregate due
to variations in their moisture content, suitable adjustments in the masses of aggregates shall be
made. In the absence of exact data, only in the case of nominal mixes, the amount of surface water
may be estimated from the values given in Table 4.8.

57

TABLE 4.8
Surface Water Carried by Aggregate
Sl No.

Aggregate

(1)

(2)

(i)
(ii)
(iii)

Very wet sand

Moderately wet sand
Moist sand 1) Moist gravel
or
crushed rock

(iv)

Approximate Quantity of Surface

Water Percent by l/m3

mass
(3)

(4)

7.5
5.0
2.5

120
80
40

1.25-2.5

20-40

4.2.4.6 No substitutions in materials used on the work or alteration in the established proportions,
except as permitted in 4.2.4.4 and 4.2.4.5 shall be made without additional tests to show that the
quality and strength of concrete are satisfactory.
4.2.5 Mixing
Concrete shall be mixed in mechanical batch type concrete mixers conforming to IS 1791 having two
blades and fitted with power loader (lifting hopper type). Half bag mixers and mixers without lifting
hoppers shall not be used for mixing concrete. In exceptional circumstances, such as mechanical
breakdown of mixer, work in remote areas or power breakdown and when the quantity of concrete
work is very small, hand mixing may be done with the specific prior permission of the Architect /
Engineer-in-Charge in writing subject to adding 10% extra cement. When hand mixing is permitted, it
shall be carried out on a water tight platform and care shall be taken to ensure that mixing is continued
until the concrete is uniform in colour and consistency. Before mixing the brick aggregate shall be well
soaked with water for a minimum period of two hours and stone aggregate or gravel shall be washed
with water to remove, dirt, dust and other foreign materials. For guidance, the mixing time may be 11/2
to 2 minutes, for hydrophobic cement it may be taken as 21/2 to 3 minutes.

4.2.5.1 Power Loader: Mixer will be fitted with a power loader complying with the following
requirements.
(i) The hopper shall be of adequate capacity to receive and discharge the maximum nominal
batch of unmixed materials without spillage under normal operating conditions on a level site.
Note: In such a case the volume of the maximum nominal batch of mixed material is 50% greater than
the nominal mixed batch capacity.
(ii) The minimum inside width of the feeding edge of the hopper shall be as specified below in
Table 4.9.
TABLE 4.9
Nominal size of mixer (T, NT or R).
liter
140
200
280
375
500
1000

Minimum inside width of hopper feeding

edge
1.0
1.1
1.2
1.4
1.5
2.0

58

T = Tilting; NT = Non-tilting; R = Reverse

(iii) The design of the loader shall be such that it allows the loading hopper to be elevated to such
a height that the centre line of the chute plate of the hopper when in discharge position, is at
an angle of not less than 50 to the horizontal. A mechanical device to aid discharge of the
contents as quickly as possible from the hopper to the drum may also be provided. Even when
a mechanical device is provided, it is recommended that the angle of centre line of the chute
plate of the hopper when in discharge position, should be as large as practicable, preferably
not less than 40 to horizontal.
(iv) When the means of raising and lowering the loading hopper includes flexible wire ropes
winding on to a drum or drums, the method of fastening the wire to rope to the drums shall be
such as to avoid, as far as possible any tendency to cut the strands of the ropes and the
fastening should preferably be positioned clear of the barrel of the drum for example, outside
the drums flange. When the loading hopper is lowered to its normal loading position, these
should be at least one and a half drums of rope on the drum.
(v) Clutch brake and hydraulic control lever shall be designed so as to prevent displacement by
liberation or by accidental contact with any person.
(vi) The clutch and brake control arrangements shall also be so designed that the operator can
control the falling speed of the loader.
(vii) Safety device shall be provided to secure the hopper in raised position when not in use.
4.2.5.2 Mixing Efficiency: The mixer shall be tested under normal working conditions in accordance
with the method specified in IS 4643 with a view to check its ability to mix the ingredients to obtain
concrete having uniformity within the prescribed limits. The uniformity of mixed concrete shall be
evaluated by finding the percentage variation in quantity (mass in water) of cement, fine aggregate and
coarse aggregate in a freshly mixed batch of concrete.
The percentage variation between the quantities of cement, fine aggregate and coarse aggregates (as
found by weighing in water) in the two halves of a batch and average of the two halve of the batch
shall not be more than the following limits:
Cement
Fine aggregate
Coarse aggregate

8%
6%
5%

4.2.5.3 Machine Mixing: The mixer drum shall be flushed clean with water. Measured quantity of
coarse aggregate shall be placed first in the hopper. This shall be followed with measured quantity of
fine aggregate and then cement. In case fine aggregate is damp, half the required quantity of coarse
aggregate shall be placed in the hopper, followed by fine aggregate and cement. Finally the balance
quantity of coarse aggregate shall be fed in the hopper, & then the dry materials are slipped into the
drum by raising the hopper. The dry material shall be mixed for atleast four turns of the drum. While
the drum is rotating, water shall be added gradually to achieve the water cement ratio as specified or
as required by the Architect / Engineer-in-Charge. After adding water, the mixing shall be continued
until concrete of uniform colour, uniformly distributed material and consistency is obtained. Mixing shall
be done for atleast two minutes after adding water. If there is segregation after unloading from the
mixer, the concrete should be remixed.
The drum shall be emptied before recharging. When the mixer is closed down for the day or at any
time exceeding 20 minutes, the drum shall be flushed cleaned with water.
4.2.5.4 Hand Mixing: When hand mixing has been specifically permitted in exceptional circumstances
by the Architect / Engineer-in-Charge in writing, subject to adding 10% extra cement, it shall be carried
out on a smooth, clean and water tight platform of suitable size. Measured quantity of sand shall be
spread evenly on the platform and the cement shall be dumped on the sand and distributed evenly.
Sand and cement shall be mixed intimately with spade until mixture is of even colour throughout.
Measured quantity of coarse aggregate shall be spread on top of cement sand mixture and mixing

59

done by showlling and turning till the coarse aggregate gets evenly distributed the cement sand
mixture. Three quarters of the total quantity of water required shall be added in a hollow made in the
middle of the mixed pile and the material is turned towards the middle of pile with spade. The whole
mixture is turned slowly over and again and the remaining quantity of water is added gradually. The
mixing shall be continued until concrete of uniform colour and consistency is obtained. The mixing
platform shall be washed and cleaned at the end of the day.
4.2.5.5 Transportation and Handling : Concrete shall be transported from the mixer to the place of
laying as rapidly as possible by methods which will prevent the segregation or loss of any of the
ingredients and maintaining the required workability.
During hot or cold weather, concrete shall be transported in deep containers, other suitable methods
to reduce the loss of water by evaporation in hot weather and heat loss in cold weather may also be
adopted.
4.2.6 Placing
The concrete shall be deposited as nearly as practicable in its final position to avoid re-handling. It
shall be laid gently (not thrown) and shall be thoroughly vibrated and compacted before setting
commences and should not be subsequently disturbed. Method of placing shall be such as to preclude
segregation. Care shall be taken to avoid displacement of reinforcement or movement of form work
and damage due to rains. As a general guidance, the maximum free fall of concrete may be taken as
1.5 meter.
4.2.7 Compaction
Concrete shall be thoroughly compacted and fully worked around embedded fixtures and into corners
of the form work. Compaction shall be done by mechanical vibrator of appropriate type till a dense
concrete is obtained. The mechanical vibrators shall conform to IS 2505, IS 2506, IS 2514 and IS
4656. To prevent segregation, over vibration shall be avoided.
Compaction shall be completed before the initial setting starts. For the items where mechanical
vibrators are not to be used, the contractor shall take permission of the Architect / Engineer-in-Charge
in writing before the start of the work. After compaction the top surface shall be finished even and
smooth with wooden trowel before the concrete begins to set.
4.2.8 Construction Joints
Concreting shall be carried out continuously upto construction joints. The position and arrangement of
construction joints shall be as shown in the structural drawings or as directed by the Engineer-inCharge. Number of such joints shall be kept minimum. Joints shall be kept as straight as possible.
Construction joints should comply with IS 11817.
4.2.8.1 When the work has to be resumed on a surface which has hardened, such surface shall be
roughened. It shall then be swept clean and thoroughly wetted. For vertical joints, neat cement slurry,
of workable consistency by using 2 Kgs of cement per Sqm shall be applied on the surface before it is
dry.
For horizontal joints, the surface shall be covered with a layer of mortar about 10-15 mm thick
composed of cement and sand in the same ratio as the cement and sand in concrete mix. This layer
of cement slurry of mortar shall be freshly mixed and applied immediately before placing of the
concrete.
4.2.8.2 Where the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet
surface with wire or bristle brushes, care being taken to avoid dislodgement of particles of coarse
aggregate. The surface shall be thoroughly wetted and all free water removed. The surface shall then
be coated with neat cement slurry @ 2 Kgs of cement per Sqm. On this surface, 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; work, thereafter, shall proceed in the normal
60

way.
4.2.9 Concreting under Special Conditions
4.2.9.1 Work in Extreme Weather Conditions: During hot and cold weather, the concreting shall be
done as per the procedure set out in IS 7861 (PartI)-1975 and IS 7861 (Part II)-1981 respectively.
Concreting shall not be done when the temperature falls below 4.5C. In cold weather, the concrete
placed shall be protected against frost. During hot weather, it shall be ensured that the temperature of
wet concrete does not exceed 38C.
4.2.9.2 Under Water Concreting: Concrete shall not be deposited under water if it is practicable to
dewater the area and place concrete in the regular manner. When it is necessary to deposit concrete
under water, the methods, equipment, materials and proportions of the mix to be used shall be
submitted to and approved by the Architect / Engineer-in-Charge before the work is started.
Under-water concrete should have a slump recommended in 4.2.2. The water-cement ratio shall not
exceed 0.6 and may need to be smaller, depending on the grade of concrete or the type of chemical
attack. For aggregates of 40 mm maximum particle size, the cement content shall be atleast 350
kg/m3 of concrete.
4.2.9.3 Concrete in Sea Water: Concrete in sea-water or exposed directly along the sea-coast shall
be at least M20 Grade in the case of plain concrete and M30 in case of reinforced concrete. The use
of slag or Pozzolana cement is advantageous under such conditions.
(i) Special attention shall be given to the design of the mix to obtain the densest possible
concrete: slag, broken brick, soft lime stone, soft sandstone, or other porous or weak
aggregates shall not be used.
(ii) As far as possible, preference shall be given to Precast members un-reinforced, well-cured
and hardened, without sharp corners, and having trowel-smooth finished surfaces free from
crazing, cracks or other defect; plastering should be avoided.
(iii) No construction joints shall be allowed within 600 mm below low water-level or within 60 mm
of the upper and lower planes of wave action. Where unusually severe conditions or abrasion
are anticipated, such parts of the work shall be protected by bituminous or silicon-fluoride
coatings or stone facing bedded with bitumen.
(iv) In reinforced concrete structures, care shall be taken to protect the reinforcement from
exposure to saline atmosphere during storage, fabrication and use. It may be achieved by
treating the surface of reinforcement with cement wash or by suitable methods.
4.2.10 Curing
Curing is the process of preventing loss of moisture from the concrete. The following methods shall be
employed for effecting curing.
4.2.10.1 Moist Curing : Exposed surfaces of concrete shall be kept continuously in a damp or wet
condition by ponding or by covering with a layer of sacking, canvas, Hessian or similar materials and
kept constantly wet for at least 7 days from the date of placing concrete in case of ordinary Portland
cement and at least 10 days where mineral admixtures or blended cements are used. The period of
curing shall not be less than 10 days for concrete exposed to dry and hot weather conditions. In the
case of concrete where mineral admixtures or blended cements are used, it is recommended that
above minimum periods may be extended to 14 days.
4.2.10.2 Membrane Curing : Approved curing compounds may be used in lieu of moist curing with the
permission of the Architect / Engineer-in-Charge. Such compound shall be applied to all exposed
surfaces of the concrete as soon as possible after the concrete has set. Impermeable membrane such
as polythene sheet covering the concrete surface may also be used to provide effective barrier against
the evaporation.

61

4.2.10.3 Freshly laid concrete shall be protected from rain by suitable covering.
4.2.10.4 Over the foundation concrete, the masonry work may be started after 48 hours of its
compaction but the curing of exposed surfaces of cement concrete shall be continued along with the
masonry work for at least 7 days. And where cement concrete is used as base concrete for flooring,
the flooring may be commenced before the curing period of base concrete is over but the curing of
base concrete shall be continued along with top layer of flooring for a minimum period of 7 days.
4.2.11 Testing of Concrete
Testing of concrete shall be done as described in chapter of R.C.C.
4.2.12 Form Work
Form work shall be as specified in R.C.C. chapter and shall be paid for separately unless otherwise
specified.
4.2.13 Finishes
Plastering and special finishes other than those, obtained through form work shall be specified and
paid for separately unless otherwise specified.
4.2.14 Durability of Concrete
A durable concrete is one that performs satisfactorily in the working environment during its anticipated
exposure conditions during service. The materials and mix proportions shall be such as to maintain its
integrity and, if applicable, to protect reinforcement from corrosion.
The factors influencing durability include:
(a) The environment;
(b) The cover to embedded steel;
(c) The type and quality of constituent materials;
(d) The cement content and water/ cement ratio of the concrete;
(e) Workmanship, to obtain full compaction and efficient curing; and
(f) The shape and size of the member.
4.2.14.1 Requirements for Durability
4.2.14.1.1 General Environment : The general environment to which the concrete will be exposed
during its working life is classified into five levels of severity, that is, mild, moderate, severe, very
severe and extreme as described in Table 4.9.
TABLE 4.9
Environmental Exposure Conditions
Sl. No

Environment

(1)

(2)

Exposure Conditions

(3)

(i)

Mild

Concrete surfaces protected against weather or aggressive conditions,

except those situated in coastal area.

(ii)

Moderate

(iii)

Severe

Concrete surfaces sheltered from severe rain or freezing whilst wet

Concrete exposed to condensation and rain Concrete continuously
under water Concrete in contact or buried under non-aggressive soil/
ground water Concrete surfaces sheltered from saturated salt air in
coastal area
Concrete surfaces exposed to severe rain, alternate wetting and
drying or occasional freezing whilst wet or severe condensation.
Concrete completely immersed in sea water. Concrete exposed to
coastal environment.

62

(iv)

Very severe

(v)

Extreme

Concrete surface exposed to sea water spray, corrosive fumes or

severe freezing conditions whilst wet.
Concrete in contact with or buried under aggressive sub-soil/ ground
water.
Surface of members in tidal zone. Members in direct contact with
liquid/ solid aggressive chemicals.

Note: For the purpose of determining exposure conditions, all places within a distance of 10 kames.
Of coastal line, sea front would be treated as coastal area.
4.2.14.1.2 Freezing and Thawing : Where freezing and thawing actions under wet conditions exist,
enhanced durability can be obtained by the use of suitable air entraining admixtures. When concrete
lower than grade M50 is used under these conditions, the mean total air content by volume of the
fresh concrete at the time of delivery into the construction should be:
Nominal Maximum Size Aggregate
Entrained Air Percentage
(mm)
20
5+1
40
4+1
4.2.14.1.3 Exposure to Sulphate Attack : For the very high sulphate concentration in Class 5
conditions given in Table 4.11, some form of lining such as polyethylene or polychloroprene sheet: or
surface coating based on asphalt, chlorinated rubber, epoxy; or polyurethane materials should also be
used to prevent access by the sulphate solution.
4.2.14.1.4 Chlorides in Concrete : The total amount of chlorides content (as CI) in the concrete at the
time of placing shall be as under :
SI. No.

Type of Use of Concrete

(1)
(i)

(2)
Concrete containing metal and steam cured at
elevated temperature and pre-stressed concrete
Reinforced concrete or plain concrete containing
embedded metal
Concrete not containing embedded metal or
any
material requiring protection from chloride

(ii)
(iii)

Maximum Total Acid Soluble

Chloride Content expressed as
kg/ m3 of Concrete
(3)
0.4
0.6
3.0

4.2.14.1.5 Sulphates in Concrete : The total water-soluble sulphate content of the concrete mix,
expressed as SO3 should not exceed 4 per cent by mass of the cement in the mix. The sulphate
content should be calculated as the total from the various constituents of the mix. The 4 per cent limit
does not apply to concrete made with super-sulphate cement complying with IS 6909.
TABLE 4.11
Requirements for Concrete Exposed to Sulphate Attack
Sl
No.

Clas
s

Concentration of sulphates, Expressed as SO3

Concrete.

In Soil
Total SO3 (%)

SO3 in
2:1
(Water:
Soil
Extract
) ( g/l)

In
Ground
Water
(g/l)

Type of
Cement

Dense, Fully
compacted made with
20 mm nominal
maximum size
Aggregates complying
with IS 383
Minimum
Maximum
Cement
Free
Content
Waterkg/m3
Cement
Ratio

63

(1)
(i)

(2)
1

(ii)

(iii)

(3)
Traces (<0.2)

0.2 to 0.5

0.5 to 1.0

1.9 to 3.1

(4)
Less
than 1.0

(5)
Less
than 0.3

1.0 to
1.9

0.3 to
1.2

1.2 to 2.5

(iv)

1.0 to 2.0

3.1 to 5.0

2.5 to 5.0

(v)

More than 2.0

More than 5.0

More than
5.0

(6)
Ordinary
Portland
cement or
Portland
slag cement
or Portland Pozzolana
cement
Ordinary
Portland
cement or
Portland
slag cement
or Portland
Pozzolana
cement
Supersulphatedor
sulphatePortland
cement

(7)
280

(8)
0.55

330

0.50

cement
resisting

310

Supersulphated cement or
sulphate resisting Portland
cement

330

Portland Pozzolana
cement or Portland slag
cement
Supersulphated or
sulphate resisting Portland
cement
Sulphate resisting
Portland cement or
supersulphated cement
with protective coatings

350

0.50

0.50

0.45

370

0.45

400

0.40

Notes
1. Cement content given in this Table is irrespective of grades of cement.
2. Use of supersulphated cement is generally restricted where the prevailing temperature is
above 40C.
3. Supersulphated cement gives an acceptable life provided that the concrete is dense and
prepared with a water-cement ratio of 0.4 or less, in mineral acids, down to pH 3.5.
4. The cement contents given in col. 7 of this Table are the minimum recommended. For SO3
contents near the upper limit of any class, cement contents above these minimum are
advised.
5. For severe conditions, such as thin sections under hydrostatic pressure on one side only and
sections partly immersed, considerations should be given to a further reduction of watercement ratio.
6. 6. Portland slag cement conforming to IS 455 with slag content more than 50 per cent exhibits
better sulphate resisting properties.
7. Where chloride is encountered along with sulphates in soil or ground water, ordinary Portland
cement with C3A content from 5 to 8 per cent shall be desirable to be used in concrete,
instead of sulphate resisting cement. Alternatively, Portland slag cement conforming to IS 455
having more than 50 per cent slag or a blend of ordinary Portland cement and slag may be
used provided sufficient information is available on performance of such blended cements in
these conditions.
4.2.15 Measurements
4.2.15.1 Dimensions of length, breadth and thickness shall be measured correct to nearest cm. except
for the thickness of slab and partition which shall be measured to nearest 5 mm. Areas shall be
worked out to nearest 0.01 Sqm and the cubic contents of consolidated concrete shall be worked out
64

to nearest 0.01 cum. Any work done in excess over the specified dimension or sections shown in the
drawing shall be ignored.
4.2.15.2 Concrete work executed in the following conditions shall be measured separately:
(a) Work in or under water
(b) Work in liquid mud
(c) Work in or under foul positions
4.2.15.3 Cast-in-situ concrete and or Precast concrete work shall be measured in stages described
in the item of work, such as:
(a) At or near the ground level
(b) Upto specified floor level
(c) Between two specified floor levels
(d) Upto specified height above or depth below plinth level/ defined datum level.
(e) Between tow specified heights or depths with reference to plinth/defined datum level.
4.2.15.4 No deduction shall be made for the following:
(a) Ends of dissimilar materials for example beams, posts, girders, rafters, purlins, trusses,
corbels and steps upto 500 sq cm in cross sections.
(b) Opening upto 0.1 sq meter (1000 sqcm)
(c) Volume occupied by pipes, conduits, sheathing etc. not exceeding 100 sq cm each in cross
sectional areas.
(d) Small voids such as shaded portions in Figure A to J below when these do not exceed 40 sq
cm each in cross section.
Note: In calculating area of opening, the thickness of any separate lintel or sill shall be included in the
height. Nothing extra shall be payable for forming such openings or voids.
Area of Fig. A to G shall be = L x B
Area of Fig. H & J shall be = L x {Average of B and B}

4.2.15.5 Cast-in-situ and Precast concrete work shall be measured separately.

4.2.15.6 Cast-in-situ concrete shall be classified and measured as follows:
(a) Foundation, footings, bases for columns

65

(b) Plain cement concrete below floors and foundations (leveling concrete), RCC grade slab at
floor level
(c) Walls (any thickness) including attached pilasters, buttresses, plinth and string courses, fillets
etc.
(d) Shelves
(e) Slabs
(f) Chajjas including portions bearing on the wall
(g) Lintels, beams and bressummers
(h) Columns, piers abutments, pillars, post and struts
(i) Stair case including stringer beams but excluding landings.
(j) Balustrades, newels and sailing
(k) Spiral staircase (including landings)
(l) Arches
(m) Domes, vaults
(n) Shell roof, arch ribs and folded plates
(o) Chimneys and shaft.
(p) Breast walls, retaining, walls, return walls
(q) Concrete filling to Precast components
(r) Kerbs, steps and the like
(s) String or lacing courses, parapets, copings, bed block, anchor blocks, plain window sills and
the like
(t) Cornices and moulded windows sills.
(u) Louvers, fins, facia.
4.2.15.7 Precast cement concrete solid article shall be measured separately and shall include use of
moulds, finishing the top surfaces even and smooth with wooden trowel, before setting in position in
cement mortar 1:2 (1 cement : 2 coarse sand). Plain and moulded work shall be measured separately
and the work shall be classified and measured as under:
Classifications
Wall panels
String or lacing courses, coping, bed
plates, plain windows sills, shelves,
louvers, steps etc.

Method of measurement
In square meters stating the thickness.
In cubic meters.

(c)
(d)

Kerbs, edgings etc.

Solid block work

(e)

Hollow block work

(f)

Light weight partitions

In cubic meters.
In square meters stating the thickness or in
cubic meters.
In square meters stating the thickness or in
cubic meters.
In square meters stating the partitions
thickness.

(a)
(b)

4.2.16 Rate
The rate is inclusive of the cost of labour and materials involved in all the operations described above.
4.3 CEMENT- FLY ASH CONCRETE
4.3.0 Fly ash concrete shall be prepared by mixing graded coarse aggregate of nominal size as
specified with fine aggregate, ordinary Portland cement and fly ash in specified proportions with
required quantity of water. The recommended composition of cement fly ash concrete are as under:

66

TABLE 4.12
Fly Ash Concrete Mixes
Composition (Dry Volume)

Proportion
(Dry
Volume)

Compressive Strength
at seven days

Lean Concrete (1:5:10)

Cement (Ordinary Portland)
Fly ash
Sand
Stone aggregate

1.0
2.5
4.0
11.0

37 kg/cm2

Lean Concrete (1:4:8)

Cement (Ordinary Portland)
Fly ash
Sand
Stone aggregate

28 kg/cm2

1.0
2.0
3.5
9.0

Note: No fly ash is to be added to Portland Pozzolana cement in any case which itself contains fly ash.
4.3.1 Proportioning
Proportioning shall be done by volume. Boxes of suitable size shall be used for measuring fly ash,
sand and aggregate. The internal dimensions of the boxes shall be generally 35x25x40 cm. deep or as
otherwise approved by the Architect / Engineer-in-Charge. The unit of measurement of cement shall
be a bag of 50 kg. and this shall be taken as 0.035 cum. While measuring the aggregate, shaking,
ramming or heaping shall not be done. The proportioning of sand shall be on the basis of its dry
volume and in case of damp sand, allowances for bulkage shall be made as given in the chapter for
mortar.
4.3.2 Mixing shall be as specified in 4.2.5 except that the fly ash shall be placed in the hopper before
cement in case of machine mixing.
4.3.3 Placing and compaction shall be as specified in 4.2.6 and 4.2.7.
4.3.4 Curing shall be as specified in 4.2.10.
4.3.5 Form work shall be as specified in 4.2.12.
4.3.6 Measurements shall be as specified in 4.2.15.
4.3.7 Rate
Rate shall include the cost of materials and labour involved in all the operations described above.
4.4 DAMP PROOF COURSE
4.4.1 Cement Concrete Layer
This shall consist of cement concrete of specified proportions and thickness. The surface of brick or
stone masonry work shall be leveled and prepared before laying the cement concrete. Edge of damp
proof course shall be straight, even and vertical. Side shuttering shall consist of steel forms and shall
be strong and properly fixed so that it does not get disturbed during compaction and the mortar does
not leak through. The concrete mix shall be of workable consistency and shall be tamped thoroughly to
make a dense mass. When the sides are removed, the surface should come out smooth without
honeycombing. Continuity shall be maintained while laying the cement concrete layer and laying shall
be terminated only at the predetermined location where damp proof course is to be discontinued.
There shall be no construction joints in the Damp Proof Course.
67

4.4.2 Curing
Damp proof course shall be cured for at least seven days, after which it shall be allowed to dry.
4.4.3 Application of Hot Bitumen
Where so directed, hot bitumen in specified quantity shall be applied over the dried up surface of
cement concrete, properly cleaned with brushes and finally with a piece of cloth soaked in kerosene
oil. Bitumen of penetration A 90 or equivalent where used shall be heated to a temperature of 160
5C.
The hot bitumen shall be applied uniformly all over, so that no blank spaces are left anywhere. It will
be paid for separately.
4.4.4 Water Proofing Materials
Where so specified, water proofing material of approved quality shall be added to the concrete mixture
in accordance with the manufacturers specification stating the quantity of water proofing material in
liters or kg per 50 kg or cement and will be paid for separately.
4.4.5 Measurements
The length and breadth shall be measured correct to a cm and its area shall be calculated in square
meters correct to two places of decimal. The depth shall not be less than the specified thickness at
any
section.
4.4.6 Rate
The rate is inclusive of the cost of materials and labour involved in all the operations described above
except for the applications of a coat of hot bitumen and addition of water proofing materials which shall
be paid for separately, unless otherwise specified.
APPENDIX A
DETERMINATION OF PARTICLE SIZE
The apparatus, sample size and test procedure shall be same as specified in sub-head MORTARS.
In order that the sieves shall not be overloaded, care must be taken to ensure that the maximum sieve
loads shown in Table A-4.1 (below) are not exceeded at the completion of sieving.
TABLE A-4.1

I.S. Sieve Designation

45 mm
40 mm
31.5 mm or 22.1 mm
20 mm
16 mm or 12.5 mm
10 mm
5.6 mm
4.75 mm
3.35 mm

Maximum weight for

45 cm dia sieve
30 cm dia sieve
kg
Kg
10
8
6
4
3
2
1.5
1.0
-

4.5
3.5
2.5
2.0
1.5
1.0
0.75
0.50
0.30

The sample weight taken will thus normally require several operations on each sieve. Each sieve
should be taken separately over a clean tray or receiver until no more than a trace passes, but in any
case for not less than two minutes. Materials should not be forced through the apertures but hand
68

placing is permitted. A light brush should be used with fine sieves. The cumulative weight passing
each sieve should be calculated as percentage of the total sample weight to the nearest whole
number.
APPENDIX B
TEST FOR SURFACE MOISTURE
Take a sample of wet aggregate and weigh it (A). Then place it in a frying pan and gently apply heat,
meanwhile stirring with a glass rod until the surface moisture disappears. This is apparent when the
aggregate loses its shining wet appearance and becomes dull, or when it just attains a free funning
condition. The saturated surface dry material is then weighed (B). Continue the heating thereafter until
the moisture is evaporated and weigh the dry sample (C). The surface moisture is then calculated as
follows:
Surface moisture

100 x A-B
C
It is expressed as a percentage of dry aggregate.
APPENDIX C
DETERMINATION OF TEN PER CENT FINE VALUE
Apparatus: The apparatus for the standard test shall consist of the following:
(a) A 15 cm diameter open-ended steel cylinder, with plunger and base-plate, as shown in Fig. in
the end of this appendix. The surfaces in contact with the aggregate shall be machined and
case hardened or otherwise treated so as to have a diamond (VH) pyramid hardness number
of not less than 650 VH.
(b) A straight metal tamping rod of circular cross-section 16 mm in diameter and 45 to 60 cm
long, rounded at one end.
(c) A balance of capacity 3 Kg, readable and accurate to one gram.
(d) I.S. Sieve of sizes 12.5, 10 and 2.36 mm.
(e) A compression testing machine capable of applying a load of 50 tones and which can be
operated to give a uniform rate of loading so that the maximum load in any test is reached in
10 minutes. This load may vary from 0.5 to 50 tones.
(f) For measuring the sample, a cylindrical metal measure of sufficient rigidity to retain its form
under rough usage and of the following internal dimensions:
Diameter
Height

11.5 cm
18.0 cm

(g) Means of measuring the reduction in the distance between the plates of the testing machine to
the nearest one millimeter during the test (for example, dial gauge).
Test Sample: Material for the test shall consist of aggregate passing a 12.5 mm I.S. Sieve and
retained on a 10 mm I.S. Sieve. The aggregate shall be tested in a surface dry condition. If dries by
heating the period of drying shall not exceed four hours, the temperature shall be 100C to 110C and
the aggregate shall be cooled to room temperature before testing.
The quantity of aggregate shall be such that the depth of material in the cylinder, after tamping as
described below, shall be 10 cm.
The weight of material comprising the test sample shall be determined (weight A) and the same weight
of sample shall be taken for the repeat test.
Note: About 6.5 kg of natural aggregate is required to provide the two test samples. Less of light
weight aggregate is required.
The measuring cylinder is filled in three layers of approximately equal depth with aggregate passing a
12.5 mm I.S. Sieve and retained on 10 mm I.S. Sieve. Each layer is subjected to 25 strokes from the
tamping rod (16 mm dia and 45 to 60 cm long) rounded to one end, care being taken in case of weak

69

materials not to break the particles. The surface of the aggregate shall be carefully leveled and the
plunger inserted so that it rests horizontally on this surface.
Test Procedure: The apparatus, with the test sample and plunger in position, shall then be placed in
the compression testing machine. The load shall be applied at a uniform rate so as to cause a total
penetration of a plunger in 10 minutes of about: 15.0 mm for rounded or partially rounded aggregates
(for example uncrushed gravel) 20 mm for nominal crushed aggregate & 24 mm for honey combed
aggregate (for example expanded shelves and slags). These figures may be varied according to the
extent of the rounding or honey combing.
After reaching the required maximum penetration, the load shall be released and the whole of the
material removed from the cylinder and sieved on a 2.36 mm I.S. Sieve. The fines passing the sieve
shall be weighed, and this weight expressed as a percentage of the weight of the test sample.
Normally, this percentage will fall within the range 7.5 to 12.5, but if it does not, a further test shall be
made at a load adjusted appropriately, to bring the percentage fines within the range of 7.5 to 12.5.
A repeat test shall be made at the load that gives as percentage fines within the range 7.5 to 12.5.
Calculations: The mean percentage fines from the two tests at this load shall be used in the following
formula to calculate the load required to give 10 percentage fines.
Load required for 10 percent fines =

14 x X
Y+4

Where X = Load in tones and

Y= mean percentage fines from two test at X tones load.
Reporting of Results: The load required to produce 10 percent fines shall be reported to the nearest
whole number for loads of 10 tones or more, the nearest 0.5 tonne for loads of less than 10 tones.
The value expressed to the nearest 0.5 tonne should be as follows:
(a) For normal concrete, not less than 5 tones.
(b) For wearing surfaces, not less than 10 tones.
(c) For granolithic concrete, not less than 15 tones.

70

Fig. C-4.1 : Apparatus for Determination of Ten per cent Fine Value
APPENDIX D
SLUMP TEST
Apparatus: Mould shall consist of a metal frustum of cone having the following internal dimensions:
Bottom diameter..20 cm
Top diameter10 cm
Height30 cm
The mould shall be of a metal other than brass and aluminium of at least 1.6 mm (or 16 BG)
thickness. The top and bottom shall be open and at right angles to the axis of the cone. The mould
shall have a smooth internal surface. It shall be provided with suitable foot pieces and handles to
facilitate lifting it from the moulded concrete test specimen in a vertical direction as required by the
test. A mould provided with a suitable guide attachment may be used.
Tamping rod shall be of steel or other suitable material 16 mm in diameter 60 mm long and rounded at
one end.
Procedure: The internal surface of the mould shall be thoroughly cleaned and free form superfluous
moisture and any set concrete before commencing the test. The mould shall be placed on a smooth
horizontal, rigid and non-absorbent surface viz. leveled metal plate. The operator shall hold the mould
firmly in place while it is being filled with test specimen of concrete. The mould shall be filled in four
layers, each approximately one quarter of height of mould. Each layer shall be tamped with twenty five
strikes of the rounded end of the tamping rod. The strokes shall be distributed in a uniform manner
over the cross section of the mould and for the second and subsequent layers shall penetrate into the
underlying layer. The bottom layer shall be tamped throughout its depth. After the top layer has been
rodded, the concrete shall be struck off level with trowel or the tamping rod, so that the mould is
exactly filled.
Any mortar which shall leak out between the mould and the base plate shall be cleaned away. The
mould shall be removed from the concrete immediately after filling by raising it slowly and carefully in a
vertical direction. The moulded concrete shall then be allowed to subside and the slump shall be
measured immediately by determining the difference between the height of the mould and that of the
highest point of specimen.
The above operations shall be carried out at a place free from vibration or shock, and within a period
of two minutes after sampling.
Result: The slump shall be recorded in terms of millimeters of subsidence of the specimen during the
test. Any slump specimen which collapses or shears off laterally give incorrect result. If this occurs, the
test shall be repeated with another sample.
The slump test shall not be used for very dry mixes as the results obtained are not accurate.
SPECIFICATIONS FOR READY MIXED CONCRETE (R.M.C.)
4.5

SCOPE
The supply of ready-mixed concrete shall be as specified in IS: 4926-1976. The strength of
RCC design mix shall be specified in the item.

4.5.1

TERMINOLOGY

4.5.1.1 For the purpose of this standard the definitions in 2.2 to 2.5 shall apply.
4.5.1.2 Ready-mixed Concrete Concrete delivered at site in plastic condition and requiring no
further treatment before being placed in the position in which it is to set and harden.

71

4.5.1.3 Agitation The process of continuing the mixing of concrete at a reduced speed during
transportation to prevent segregation.
4.5.1.4 Agitator Truck mounted equipment designed to agitate concrete during transportation to the
site of delivery.
4.5.1.5 Truck Mixer A mixer generally mounted on a self-propelled chassis capable of mixing the
ingredients of concrete and of agitating the mixed concrete during transportation.
4.5.2

TYPES OF MIXING

4.5.2.1 For the purpose of this standard, the ready-mixed concrete shall be of the following type,
according to the method of production and delivery as specified in 3.2
4.5.2.2 Centrally Mixed Concrete Concrete produced by completely mixing cement, aggregates,
admixtures, if any and water at a central mixing plant and delivered in containers fitted with
agitating devices.
4.5.3.0 Truck-Mixed Concrete: Concrete produced by placing cement, aggregates and admixtures, if
any, other than those to be added with mixing water, in a truck mixer at the batching plant, the
addition of water and admixtures to be added along with mixing water, and the mixing being
carried out entirely in the truck mixer either during the journey or on arrival at the site of delivery.
No water shall be added to the aggregate and cement until the mixing of concrete commences.
4.5.4.0 MATERIALS
Materials such as cement, coarse & fine aggregates, water & admixture, etc. shall confirm to
the specifications mentioned in the RCC works. Use of mineral admixtures like fly ash,
GGBFS, etc. shall not be permitted unless otherwise specifically permitted by Engineer-incharge. Cement shall be Ordinary Portland Cement 43 grade/ Portland Pozzolana cement
(Fly ash based meeting the 28 day strength requirement of OPC 43 grade cement) only.
4.5.4.1 Aggregates: Unless otherwise agreed to between the purchaser and the manufacturer, the
aggregates shall conform to IS: 383-1970. Fly ash when used as fine aggregate shall conform to
the requirements of IS: 3812-1981. Flyash is allowed in RMC controlled concrete as per IS
code and not in the site controlled concrete.
4.5.4.2 Water used for concrete shall conform to the requirements of IS: 456-2000.
4.5.4.3 Admixtures: Admixtures shall only be used when so agreed to between the purchaser and the
manufacturer. The admixtures shall conform to the requirements of IS: 456-2000 and their
nature, quantities and methods of use shall also be specified. Fly ash when used as an
admixture for concrete, shall conform to IS: 3812-1981.

4.5.4.4 Measurement and Storage of Materials: Measurement and storage of materials shall be done
in accordance with the requirements of IS: 456-2000.
4.5.5.0 BASIS OF SUPPLY
4.5.5.1 Depending upon the agreement between the purchaser and the manufacturer, the ready-mixed
concrete shall be manufactured and supplied on either of the following basis:
a) Specified strength based on 28-day compressive strength of 15-cm cubes tested in
accordance with IS: 456-2000.
b) Specified mix proportion.
Note: Under special circumstances and subject to the agreement between the purchaser and
the supplier, strength of concrete in (a) above may be based on 28-day or 7-day flexural strength
of concrete instead of compressive strength of 15-cm cube tested in accordance with IS: 4562000.
72

When the concrete is manufactured and supplied on the basis of specified strength, the
responsibility for the design of mix shall be that of the manufacturer and the concrete shall
conform to the requirements specified in

When the concrete is manufactured and supplied on the basis of specified mix proportion, the
responsibility for the design of the mix shall be that of the purchaser and the concrete shall
conform to the requirements specified in

10 The general requirements specified shall apply to the concrete supplied either on the basis given
in 2.2.8.1 (a) & (b).
4.5.5.2 Measurement of Ready-Mixed Concrete :
A) The basis of purchase shall be the cubic meter of plastic concrete as delivered to the purchaser.
B) The volume of plastic concrete in a given batch shall determined from the total mass of the
batch divided by the actual mass per cum of concrete. The total mass of the batch shall be
calculated either as the sum of the masses of all materials, including water, entering of batch or
as the net mass of concrete in the batch as delivered. If the purchaser wishes to verify the total
mass, of the batch, this shall be obtained from the gross and tare masses of the vehicle on a
tamped weigh bridge. The mass per cum shall be determined in accordance with the method
given in IS: 1199-1959.
4.5.6.0 GENERAL REQUIREMENTS
4.5.6.1 In addition to the requirements specified in this standard and subject to such modifications as
may be agreed to between the purchaser and the manufacturer at the time of placing order, the
ready-mixed concrete shall generally comply with the requirements of IS:456-2000.
4.5.6.2 Unless otherwise agreed to between the purchaser and the supplier, the minimum quantity of
cement and the details regarding proportioning and works control shall be in accordance with
IS:456-2000.
4.5.6.3 When a truck mixer agitator is used for mixing or transportation of concrete, no water from the
truck-water system or from elsewhere shall be added after the initial introduction of the mixer
water for the batch, except when on arrival at the site of work, the slump of the concrete is less
than that specified; such additional water to bring the slump within required limits shall be
injected into the mixer under such pressure and direction of flow that the requirements for
uniformity specified in Appendix-A are met.
A)
Unless otherwise agreed to between the purchaser and the supplier, when a truck mixer
or agitator is used for transporting concrete, the concrete shall be delivered to the site of
work and discharge shall be complete 1-1/2 hour (when the prevailing atmospheric
temperature is above 20 Deg C) and within 2 hours (when the prevailing atmospheric
temperature is at or below 20 Deg C) of adding the mixing water to the dry mix of
cement and aggregate or of adding the cement to the aggregate, whichever is earlier.
4.5.6.4 Temperature:
10.0
The temperature of the concrete at the place and time of delivery shall be not
less than 5 Deg C. Unless otherwise required by the purchaser, no concrete shall be
delivered, when the site temperature is less than 2.5 Deg C and the thermometer
reading is failing.
10.1
The temperature of the concrete shall not exceed 5 Deg C above the prevailing
shade temperature when the shade temperature is over 20 Deg. C. The temperature of
concrete mass on delivery shall not exceed 40 Deg. C.
4.5.7.0 Sampling and Testing :
4.5.7.1 Adequate facilities shall be provided by the manufacturer for purchaser to inspect the
materials used, the process of manufacture and methods of delivery of concrete. He shall also
provide adequate facilities for the purchaser to take samples of the materials used.

73

4.5.7.2 Sampling and Testing The sampling and testing of concrete shall be done in accordance
with the relevant requirements of IS: 456-2000, IS: 1199-1959 and IS: 516-1959.
4.5.7.3 Consistency or Workability The testes for consistency or workability shall be carried out in
accordance with the requirements of IS: 1199-1959 or by such other method as may be
agreed to between the purchaser and the manufacturer.
4.5.7.4 Strength Test The compressive strength and flexural strength tests shall be carried out in
accordance with requirements of IS: 516-1959 and the acceptance criteria for concrete
supplied on the basis of specified strength shall conform to the requirements of IS: 456.
a) Compressive Strength : The concrete shall be deemed to comply with the strength
requirements when both the following conditions are met :
b) The mean strength determined from any group of four consecutive test results
complies with the appropriate limits of Table A
c) Any individual test result complies with the appropriate limits of Table A
d) Flexural Strength: When both the following conditions are met, the concrete complies
with the specified flexural strength.
e) The mean strength determined from any group of four consecutive test results
exceeds the specified characteristic strength by atleast 0.3 N/Sqmm
f) The strength determined from any test result is not less than the specified
characteristic strength less 0.3 N/Sqmm.
g) Quantity of Concrete Represented by Strength Test Results: The quantity of
concrete represented by a group of four consecutive test results shall include the
batches from which the first and last samples were taken together with all intervening
batches.
For the individual test result requirements given in Co. 2 of Table or in item (b) of 16.2
only the particular batch from the sample was taken shall be at risk.
Where the mean rate of sampling is not specified the maximum quantity of concrete that
four consecutive test results represent shall be limited to 60 Cum.
h) If the concrete is deemed not to comply pursuant to 2.2.9.5 (D) (c), the structural
adequacy of the parts affected shall be investigated and any consequential action as
needed shall be taken.
i)

Concrete of each grade shall be assessed separately.

j)

Concrete is liable to be rejected if it is porous or hone-combed, its placing has been

interrupted without providing a proper construction joint, the reinforcement has been
displaced beyond the tolerances specified, or construction tolerances have not been
met. However, the hardened concrete may be accepted after carrying out suitable
remedial measures to the satisfaction of the engineer-in-charge.
Table A Characteristic Compressive Strength Compliance Requirement
(Clause
)

Specified Grade
(1)
M 15

M 20 or above

Mean of Group of 4 Non-overlapping

Consecutive Test Results in N/Sqmm
(2)
+0.825
x
established
standard
deviation (rounded off to nearest 0.5
N/Sqmm)
+ N/Sqmm whichever is greater +
0.825 established standard deviation
(rounded off to nearest 0.5 N/Sqmm)
or + 4 N/Sqmm, whichever is greater

Individual Test Results in

N/Sqmm
(3)
N/Sqmm

N/Sqmm

74

Note: In the absence of established value of standard deviation, the value given in Table
8 of IS: 456-200 may be assumed and attempt should be made to obtain results of 30
samples as early as possible to establish the value of standard deviation.
4.5.7.5 Cost of Testing The cost of the tests carried out in accordance with requirements of this
specification shall be borne by the contractor.
Manufacturers Records and Certificates -The manufacturer shall keep batch records of the
quantities by mass of all solid materials, of total amount of water used in mixing and of the
results of all tests. If required by the purchaser, the manufacturer shall furnish certificate, at
agreed intervals, giving this information.
4.5.8.0 CONCRETE MANUFACTURED AND SUPPLIED ON THE BASIS OF SPECIFIED
STRENGTH
4.5.8.1 The manufacturer shall supply the following information for guidance of the supplier for
approval:
a) The type of cement to be used. b) The maximum size and type of aggregates. c) The type
of admixtures to be used) The minimum accepted compressive strength or flexural strength or
both, determined from samples of plastic concrete taken at the place and time of delivery, in
accordance with requirements of IS: 456-2000.
e)
The slump or compacting factor or both, or other requirement for consistency or
workability at the place and time of delivery of the concrete.
f)
The ages at which the test cubes or beams are to be tested and the frequency and
number of tests to be made shall be as required by the purchaser.
Tolerances The concrete shall be deemed to comply with the requirements of this
specification, if the results of the tests where applicable, lie within the tolerances specified in
7.2.1.
Consistency or Workability The slump (average of two tests) shall not differ from the
specified value by + 10 mm for a specified slump of 75 mm or less and + 25 mm when the
specified slump is greater than 75 mm. The compacting factor average of two tests shall be
within + 0.03 of the value specified. The test for consistency or workability shall be completed
within 15 minutes of the time of receipt of the ready-mixed concrete at site.
Aggregates When tested in accordance with IS:2386 (Part I) -1963, the quantity of aggregate
larger than the maximum size specified by the purchaser shall not exceed 5 percent of the
quantity of coarse aggregate and all such excess shall pass through sieve (conforming to IS:460
(Part 1-3) 1985 of the next higher size.
4.5.8.2

CONCRETE MANUFACTURED AND SUPPLIED ON THE BASIS OF MIX PROPORTION:

4.5.8.3 The purchaser shall supply the following information for guidance of the manufacturer:
10.1.1 The type of the cement to be used;
10.1.2 The sizes and types of the aggregate;
10.1.3 The type of admixtures to be used;
10.1.4 The proportions of the mix including the maximum water cement ration at the place and
time of delivery of the concrete;
10.1.5 The minimum mixing time after addition of the water; and
10.1.6 Any other requirements.
4.5.8.4 Tolerances - Unless otherwise agreed to between the purchaser and the manufacturer, the
concrete shall be deemed to comply with the requirements of this standard, if the result of tests
where applicable, lie within the tolerance specified in 2.2.11.2. (A) and 2.2.11.2 (D)
A) Cement Content The cement content, as shown by the samples taken, shall be not less
than 95 percent of that specified.
B) Ration of Coarse to Fine Aggregates: The ratio of coarse to fine aggregates, as indicated
by the sample taken shall neither exceed nor fall below the ration specified by the purchaser

75

by more than 10 percent.

C) Water / Cement Ration | 5 percent of the specified value.
D) Consistency or Workability The slump shall not differ from the amount specified | 10
mm for a specified slump of 75 mm or less and | 25 mm when the specified a slump is
greater than 75mm. The compacting factor shall be within | 0.03 of the value specified. If
any other method of determining consistency is used, a suitable tolerance shall be agreed to
between the purchaser and the supplier.
APPENDIX A
(Clause 4.5.6.3)
CONCRETE UNIFORMITY REQUIREMENT
A-1

TESTS:

A.1.1

The variation within a batch as provided in Table | shall be determined for each property listed as
the difference between the highest value and the lowest value obtained from the different
portions of the same batch. For this specification the comparison shall be between two samples,
representing the first and last portions of the batch being tested. Test results conforming to the
limit of five of the six tests listed in Table | shall indicate uniform concrete within the limits of this
specification. Analysis of concrete samples shall be made in accordance with the relevant
requirements of IS:1159-1959.

A-2

COARSE AGGREGATE CONTENT:

A.2.1

Coarse aggregate content shall be determined using the following equation:

P =

{ c
}
{ --- x 100 }
{ b
}

Where P = Percentage of coarse aggregate by mass in concrete;

C = saturated surface dry mass in kg of aggregate retained on 4.75 mm IS Sieve,
Resulting from washing all material finer than this sieve from the fresh concrete; &
B = mass of sample, in kg of fresh concrete in unit mass container.
IS : 4926 1976
TABLE 1 REQUIREMENTS FOR UNIFORMITY OF CONCRETE
(Clause A.1.1)
Sl.
No.
TEST
A
1)
2)
3)

4)

5)
6)

B
Mass per cubic meter calculated to an air-free
basis
Air-content, percent by volume of concrete
Slump:
If average slump is 10 cm or less
If average slump is 10 to 15 cms
Coarse aggregate content, percent (portion by
mass of each sample retained by 4.75 mm IS
Sieve)
Unit mass of air-free mortar, percent based on
average for all comparative samples tested
Average compressive strength at 7 days for
each comparative test specimens percent

Requirement expressed as maximum

permissible difference in results of tests or
samples representing the first and last
portions of concrete batch
C
16 Kgs/Cum
1.0
2.5 cm
3.8 cm
6.0

1.6
7.5

76

A-3
A.3.1

UNIT MASS OF AIR FREE MORTAR

Unit mass of air free mortar shall be calculated as follows :
{ B - C }
M = -----------------------------------{ VxA
C
}
{ ------- + --------- }
{ 100
1000G }

Where M = Unit mass of air free mortar in Kg/Cum

B = Mass of concrete sample in unit mass container in kg.
C = Saturated surface-dry mass of aggregate in kg retained on 4.75 mm IS Sieve
V = Volume of unit container in Cum
A = Air content of concrete in percent measured in accordance with the relevant requirement
of IS:1199-1959*, and
G = Specific gravity of coarse aggregate.

4.5.9.0 PLACING OF READY-MIXED CONCRETE:

The ready-mixed concrete shall be placed in the required location/position, level, heights, etc.
by using pumping arrangement method/mechanically as directed by the Engineerin-Charge.
4.5.10.0 PRECAST CONCRETE WORK:
4.5.11.0 GENERAL:
All pre-cast units shall be cast on a suitable firm bed or platform. The moulds shall be accurate to
the dimensions specified in the drawings.
The cost to include the cost of mould, finishing face and steel if any Alternately, steel supplied
by the Employer can be used and measured for separately with the permission of the Employer.
Inserts of steel, wood or other material, bolts, nuts, sleeves, lifting hooks, hold-fasts, etc; shall be
provided as shown in the drawing.
Casting, consolidating, curing, hoisting, transporting to the work spot, lifting and fixing in position
shall be included in the item rate.
Cost of providing slots, holes, openings, etc; as shown in the drawing shall be included.
4.5.12.0 CONCRETE PAVEMENTS:
4.5.12.1 GENERAL:
4.5.12.2 Pavement shall consist of plain cement concrete or reinforced cement concrete as indicated in
drawings. Unless otherwise specified the proportion of concrete shall be 1:2:4 finished
monolithically with wooden trowel or rough finished as directed. The thickness unless otherwise
specified shall be 150 mm for traffic movement areas or as directed.
4.5.12.3 The sub base shall be examined for existence of soft pockets and extra materials added to
make up for the required level and consolidated and the sub base prepared to take the
concrete.
4.5.12.4 The side forms shall be steel or timber. Bent, twisted or worn out forms shall not be used. The
forms shall be rigidly supported at sides during concreting, compacting and finishing. The forms
shall be fixed to the required line and gradient.

77

4.5.12.5 Concrete shall be laid in panels as directed leaving the expansion and contraction joints as
shown in the drawing or as directed. Reinforcements shall be fixed if required and shall be
measured separately. The sub-base shall be thoroughly cleaned and watered before laying
concrete.
4.5.12.6 The concrete shall be laid in layers and thoroughly vibrated by means of mechanical vibrators
like screed vibrators, pin vibrators, etc;
4.5.12.7 The finishing shall be done along with the concreting as and when the concrete starts setting.
The finishing shall be done with wooden flats/trowels, with the workmen sitting on a platform
spanning the width of the slab so as not to disturb the finished surface of concrete.
4.5.12.8 Curing shall be done for a minimum period of 15 days.

78

SUB-HEAD 5.0

SPECIFICATION FOR FORM WORK

79

Clause No.

Brief Description

5.1

Scope

5.2

Applicable Codes & Standards

5.3

Design of Form Work

5.4

Tolerances

5.5

Type of Work

5.6

Form Work Requirements

5.7

Bracings, Struts and Props

5.8

Form Oil

5.9

Chamfers and Fillets

5.10

Wall Ties

5.11

Reuse of Forms

5.12

Removal of Forms

5.13

Mode of Measurement

5.14

Specification for Staging Work

Page No.

80

5.0 - SPECIFICATION FOR FORM WORK

5.1.0

SCOPE:

5.1.1

The formwork shall consists of shores, bracings, side of beams and columns, bottom of slabs,
etc. including ties, anchors, hangars, inserts, etc. complete which shall be properly designed
and planned for the works.
The formwork shall be so constructed that up and down vertical adjustments can be made
smoothly. Wedges may be used at top or bottom of shores, but not at both the ends to
facilitate vertical adjustment for dismantling of the formwork.

5.2.0

APPLICABLE CODES AND SPECIFICATIONS:

The relevant IS specification, standards and codes given below are made a part of this
specification. All standards, specifications, code of practices refer to herein shall be the latest
edition including all applicable amendments, revisions and additional publications.

5.3.0

DESIGN OF FORMWORK:
No.
1.
2.

I.S. No.
IS: 303
IS: 1200 (Part V)

I.S. Particulars
Plywood for general purpose
Method of Measurement of building and civil
engineering work (Form work)

3.
4.
5.
6.
7.

IS: 2750
IS: 3696
IS: 4014 (Part I)
IS: 4014 (Part II)
IS: 4990

Specification for steel scaffolding

Safety code for scaffolds and ladders
Code of Practice for steel tubular scaffolding
Code of Practice for steel tubular scaffolding
Specification for plywood for concrete shuttering
work

5.3.1

The design and engineering of the formwork as well as its construction shall be the
responsibility of the contractor. If so instructed, the drawings and calculations for the design of
the formwork shall be submitted well in advance to the Engineer-in-charge for approval before
proceeding with the work at no extra cost to the department. Engineer-in-charges approval
shall not relieve the contractor of the full responsibility for the design and construction of the
formwork.

5.3.2

The design shall take into account all the loads vertical as well as lateral that the forms will be
carrying including live load and vibration loads.

5.3.3

Depending upon the height of the staging suitable vertical and horizontal cross bracings shall
be provided.
The contractor shall note that no concrete work of floor, beam, slab including roof slab will be
permitted unless the staging work is inspected and the approval in writing for its soundness is
given to the Engineer-in-charge prior to commencement of concrete work.

5.4.0

TOLERANCES:

5.4.1

Tolerance is a specified permissible variation from lines, grade or dimensions given in the
drawings. No tolerance specified for horizontal and vertical building lines or footings shall be
considered to permit encroachment beyond the legal boundaries. Unless otherwise specified,
following tolerances shall be permitted -

5.4.1.1 Tolerance for R.C. Building:

81

5.4.1.1.1
No.
1.
2.

Variation from the plumb:

Building Members
In the line and surface of columns, piers, walls
and buttresses
For exposed corner columns and other
conspicuous lines

Tolerances
5 mm per 2.50 M but not more
than 25 mm
In any bay or 5 M maximum:
(+/-) 5 mm. In 10 M or
more: (+/-) 10 mm

5.4.1.1.2 Variation from the level or frame the grade indicated in the drawings:
No.
1.

Building Members
In slab soffits, ceilings, beam soffits and
staircases

Tolerances
In 2.50 M : (+/-) 5 mm In any
bay or 5 M maximum:
(+/-) 8 mm. In 10 M or
more: (+/-) 15 mm

2.

For

In any bay or 5 M maximum:

(+/-) 5 mm. In 10 M or
more: (+/-) 10 mm

exposed lintels, parapets, horizontal

grooves and other conspicuous lines

5.4.1.1.3 Variation of the linear building lines from established position in plan and related position of
columns, walls and partitions:
No.
1.
2.

Building Members
In any bay or 5 M maximum
In 10 M or more

Tolerances
(+/-) 5 mm
(+/-) 20 mm

5.4.1.1.4
No.
1.

Building Members
Variation in the sizes and locations of sleeves,
openings in walls and floors except in the
case of anchor bolts

Tolerances
(+/-) 5 mm

5.4.1.1.5
No.
1.

Building Members
Variation in cross sectional dimensions of
columns and beams and thickness of
slabs and walls

Tolerances
(-) 5 mm and (+) 10 mm.

5.4.1.1.6: Footings:
5.4.1.1.6.1 Variation in steps:
No.
1.
2.

Building Members
Variation in dimension in plan
Misplacement or eccentricity in the direction of
misplacement

Tolerances
(-) 5 mm and (+) 50 mm.
0.02 times the width of the
footing in the direction
of the deviation but not
more than 50 mm

82

No.
1.
2.
3.
4.

Building Members
In a flight of stairs riser
In a flight of stairs tread
In consecutive steps riser
In consecutive steps tread

Tolerances
(+/-) 3 mm
(+/-) 5 mm
(+/-) 1.5 mm
(+/-) 3 mm

5.4.1.2 Tolerances in other Concrete structures:

5.4.1.2.1.1 All structures:
No.
1.

Building Members
Variation of the constructed linear outline from
established position in plan
Variation of dimensions to individual structure
features from established positions in plan

Tolerances
(+/-) 10 mm in 5 M (+/-) 15 mm
in 10 M or more
(+/-) 25 mm in 20 M or more
(+/-)
50mm
in
buried
construction

3.

Variation from plumb, specified batter or curved

surfaces of all structures

(+/-) 10 mm in 2.50 M (+/-) 15

mm in 5 M (+/-) 25 mm in 10 M
or more (+/-) Twice the above
amounts in buried construction

4.

Variation from level or grade indicated on

drawings in slabs and beams soffits, horizontal
grooves and visible arises

(+/-) 5 mm in 2.50 M (+/-) 10

mm in 7.5 M or more (+/-)
Twice the above amounts in
buried construction

5.

Variation in cross sectional dimensions of

columns, beams, buttresses, piers and similar
members

(-) 5 mm and (+) 10 mm

6.

Variation in the thickness of slabs, walls, arch

sections and similar members

(-) 5 mm and (+) 10 mm

2.

5.4.1.2.2 Footings for columns, piers, walls, buttresses and similar members:
No.
1.

Building Members
Variation in dimension in plan

Tolerances
(-) 10 mm and (+) 50 mm.

2.

Misplacement or eccentricity in the direction of

misplacement

0.02 times the width of the

footing in the direction
of the deviation but not
more than 50 mm

3.

Reduction in thickness

(+/-) 0.05 times the specified

thickness

5.4.1.2.3
Tolerances in other types of structures shall generally conform to those given in
clause 2.4 of recommended Practice for Concrete Formwork (ACI 347).
5.5.0.0 TYPE OF FORMWORK:
5.5.1.0 Formwork may be of timber, plywood, metal, plastic or concrete. For special finishes the
formwork may be lined with plywood, steel sheets, oil tempered hard board, etc. sliding forms
and slip forms may be used with the approval of engineer-in-charge

83

5.6.0

FORMWORK REQUIREMENTS:

5.6.1

Forms shall conform to the shapes, lines, grades and dimensions including camber of the
concrete as called for on the drawings. Ample studs, Waller braces, ties, straps, shores, etc.
shall be used to hold the forms in proper position without any distortion whatsoever until the
concrete has set sufficiently to permit removal of forms. Form shall be strong enough to permit
the use of immersion vibrators; in special case form vibrators may also be used. The
shuttering shall be close boarded. Timber shall be well seasoned, free from sap, shakes,
loose knots, worm holes, warps or other surface defects in contact with concrete shall be free
from adhering grout, plaster, paint, projecting nails, splits or other defects. Joints shall be
sufficiently tight to prevent loss of water and fine material from concrete.

5.6.2

Plywood shall be used for exposed concrete surface where called for. Sawn and wrought
timber may be used for unexposed surfaces. Inside faces of forms for concrete surface, which
are to be rubbed finished shall be planed to remove irregularities or unevenness in the face.
Formwork with lining will be permitted.

5.6.3

All new and used form timber shall be maintained in a good condition with respect to shape,
strength, rigidity, water tightness, smoothness and cleanliness of surfaces. Form timber
unsatisfactory in any respect shall not be used and if rejected by the Engineer-in-charge shall
be removed from the site.

5.6.4

Shores supporting successive stories shall be placed directly over those below or be so
designed and placed that the load will be transmitted directly on them. Trussed supports shall
be provided for shores that can be secured on adequate foundation.

5.6.5

Form work during any stage of construction showing signs of distortion or disturbed to such a
degree that the intended concrete work will not conform to the exact contours indicated on the
drawings shall be re-positioned and strengthened. Poured concrete affected by faulty
formwork shall be removed entirely and the formwork shall be corrected prior to placing new
concrete.

5.6.6

Excessive construction camber to compensate for shrinkage settlement etc. that may impair
the structural strength of the members will not be permitted.

5.6.6.1 Forms for substructure concrete may be omitted in the opinion of the Engineer-in-charge the
open excavation is firm enough to act as the form. Such excavation shall be slightly larger
than that required by drawings to compensate for irregularities in excavation and to ensure the
design requirement.
5.6.7

Forms shall be designed and constructed that they can be stripped in order required and their
removal do not damage the concrete. Face form work shall provide true vertical and horizontal
joints conforming to the architectural features of the structure as to location of joints and be as
directed by the Engineer-in-charge.
Where exposed smooth or rubbed concrete finishes are required, the forms shall be
constructed with special care so that the desired concrete surfaces could be obtained which
require a minimum finish.

5.7.0

BRACINGS, STRUTS AND PROPS:

5.7.1

Shuttering shall be braced, strutted, propped and so supported that it shall not deform under
weight and pressure of the concrete and also due to the movement of men and other
materials. Bamboos shall not be used as props or cross bracings.

5.7.2

The shuttering for beams and slabs shall be so erected that the shuttering on the sides of the
beams and under the soffits of slab can be removed without disturbing the beam bottoms.

5.7.3

Re-propping of the beams shall not be done except when the props have to be reinstalled to
take care of construction loads anticipated being excess of the design load. Vertical props
shall be supported on wedges or other measures shall be taken whereby the props can be
84

gently lowered vertically while striking the shuttering.

If the shuttering for a column is erected for the full height of the column, one side shall be left
open and built upon sections as placing of concrete proceeds or windows may be left for
pouring concrete from sides to limit the drop of concrete to one meter or as directed by the
engineer-in-charge.
5.8.0

FORM OIL:

5.8.1

Use of the form oil shall not be permitted on the surface that requires painting. If the contractor
desires to use form oil on the inside of form work of the other concrete surfaces, a non
staining mineral oil or other approved oil CEMOL-35 of M/s Hindustan Petroleum Co. Ltd. or
equivalent may be used provided it is applied before placing of reinforcing steel and
embedded parts.
All excess oil on the form surfaces and any oil on metal or other parts to be embedded in the
concrete shall be carefully removed. Before treatment with oil forms shall be thoroughly
cleared of dried splatter of concrete from placement of previous lift.

5.9.0

CHAMFERS AND FILLETS:

5.9.1

All corners and angles in the finished structure shall be formed with mouldings to form
chamfers or fillets on the finished concrete. The standard dimensions of chamfers and fillets
unless otherwise specified shall be 20 mm x 20 mm. Care shall be exercised to ensure
accurate mouldings. The diagonal face of the moulding shall be planed or surface to the same
texture as the forms to which it is attached.
Vertical construction joints on faces which will be exposed at the completion of the work shall
be chamfered as above except where not permitted by Engineer-in-charge for structural or
hydraulic reasons.

5.10.0 WALL TIES:

5.10.1 Wall ties passing through the walls shall not be allowed. Also through bolts shall not be
permitted.
For fixing of formwork alternate arrangements such as coil nuts shall be adopted at the
contractors cost.
5.11.0 REUSE OF FORMS:
Before reuse all forms shall be thoroughly scraped, cleaned, nails removed, holes that may
leak suitably plugged and joints examined and when necessary repaired and the inside
retreated to prevent adhesion to the satisfaction of Engineer-in-charge. Warped timber shall
be resized. Contractor shall equip himself with enough shuttering to complete the job in the
stipulated time.
5.12.0 REMOVAL OF FORMS:
5.12.1 Contractor shall record in the drawings or a special register the date upon which the concrete
is placed in each part of the work and the date on which the shuttering is removed there from.
5.12.2 In no circumstances shall form struck until the concrete reaches a strength of at least twice
the stress due to self weight and any construction/erection loading to which the concrete may
be subjected at the time of striking of formwork. The strength referred to shall be that of
concrete using the same cement and aggregates and admixture, if any, with the same
proportions and cured under conditions of temperature and moisture similar to those existing
on the work.
o

5.12.3 In normal circumstances where the ambient temperature does not fall below 15 C and where
Ordinary Portland Cement is used and adequate curing is done the stripping time is to be
85

followed as specified in IS: 456-2000 (clause 11.3).

5.12.4 Striking shall be done slowly with utmost care to avoid damage to arise and projections and
without shock or vibration by gentling easing the wedges. If after removing the formwork it is
founds that timber has been embedded in the concrete, it shall be removed and made good
as specified earlier.
5.12.5 Reinforced temporary openings shall be provided as directed by the Engineer-in-charge to
facilitate removal of formwork which otherwise may be inaccessible.
Tie rods, clamps, form bolts, etc. which must be entirely removed from walls or similar
structure shall be loosened not sooner than 16 hours not later than 24 hours (in case the
conditions in 12.3 are satisfied) after the concrete has been deposited. Ties except those
required to hold the forms in place may be removed at the same time. Ties withdrawn from
walls and grade beams shall be pulled towards the inside face. Cutting ties back from the
faces of forms and grade beams will not be permitted. Work damaged due to premature or
careless removal of forms, any undulation in exposed concrete surface due to sag /
settlement or movement of supports found after removal of shuttering shall be reconstructed
or rectified to the satisfaction of the Engineer-in-charge by the contractor at his own risk and
cost. Abrupt changes in surface of concrete, mortar fins at formwork joints shall be made even
by chipping, grinding and finishing with cement mortar, curing, etc. as directed by Engineer-incharge at his own cost.
5.12.6 STRIPPING TIME:
5.12.6.1 Unless otherwise specified or instructed by the Architect/ Engineer, where ordinary Portland
cement is used, formwork may generally be removed after the following periods:
a) Walls, Columns & Vertical faces
24 Hours to
of all structural members as instructed.
48 Hours
b) Slabs (Props left under).
3 Days.
c) Beam Soffits (Props left under)
7 Days.
d) Removal of props under Slabs:
1) Spanning up to 4.50 Meters
7 Days.
2) Spanning over 4.50 Meters
14 Days.
e) Removal of props under Beams & Arches
1) Spanning up to 6.00 Meters
14 Days.
2) Spanning over 6.00 Meters
21 Days.
5.13.0 MODE OF MEASUREMENT:
5.13.1 The net area of exposed surfaces of concrete members as shown in the drawings coming in
contact with form work shall be measured under item of form work in square meter.
5.13.2 The dimensions of the formwork shall be measured correct to a centimeter.
5.13.3 No deductions shall be made from the shuttering for openings/obstructions up to an area of
2

0.10 m and nothing extra shall be paid of forming such opening.

For the purpose of measurements for formwork IS: 1200 (Part V) shall be referred.
5.14.0 SPECIFICATION FOR STAGING WORK:
5.14.1 The contractor shall note that only steel tubular staging (acrow type or equivalent) shall be
used for all RCC beams, slabs, etc. at all floor levels and the same shall be designed by him
and the detailed drawings and the design calculations shall be submitted for the approval of
Engineer-in-charge at least two months in advance of the scheduled date of its erection at
site. Depending upon the height of the staging, suitable vertical and horizontal cross bracings
shall be provided. The contractor shall note that no concreting of floor beams, stairs and slabs
including roof slab will be permitted unless the staging work is inspected and approval in
writing for its soundness by the Engineer-in-charge is given prior to the commencement of
concreting.
86

SUB-HEAD 6.0

SPECIFICATION FOR REINFORCEMENT STEEL

87

Clause No.

Brief Description

6.1

Standards

6.2

Applicable Codes

6.3

Steel Reinforcement

Page No.

88

6.0 - SPECIFICATIONS FOR STEEL REINFORCEMENT

6.1.0

Standards

6.2.0

Applicable Codes :
The provisions of the latest Indian Standards listed below, but not restricted to, form part of
these specifications:
IS-1785
IS-1786
IS-2751
IS-5525
Works.
IS-6006
IS-14268
IS-8OO
IS-816
IS-817
IS-226
IS-2062
IS-814
IS-919
IS-1477
IS-1977
IS-7205
IS-7215
IS-8500

6.3.0

Cold Drawn Stress relieved wire (Part I).

Specification for Cold Twisted Steel Bars for Concrete Reinforcement.
Code of Practice for Welding of M.S.Bars.
Recommendation for detailing of Reinforcement in Reinforced Concrete
Uncoated Stress Relieved Strand for Prestressed Concrete.
Specifications for uncoated stress Relieved Low
Relaxation Seven Ply Strand for Prestressed Concrete.
General Construction in Steel
Metal-arc welding for general construction in mild steel
Training & Testing of metal-arc welders
Structural Steel Sections
Weldable Structural Steel
Welding Electrodes
Recommendations for limits and fits for engineering.
Code of practice for painting of ferrous metals in buildings.
Structural Steel (Ordinary quality)
Safety code for erection of structural steel work
Tolerances for fabrication of steel structures
Weldable structural steel (medium and high strength qualities).

STEEL REINFORCEMENT :
All reinforcement used in this work will confirm to I.S.1786 with Fy = 415 N/sq.mm and will be
in the form of deformed bars.

6.3.1

Bending of Reinforcement:
Reinforcing steel shall conform accurately to the dimensions shown on relevant drawings and
conforming to IS:2502.
Bars shall not be bent or straightened in a manner that will injure the material.
Bars bent during transport or handling shall be straightened before being used on work, they
shall not be heated to facilitate bending.

6.3.2

Placing of reinforcement.
All reinforcing bars shall be accurately placed in exact position shown on the drawings, and
shall be securely held in position during placing of concrete by annealed binding wire not less
than 1 mm in size and conforming to IS:280, and by using stay blocks or metal chairs,
spacers, metal hangers, supporting wires or other approved devices at sufficiently close
intervals. Bars will not be allowed to sag between supports nor displaced during concreting or
any other operation over the work. All devices used for positioning shall be of non-corrodible
material. Wooden and metal supports will not extend to the surface of concrete, except where
shown
on the drawings. Placing bars on layers of freshly laid concrete as the work
progresses for adjusting bar spacing will not be allowed. Pieces of broken stone or brick and
wooden blocks shall not be used. Layers of bars shall be separated by spacer bars, Precast
mortar blocks or other approved devices.
Spacer bars between two closely positioned layers of bars shall be placed not more than 1 m

89

apart. The diameter of the spaces shall be minimum 25 mm.

Chairs used to separate the two layers of slabs, walls etc. shall be spaced not more than 2 m
clear in all four directions. The ratio of the maximum horizontal length between the legs of the
chair to the diameter of the bars used in preparing chairs shall not be more than 100.
Spacing of cover blocks shall not exceed 1 m in any direction.
Reinforcement after being placed in position shall be maintained in a clean condition until
completely embedded in concrete. Special care shall be exercised to prevent any
displacement of reinforcement in concrete already placed.
To protect reinforcement from corrosion, concrete cover shall be provided as indicated on the
drawings. All bars protruding from concrete and to which other bars are to be spliced and
which are likely to be exposed for an indefinite period shall be protected by a thick coat of neat
cement grout.
In the case of columns and walls, vertical bars shall be kept in normal position with timber
templates having slots accurately cut in for bar position. Such templates shall be removed
after the concreting has progressed upto a level. Bars crossing each other, where required,
shall be secured by binding wire(annealed) of size not less than 1 mm and conforming to
IS:280 in such a manner that they do not slip over each other at the time of fixing and
concreting.
As far as possible, bars of full length shall be used. In case this is not possible, over
lapping of bars shall be done as directed by the Engineer. When practicable, overlapping
bars shall not touch each other, but be kept apart by 25 mm or 1.25 times the maximum size
of the coarse aggregate whichever is greater, by concrete between them, where this is not
feasible, overlapping bars shall be bound with annealed steel wire, not less than 1 mm
thickness twisted tight. The overlaps shall be staggered for different bars and located at
points, along the span where neither shear nor bending moment is maximum.
Dowels if provided for future lapping, shall be coated with approved quality bitumen paint over
and above the anti-corrosive treatment.
6.3.3

Welding of Bars.
Welding of HYSD reinforcement shall be carried out in accordance with IS:2571. When
permitted or specified on the drawing joints of reinforcement bars shall be butt-welded so as to
transmit their full strength. Welded joints shall preferably be located at points where steel will
not be subject to more than 75 percent of the maximum permissible stresses and welds so
staggered that , at any one section, not more than 33 percent of the rods are welded. Only
electric are welding using a process which excludes air from the molten metal and
nonconforming to any or all other special provisions for the work will be accepted. Suitable
means shall be provided for holding the bars securely in position during welding. It must be
ensured that no voids are left in welding when welding is done in 2 or 3 stages, previous
surface shall be cleaned properly. Ends of the bars shall be cleaned of all loose scale, rust,
grease, paint and other foreign matter before welding. Only competent welders shall be
employed on the work. The M.S. electrodes used for welding shall conform to IS:814.
Welded pieces of reinforcement shall be treated. Specimens shall be taken from the actual
site and their number and frequency of tests shall be as directed by the Engineer.

90

SUB-HEAD 7.0

SPECIFICATION FOR STRUCTURAL STEEL

91

Clause No.

Brief Description

7.1

Scope

7.2

Applicable Codes and Specifications

7.3

Steel Reinforcement

7.4

Fabrication

7.5

Welding

7.6

Tolerances

7.7

End Milling

7.8

Inspection

7.9

Drilling Holes for Other Works

7.10

Handling and Storage

7.11

Inspection at Site

7.12

Painting

7.13

Mode of Measurements

7.14

Structural Steel with Tubes

7.15

Caps and Basis for Columns

7.16

Sealing of Tubes

7.17

Flattened Ends

7.18

Connections

7.19

Tolerances

7.20

Marking for Identification

7.21

Shop Tests Pre-Assembly

7.22

Shop Inspection and approval

7.23

Painting and Delivery

7.24

Field Erection and Tolerance

7.25

Method of Payment

7.26

Grouting of Pockets

7.27

Sheet Roofing and Cladding Works

7.28

PVC / Polycarbonate / FRP sheet Roofing & Cladding

Page No.

92

7.0 - SPECIFICATION FOR STRUCTURAL STEEL

7.1.0.

SCOPE :

7.1.1.

This specification covers requirements for the supply wherever, fabrication and delivery of
structural steel and miscellaneous steel items for the work.
This specification also covers redesign wherever necessary, design of all connections and
published members, preparation of all shop fabrication drawings, inspection and painting of
structures by the fabricators.

7.2.0

APPLICABLE CODES AND SPECIFICATIONS :

7.2.1

Unless otherwise specified herein, the design, materials and workmanship shall conform to
the latest edition of the one or as many as applicable of the following standards or their
approved equivalents.

7.2.2.

All standards, specifications and code of practices, referred to herein shall be the latest edition
including all applicable amendments, revisions and additional publications.

7.2.3.

List of Indian Standards :

I.S. Nos.
I.S. Particulars
I.S. 226 :
Structural steel (standard quality)
I.S. 808 :
Rolled steel beams, channel and angles sections.
I.S. 1099 :
Structural steel (ordinary quality)
ASTM 06 :
General requirements for delivery of rolled steel plates, sheet piling and bars
for
structural use.
I.S. 1367 :
Technical supply conditions for threaded fasteners.
I.S. 3757 :
High tensile friction grip fasteners for structural engineering purposes.
I.S. 814 :
Specifications for covered electrodes for metal arc welding for mild steel.
I.S. 3613 :
Acceptance tests for wire flux combination for submerged-arc welding.
B.S. 639 :
Covered electrodes for the manual metal arc welding of mild steel and
medium
tensile steel
AWS. A-5.1 : Specification for mild steel covered arc welding electrodes.
AWS.A-5-17 : Specification for hard mild steel electrodes and submerged arc welding.
I.S. 1052 :
Specification for rolling and cutting tolerances for hot rolled steel products.
I.S. 2074 :
Ready mixed paint, red oxide zinc chrome, priming.
I.S. 102 :
Ready mixed paint, brushing, red lead, non-setting, priming.
I.S. 300 :
Code of practice for use of structural steel in general building construction.
I.S. 875 :
Code of practice for structural safety of building : Loading standards.
I.S. 1893 :
Recommendations for earthquake resistant design of structures.
B.S. 449 :
The use of structural steel in building.
I.S. 816 :
Code of practice for use of metal arc welding for general construction.
I.S. 4353 :
Recommendations for submerged arc welding of mild steel and low alloy
steel.
I.S. 823 :
Code of procedure for manual metal arc welding of mild steel.
I.S. 817 :
Codes of practice for training and welding of metal arc welders.
I.S. 1182 :
Recommended practice for radiographic examination of fusion-welded butt
joints
in steel plates
I.S. 5334 :
Codes of practice for magnetic particle flaw detection of welds
ASTM E. 94 : Recommended practice for radiographic testing.
ASTME. 109 : Dry powder magnetic particle inspection.
ASTME. 130 : Wet magnetic particle inspection.
ASTME. 165 : Liquid penetrant inspection.
I.S. 1477 :
Code of practice for painting of ferrous metals in building all allied finishes.
I.S. 1161 :
Steel Tubes for structural purposes
IS:1363 :
Hexagon Head Bolts, Screws and Nuts of product (Part I to III)
I.S. 1852 :
Rolling and Cutting Tolerances for Hot Rolled Steel Products
93

I.S. 3502 :
I.S. 3757 :
I.S. 1200 :

Steel Chequered Plate

High Strength Structural Bolts
Method of Measurement

7.3.0.

STEEL MATERIALS :

7.3.1.

Structural steel shall be procured by the contractor conforming to relevant IS codes and
manufactured by M/s SAIL or TISCO or RINL only and shall be rolled from their own plants
and from virgin material. Materials manufactured by their authorized conversion agents and
re-rollers shall not be accepted. Documentary evidence of purchasing steel produced from
these manufacturers and their manufacturing test certificate shall be submitted. The third
party test shall be carried out as directed in line with the relevant Indian standards and cost of
which shall be included in the item rate and no separate payment shall be made on account of
this.

7.3.2.

Contractor shall take proper care of the steel supplied by department and protect the same
from weathering and damage. Any such materials rendered unserviceable or damaged while
in the contractors custody shall be replaced by contractor at his own cost as directed by the
Engineer-in-Charge.

7.3.3.

Contractors stock material may be used provided the mill test reports identified with the
materials, satisfactorily demonstrate specified grade and quality. Also all such materials
supplied by contractor shall be in a sound condition of recent manufacture, in full length, free
from defects, loose mill scale, slag intrusions, laminations, pitting, flaky rust etc. and be of full
weight of thickness specified.

7.3.4.

Unidentified steel material may be used only with prior permission from Engineer-in charge, in
writing, for short sections of minor importance or for small unimportant welds and connections
where in the opinion of the Engineer-in-charge the quality of such material would not adversely
affect the strength and / or durability of the structure. Engineer-in-charge may also permit use
of such material for other work if adequate and random samples taken out and tested to
demonstrate conformity with specification & requirement for work in view.

7.3.5.

Contractor shall submit the fabrication drawing for the Engineer-in-charges approval before
fabrication commences and make any modification therein as directed by the Engineer-incharge. Approval by the Engineer-in-charge of any of the drawings shall not relieve the
Contractor from the responsibility for correctness of engineering & design of connections,
workmanship, fit of parts, details, material, errors or omissions of any and all work shown
thereon. The Engineer-in-charges approval shall constitute approval of the size of members,
dimensions and general arrangement but shall not constitute approval of the connections
between members and other details.

7.3.6.

Approved design drawings will be furnished to the contractor and all drawings so furnished
shall form a part of this specification. Contractor shall consult these in detail for all the
information contained therein; which pertains to and is required for his work.

7.3.7.

The Engineer-in-Charge reserve the right to make changes, revisions to drawings even after
release for preparation of shop drawings are very likely to be made to reflect additional
data/details received and more updated requirements.

7.3.8.

Revisions in drawings and any new drawings made to include additional work by the Engineerin-charge shall be considered a part of this specification and contract and the contractor shall
have no extra claims on this account.

7.3.9.

Unless otherwise specified, the drawings and specifications are intended to include every
thing obviously requisite and necessary for the proper and entire completion of the work and
job shall be carried out accordingly for the completeness as required.

7.3.10. Design drawings prepared by the Engineer-in-Charge will show all the dimensions and if
necessary clearance of structure, landings where necessary, size of each member, definite
location of openings at various levels and all other information necessary to enable the
94

contractor in prepare drawings for fabrication and erection.

7.3.11 It shall be clearly understood that the Engineer-in-charges drawings are design drawing and
are not intended to show connection details, thickness of members, cuts, notches, bends and
such other details.
7.3.12 In the case of variation in drawings and specifications the decision of the Engineer-in-Charge
shall be final.
Should contractor in the execution of his work, find discrepancies in the information furnished
by the Engineer-in-charge he shall refer such discrepancies to the Engineer-in-Charge before
proceeding with the work.
7.4.0

FABRICATION :

7.4.1

All workmanship and finish shall be of the best quality and shall conform to the best-approved
method of fabrication.

7.4.2.

All materials shall be finished straight and shall be machined true and square where so
specified. All holes and edges shall be free of burrs.

7.4.3.

Shearing and chipping shall be neatly and accurately done and all portions of work exposed to
view shall be neatly finished.

7.4.4.

Standard fabrication clearance as detailed in American Institute of steel construction manuals

shall generally be followed unless otherwise directed approved.

7.4.5.

Material at the shops shall be kept clean and protected from weather.

7.4.6.

Shop connections shall be effected by welding as specified on the Engineer-in-Charges

design drawings.

7.4.7.

Rolled materials
required/specified.

7.4.8.

If straightening or flattening is necessary it shall be done by methods that will not injure the
material. Long plates shall be straightened by passing through a mangle or leveling rolls and
structural shapes by the use of mechanical or hydraulic bar straightening machines.

7.4.9.

Heating or forging shall not be resorted to without the prior approval of the Engineer-in-charge
in writing.

before

being

worked

shall

be

straightened

unless

otherwise

7.4.10. Cutting may be by shearing, cropping, sawing or machine flame cutting. All reentrant corners
shall be shaped notch-free to a radius of at least 12 mm. Sheared or cropped edges shall be
dressed to a neat workmanlike finish and shall be free from distortion and burrs.
7.4.11. The korf on machine flame cut edges shall be removed. Where machine flame cutting is
permitted for high tensile steel, special care shall be taken to leave sufficient metal and all
flame hardened material shall be removed by machining/edge planning.
7.4.12. Hand flame cutting shall be undertaken only if so permitted by Engineer-in-charge and only be
carried out by an expert in such work. Hand flame cut edges shall be ground smooth and
straight.
Edge planning of sheared, chopped or gas cut edges is not intended unless the sheared,
chopped or gas cut edges are such as to warrant it or specifically called for.
7.5.0

WELDING :

7.5.1.

Welding procedure shall be submitted to Engineer-in-charge for approval. Welding shall be

entrusted to only qualified and experienced welders who shall be periodically tested and
graded as per IS 817, IS: 7310 (Part 1) and IS: 7318 (Part 1).
95

7.5.2.

Electrodes for structural welding works shall comply with the requirements of IS: 226 and / or
BS: 634 or AWS: A-5.1 and shall be of approved make.

7.5.3.

The electrodes shall be suitable for use in the position and type of work as laid down in the
above specifications and as recommended by the manufacturer.

7.5.4.

Electrodes of classification AWS E 60 XX and C 70 XX shall be used for welding steel

conforming to I.S. 226 and I.S. 2062 and of classification AWS E 70 XX for steel conforming
to I.S. 961. Electrodes other than low-hydrogen electrodes shall not be permitted for thickness
of 32mm & above.

7.5.5.

Joints in materials above 20 mm thick and all the important connections shall be made with
low Hydrogen electrodes of AWS E 7016 or E 7010 classification.

7.5.6.

The filler wire and flux combination for submerged arc welding shall conform to the
requirements for the desired application as laid down in I.S. 3613. The weld metal deposited
by the submerged arc process shall have mechanical properties not less than that specified
for American Welding Societys classification 5.17 E 60 for steel to I.S. 226 and I.S. 2042 and
AWS classification 5.17 E 70 for steel to IS: 961.

7.5.7.

Electrode Flux covering shall be sound and unbroken. Broken or damaged coating shall cause
the electrodes to be discarded. Covered electrodes for manual-arc welding shall be properly
stored to an oven prior to use in a manner recommended by the manufacturer and only an
hours quota shall be issued to each welder from the oven.

7.5.8.

Electrodes larger than 5mm diameter shall not be used for root-runs in butt welds.

7.5.9.

Welding plants and accessories shall have capacity adequate for the welding procedure laid
down and shall satisfy appropriate standards and be of approved make and quality. Contractor
shall maintain all welding plants in good working conditions. All the electrical plants in
connection with the welding operation shall be properly and adequately earthen and adequate
means of measuring the current shall be provided.

7.5.10. All welds shall be made only by welders and welding operators who have been properly
trained and previously qualified by tests to perform the type of work required as prescribed in
the relevant applicable standards.
7.5.11. All welds shall be free from defects like blowholes, slag inclusions, lack of penetration, under
cutting, cracks etc. All welds shall be cleaned of slag or flux and show uniform sections,
smoothness of weld metal, featheredges without overlap and freedom from porosity.
7.5.12. Fusion faces and surfaces adjacent to the joint for a distance of at least 50 mm on either side
shall be absolutely free from grease, paint, loose scales, moisture or any other substance
which might interfere with welding or adversely affect the quality of the weld.
7.5.13. Joint surfaces shall be smooth, uniform and free from fins, tears, laminations etc.
7.5.14. Preparation of fusion faces shall be done in accordance with the approved fabrication
drawings by shearing, chipping, achining or machine flame cutting except that shearing shall
not be used for thickness over 8 mm.
7.5.15. In the fabrication of cover plated beams and built up members all shop splices in each
component part shall be made before such component part is welded to other parts of the
member. Wherever weld reinforcement interiors with proper fit-up between components to be
assembled for welding, these welds shall be ground flush prior to assembly.
7.5.16. The members to be joined by fillet welding shall be brought and held as close together as
possible and in no event shall be separated by more than 3 mm. If the separation is 1.5 mm or
greater the fillet weld size shall be increased by the amount of separation. This shall only apply
if the surfaces are completely sealed by welds. In all other cases the fit-up shall be close
96

enough to exclude water after painting.

7.5.17. The separation between faying surfaces of lap joints and butt joints with backing plate shall
not exceed 1.5 mm. A butting part to be butt-welded shall be carefully aligned and the correct
root gap maintained throughout the welding operation.
7.5.18. Misalignments greater than 25 percent of the thickness of the thinner plate or 3 mm whichever
is smaller shall be corrected and in making the correction the parts shall not be drawn into a
shape sharper than 2 degrees (1 in 27.5).
7.5.19. Pre-qualified procedures recommended for appropriate welding standards and known to
provide satisfactory welds shall be followed. For non-standard procedures, qualification testes
are prescribed in IS: 823 shall be made to verify the adequacy of the procedures. A welding
procedure shall be prepared by the contractor and submitted to the Engineer-in-charge for
approval before the welding starts. This shall include all the details of welding procedures with
reference to the provisions of IS: 823 and IS: 4353. Approval of the welding procedure by the
Engineer-in-charge shall not relieve the contractor from his responsibility for correct & sound
fabrication without distortion to the finished structure.
7.5.20. Submerged arc automatic or semi automatic welding shall generally be employed. Only where
it is not practicable to use submerged arc welding manual arc welding may be resorted.
7.5.21. Voltage and current (and polarity if direct current is used) shall be set according to the
recommendations of the manufacturer of the electrode being used and suitability to thickness
of material, joint form etc.
7.5.22. The work shall be positioned for flat welding wherever practicable and overhead weld shall be
avoided.
7.5.23. No welding shall be done when the surface of the member is wet nor during periods of high
wind unless the welding operator and the work are properly protected.
7.5.24. In joints connected by fillet welds the minimum sizes of single run fillet welding or first runs
and minimum full sizes of fillet welds shall conform to the requirement of IS: 816 and IS: 823.
7.5.25. All complete penetration butt welds made by manual arc welding except when produced with
the aid of backing material or welded in flat position from both sides in square-edge material
not over 8 mm thick with root opening not less than one-half the thickness of the thinner part
joined shall have the root of the initial layer gouged and on the back side before welding is
started from that side and shall be so welded as to secure sound metal and complete fusion
throughout the entire core section.
7.5.26. Butt welds shall be terminated at the ends of joint in a manner that will ensure their
soundness. Where abutting parts are 20 mm or more in thickness run-on and run-off plates
with similar edge preparation and having a width not less than the thickness of the thicker part
joined shall be used. These extension pieces shall be approved upon completion of the weld
and the ends of the weld made smooth and flush with the abutting parts. Where the abutting
parts are thinner than 20 mm the extension pieces may be omitted but the ends of the butt
welds shall then be chipped or gouged out to sound metal and side welded to fill up the ends
to the required reinforcement.
7.5.27. Each layer of a multiple layer weld except root and surface runs may be moderately peened
with light blows from a blunt tool. Care shall be exercised to prevent scaling or flaking of weld
and base metal from over-peening.
o

7.5.28. No welding shall be done on base metal at a temperature below 5 C. Base metal shall be
preheated as required to the temperature given in the table below prior to tack welding or
welding. When base metal not otherwise required to be preheated is at a temperature below
o

zero degree centigrade it shall be preheated to at least 20 C prior to tack welding or welding.
Preheating shall bring the surface of the base metal within 75 mm of the point of welding to
97

the specified preheat temperature and this temperatures shall be maintained as minimum
inter pass temperature while welding is in progress.
7.5.29.
Thickness
of
thickest
part
point of welding

Min. Preheat & Inter pass Temp.

Other than low Hydrogen Low Hydrogen welding
welding electrodes
electrodes
I.S : 226 I.S : Steel conforming to IS : 961 IS: 226 IS:
2062
2062 IS: 961

Up to 20 mm.

None

20 mm to 40 mm.

65 D.C

40 mm to 63 mm.
Over 63 mm.

Welding with
this process not
allowed

None

10 D.C

10 D.C.

65 D.C.

110 D.C.

95 D.C.

110

150 D.C.

110 D.C

D.C.
150
D.C.

7.5.30. Minimum preheat for I.S. 226 steel in thickness up to 80 mm shall be 10 degree centigrade.
7.5.31. Electrodes other than low-hydrogen electrodes shall not be permitted for thickness of 75 mm
and above.
7.5.32. Before commencing fabrication of a member or structure in which welding is likely to result in
distortion and or locked up stresses a complete programme of fabrication, assembly and
welding shall be made and submitted to the Engineer-in-charge for approval. Such a
programme shall include, besides other appropriate details, full particulars in regard to the
following:
7.5.33.1 Proposed preheating in components such as flanges and presetting of joints to offset
expected distortion.
7.5.33.2 Make up of sub-assemblies proposed to be welded before incorporation in final assembly.
7.5.33.3 Proposed joint forms, classification of wire and flux or covered electrodes, welding process
including fitting and welding sequence with directions in which freedom of movement is to be
allowed.
7.5.33.4 Proposed number, spacing and type of strong backs and details of jigs and fixtures for
maintaining proper fit-up and alignment during welding.
7.5.33.5 Any other special features like assembling similar members back to back or stress relief.
7.5.34 If so desired by the Engineer-in-Charge mock-up welding shall be carried out at contractors
cost to establish the efficiency of the proposed programme, with any modification suggested
by the Engineer-in-charge in limiting distortion or/ and residual stress to acceptable levels.
7.5.35. All welds shall be inspected for flaws by any of the methods described under the clause of
Inspection given below in this specification. The choice of the method adopted shall be
determined by Engineer-in-charge.
7.5.36. Contractor shall quote separately for carrying out such tests as called for in the schedule of
quantities. Contractor shall be paid only for tests, which establish soundness of welds. In
case the tests wherever defective work such tests will be at the contractors cost and
98

contractor shall correct such defects at his own cost and prove the soundness of rectified
work.
The correction of defective welds shall be carried out as directed by the Engineer-in charge
without damaging the parent metal. When a crack in weld is removed, magnetic particle
inspection or any other equally positive means as prescribed by the Engineer-in-charge shall
be used to inspect that the whole of the crack and material up to 25 mm beyond each end of
the crack has been removed. Cost of such test & operation incidental to correction shall be on
contractors account.
7.6.0

TOLERANCES;

7.6.1.

The dimensional and weight tolerances for rolled shapes shall be in accordance with I.S. 1852
and / or ASTM A6.

7.6.2

No rolled or fabricated member shall deviate from straightness by more than 1/1000 of the
length or 10 mm whichever is smaller.

7.6.3

The length of members with both ends finished for contact shall have a tolerance of () 1 mm.

7.6.4

Members without ends finished for contact bearing shall have a tolerance of () 1.5 mm for
members up to 10 meters long and a tolerance of () 3 mm for members over 10 meters in
length.

7.6.5

Lateral deviation between center line of web plates and center line of flange plate at contact
surface in the case of built up sections shall not exceed 6 mm.

7.6.6

The combined warpage and filet of flanges in welded built up sections shall not exceed 1/200
of the flange width or 3 mm whichever is smaller.

7.6.7

The deviation from flatness of welded plate girder web in the length between stiffeners or a

th

th

th

length equal to the depth of the girder shall not exceed 1/150 of each length.
Deviations from the specified depth of welded girders measured at the center line of the web
shall not exceed () 3 mm up to a depth of 1000 mm, () 5 mm for depths above 1000 mm up
to 2000 mm and (+) 0 mm and (-) 5 mm for depths over 2000 mm.
7.7.0

END MILLING :

7.7.1.

Column ends bearing on each other or resting on based plates and compression joints
designed for bearing shall be milled true and square to ensure proper bearing and alignment.

7.7.2.

Base plates shall also have their surfaces milled true and square.

7.8.0

INSPECTION :

7.8.1.

The Contractor shall give due notice to the Engineer-in-charge in advance of the works getting
ready for inspection. All rejected material shall be promptly removed from the shop and
replaced with new material for the Engineer-in-charges approval/ inspection. The fact that
certain material has been accepted at the Contractors shop shall not invalidate final rejection
at site by the Engineer-in-charge; if it fails to conform to the requirements of these
specifications, to be in proper condition or has fabrication inaccuracies which prevents proper
assembly nor shall it invalidate any claim which the department may make because of
defective or unsatisfactory materials and/or workmanship.

7.8.2.

No materials shall be painted or dispatched to site without inspection and approval by the
Engineer-in-charges unless such inspection is waived in writing by the Engineer-in-charge.
Shop inspection by the Engineer-in-charge or his authorized representative on submission of
test certificates and acceptance thereof by the Engineer-in-charge shall not relieve contractor
from the responsibility of furnishing material conforming to the requirements of these

7.8.3.

99

specifications nor shall it invalidate any claim which the engineer-in-charge may make
because of defective or unsatisfactory material and of workmanship.
7.8.4.

Contractor shall provide all the testing and inspection services and facilities for shop work
except where otherwise specified. Contractors inspection work shall be under the control of a
competent Chief Inspector whose primary responsibility is inspection reporting to management
and not to production departments.

7.8.5.

For fabrication work carried out in the field the same standard of supervision and quality
control shall be maintained as in shop fabricated work. The inspection and testing shall be
conducted in a manner satisfactory to the Engineer-in-charge.

7.8.6.

The inspection and tests on structural steel members shall be as set forth below:

7.8.7

If mill test reports are not available to any steel material the same shall be got tested by
contractor to the Engineer-in-charges satisfaction to demonstrate conform with the relevant
specification.

7.8.8

The under mentioned tests are not generally required for the work and if required will be paid
extra.

7.8.9

Magnetic Particle Test: Where root and intermediate passes of weld is examined by
magnetic particle testing such testing shall be carried out throughout. Its entire length in
accordance with ASTM specification E-109. In the case of completed welds such tests shall
be carried out in accordance with ASTM specification E-109 0r E-130 as decided by the
Engineer-in-charge. If heat treatment is performed the completed weld shall be examined
after the heat treatment. All defects shall be replaced and retested. Magnetic particle tests
shall be carried out using alternating current. Direct current may be used with the permission
of the Engineer-in-charge.

7.8.10. Liquid Penetrant Inspection : In the case of welds examined by liquid penetrant inspection
such tests shall be carried out in accordance with ASTM E164 or I.S. 3650. All defects shown
shall be repaired and rechecked.
7.8.11. Radiographic Inspection : All full strength butt welds shall be fully radiographed in
accordance with the recommended practice for radiographic testing as per ASTM E-94 and
Part U.W. 51 ASME Code Section VIII.
7.8.12 Dimension, Workmanship & Cleanliness :
7.8.12.1 The structural steel members shall be inspected at all stages of fabrication and assembly to
verify that dimensions, tolerances, alignment and surface finish, painting where specified are
in accordance with the requirements shown on contractors approved shop drawings and
Engineer-in-charges drawings.
7.8.13 Inspection or Test failure :
7.8.131 In the event of any failure of structural steel members to meet an inspection or test
requirement, contractor shall notify Engineer-in-charge or his authorized representative.
Contractor must obtain permission from Engineer-in-charge before repair is undertaken.
7.8.13.2 The quality control procedures to be followed to ensure satisfactory repair shall be subject to
approval by Engineer-in-charge.
7.8.13.3 Engineer-in-charge has a right to specify additional inspection or testing, as he deems
necessary and the additional cost of such testing will be borne by the department.
7.8.13.4 Contractor shall maintain records of all inspection and testing which shall be made available
to Engineer-in-charge or his authorized representative.

100

Some steel work particularly columns along with the tie beams/bracings may have to be shop
assembled to ensure satisfactory fabrication, obtaining of adequate bearing areas etc.; if so
desired by Engineer-in-charge at no extra cost to purchaser.
7.9.0

DRILLING HOLES FOR OTHER WORKS :

Holes in members required for installing equipment or steel furnished by other manufacturers
or other contractors shall be drilled in contractors shop as part of this contract. The
information for which will be supplied by Engineer-in-charge before fabrication of the steel.

7.10.0 HANDLING AND STORAGE :

7.10.1 No dragging of steel shall be permitted. All steel shall be stored 300 mm above ground on
suitable packing to avoid damage in the order required for erection and with erection marks
visible. All storage areas shall be prepared and maintained by contractor.
7.10.2 Steel shall not be stored in the vicinity of area where the excavation or grading will be done
and if stored temporarily, this shall be removed by contractor well before such excavation and
/or grading commence in a safe distance to avoid burial under debris.
7.10.3 Scratched or abraded steel shall be given a coat of the primer specified on drawings for
protection after unloading and handling prior to erection. All milled and machined surfaces
shall be properly protected from rust/corrosion by suitable coating and also from getting
damaged.
7.10.4 After checking and inspection, all members shall be marked for identification during erection.
This mark shall correspond to distinguishing marks on approved erection drawings and shall
be legibly painted and stamped on it. The erection mark shall be stamped with a metal dye
with figures at least 20 mm high and to such optimum depth as to be clearly visible.
Structural steel frames shall be erected plumb and true. All steel columns and beams shall be
checked for plumb and level individually before and after connections are made. Temporary
bracings may be introduced wherever necessary to take care of all loads to which the
structure may be subjected including erection equipment and the operation thereof. Such
bracings shall be left in place as long as may be required for safety and stability.
7.11.0 INSPECTION AT SITE:
Engineer-in-charge or their authorized representatives shall have free access to all parts of
the job during erection and all erection shall be subject to their approval. In case of faulty
erection all such dismantling and re-erection required will be at contractors cost. No paint
shall be applied to field welds until these have been approved by Engineer-in-charge.
7.12.0 PAINTING:
7.12.1. All fabricated steel material except those galvanized shall receive protective paint coating as
specified on design drawings.
7.12.2. The surface of steel work to be painted shall be thoroughly cleaned of all mill scale, rust,
grease, dirt and other foreign matter by hand tool cleaning, power tool cleaning, flame
cleaning or sand/ shot blasting as indicated on drawings. In power brushing sufficient care
shall be taken not to burnish mill scale to a slick finish to which paint may not adhere properly.
7.12.3. The paint treatment as specified on drawings shall be applied either by brushing or spraying
on the thoroughly cleaned and dry surface. Airless spraying shall be done if so specified.
7.12.4. Surfaces inaccessible after assembly shall receive and additional coat of the specified paint
prior to assembly.
Paint shall be stirred frequently to keep the pigment in suspension. All paint delivered to the

101

fabrication shop shall be ready mixed in original sealed containers as packed by the paint
manufacturers and no thinners shall be permitted. No painting shall be done in frosty / foggy
weather or when the humidity is high enough to cause condensation of the surface to be
painted. Paint shall not be applied when the temperature of the surface to be painted is 5
degree centigrade or lower.
7.13.0 MODE OF MEASUREMENTS :
7.13.1. For the purpose of payment the weight of the actual completed structures shall be calculated
from the approved drawings for different items of work.
7.13.2. The allowances will be permitted for galvanizing, welding or for cutting margins. One Tonne
for the purpose of payment shall mean One Metric Tonne i.e., 1000 Kg.
7.13.3. The weight of member made out of standard rolled section such as beam, channels, angles,
etc. shall be based on the standard IS: 800. The weight of member shall be considered
without deducting for holes, notches, bevels cuts etc. Where a component consists of a cut
joist or channels, the full weight of the rolled section shall be considered only if more than half
the depth of the original section is used. Otherwise, only half the section unit weight shall be
considered for calculation of the weight of plates for skew cuts and notches of 900 square
centimeter or larger.
7.13.4. The weight of any built-up member shall be separated into weight of each component.
7.14.0 STRUCTURAL WORK WITH STEEL TUBES:
7.14.1 GENERAL: Same as in 15.1.0 but for structural steel tubes conforming to IS 1161-1979 Sec. IV.
7.14.2 FABRICATION DRAWINGS: Same as in 15.2.0 but for structural steel tubes.
7.14.3 BILL OF MATERIALS: Same as in 15.3.0 but for structural steel tubes.
7.14.4 MATERIALS:
7.14.4.1 STEEL TUBES (ERW): Steel tubes used in building construction shall be hot finished tubes
conforming to the requirements specified in IS 1161-1979.
7.14.4.2 DESIGNATION: Steel tubes shall be designated by their nominal bore and shall be classified
as 'Light', 'Medium' and 'Heavy', depending on the wall thickness ( refer Table I of IS 1161- 1979
for properties.)
They shall be further graded as Yst 210, Yst 240 and Yst 310 depending on the yield stress of
the material as indicated under:
Grade
Tensile Strength.
Yield Stress.
Min ( N/Sqmm )
Min( N/Sqmm )
Yst 210
330
210
Yst 240
410
240
Yst 310
540
310
7.14.4.3 DIMENSIONS AND WEIGHTS: The standard sizes and weights of tubes for structural purpose
shall be as given in Table I of IS 1161-1979. Tubes of thickness lower than Light Tubes
specified in Table I shall not be permissible.
7.14.4.4 WELDING ELECTRODES: Same as in 15.4.2.
7.14.4.5 BOLTS, NUTS AND WASHERS: Same as in 15.4.3.
7.14.5 RECEIPT AND STORING OF MATERIALS : Same as in 15.5.0.
7.14.6 MATERIAL TESTS : Apart from those specified in 15.6.0 the tests for ERW tubes shall be
102

carried out as specified in IS 1161-1979 Section IV.

7.14.7 FABRICATION :
7.14.7.1 GENERAL:
a) The fabrication of structures with steel tubes shall generally conform to IS 806
b) The general provisions in Section V of IS 800 are also applicable to the fabrication of
structures using steel tubes. Where welding is adopted, reference to appropriate provision of
IS 820 and IS 816 shall be made.
c) The component parts of the structure shall be assembled in such a manner that they are
neither twisted nor otherwise damaged and be so prepared that the specified cambers, if
any, are maintained.
7.14.7.2 STRAIGHTENING: All materials before being assembled, shall be straightened unless required
to be of a curvilinear form and shall be free from twists.
7.14.7.3 BOLTING: Washers shall be specially shaped where necessary or other means used, to give
the nuts and the heads of the bolts a satisfactory proper bearing.
In all cases where the full bearing area of the bolt is to be developed, the threaded portion of the
bolt shall not be within the thickness of the parts bolted together, and washers of appropriate
thickness shall be provided to allow the nut to be completely tightened.
7.14.7.4 CUT EDGES: Edges should be dressed to a neat and workmanlike finish and be free from
distortion where parts are to be in contact, metal to metal.
For tube to tube connections the cutting of individual members shall be done with Profile Cutting
Machines only.
7.15.0 CAPS AND BASES FOR COLUMNS : The ends of all tubes for columns, transmitting loads
through the ends, should be true and square to the axis of the tube and should be provided with
a cap or base accurately fitted to the end of the tube and screwed, welded or shrunk on. The cap
or base plate should be true and square to the axis of the column.
7.16.0 SEALING OF TUBES : When the end of a tube is not automatically sealed by the virtue of its
connection by welding to another member, the end shall be properly and completely sealed.
Before sealing, the inside of the tube should be dry and free from loose scale.
7.17.0 FLATTENED ENDS : In tubular construction, the ends of tubes may be flattened or otherwise
formed to provide for welded, riveted or bolted connections provided that the methods adopted
for such flattening do not injure the material. The change of section shall be gradual.
7.18.0 CONNECTIONS:
A. GENERAL: Connections in structures using steel tubes shall be provided by welding, riveting
or bolting. Wherever possible, connections between tubes shall be made directly, tube to
tube without gusset plates and other attachments. Ends of tubes may be flattened as
specified in 15.7.7, or otherwise formed to provide for welded, riveted or bolted connections.
B. ECCENTRICITY OF MEMBERS: Tubes meeting at a point, shall wherever practicable,
having their gravity axes, meeting at a point so as to avoid eccentricity.
C. ECCENTRICITY OF CONNECTIONS: Wherever practicable, the center of resistance of the
connection shall lie on the line of action of the load, so as to avoid eccentricity moment of
connection.
D. WELDED CONNECTIONS: A weld connecting two tubes end to end, shall be full penetration
butt weld. The effective throat thickness of the weld shall be taken as the thickness of the
thinner part joined.

103

A weld connecting the end of one tube (branch tube) to the surface of another tube (main
tube) with their axes at an angle of not less than 30 degrees shall be of the following types:
a) A butt weld throughout.
b) A fillet weld throughout, and
c) A fillet-butt weld, the weld being a fillet weld in one part and a butt weld in another with
a continuous change from one form to the other in the intervening portions.
Type (a) may be used whatever the ratio of the diameters of the tubes joined, provided
complete penetration is secured either by the use of backing material, or by depositing a
sealing run of metal on the back of the joint, or by some special method of welding. When
type (a) is not employed, type (b) should be used where the diameter of the branch tube is
less than 1/3rd of the diameter of the main tube, and type (c) should be used where the
diameter of the branch tube is equal to or greater than 1/3rd of the diameter of the main tube.
E. ANGLE BETWEEN TUBES : A weld connecting the end of one tube to the surface of
another, with the axes of the tubes intersecting at an angle of less than 30 degrees, shall be
permitted only if adequate efficiency of the junction has been demonstrated.
7.19.0 TOLERANCES : The following tolerances (IS 1161-1979) shall apply:
a) Outside diameter
1) Upto and including 48.3 mm
2) Over 48.3 mm
b) Thickness (for all sizes)
1) Welded tubes
2) Seamless tubes
c) Weight:
1) Single tube (irrespective of quantity)

+ 0.4 mm
- 0.8 mm
+/- 1.0 %

+ Not limited
- 10 %
+ Not limited
- 12.5 %
+ 10 %
-8%

2) For quantities of less than

150 M of one size

+ 10 %
-8%

3) For quantities of 150 M and

over of one size

+/- 4 %

7.20.0 MARKING FOR IDENTIFICATION:

7.21.0 SHOP TESTS PRE-ASSEMBLY:
7.22.0

SHOP INSPECTION AND APPROVAL:

7.23.0

PAINTING AND DELIVERY:

7.24.0 FIELD ERECTION AND TOLERANCE:

7.25.0

METHOD OF PAYMENT:

7.26.0 GROUTING OF POCKETS:

7.27.0 SHEET ROOFING AND CLADDING WORK :
7.27.1 GENERAL: The work shall cover supplying and installing sheet roofing and cladding. The work
shall be carried out in strict accordance with this specifications and applicable drawings.
7.27.2 ASBESTOS CEMENT SHEET ROOFING AND CLADDING: Unless otherwise specified the
104

Work to be carried out as per Manufacturers specifications.

7.27.3 ALUMINIUM SHEET ROOFING AND CLADDING: Unless otherwise specified the Work to be
carried out as per Manufacturers specifications.
7.27.4 PREPAINTED MS SHEET ROOFING AND CLADDING: Unless otherwise specified the Work to
be carried out as per Manufacturers specifications.
7.27.5 SANDWICH PANEL ROOFING AND CLADDING: Unless otherwise specified the Work to be
carried out as per Manufacturers specifications.
7.28.0 PVC/POLYCARBONATE/FRP SHEET ROOFING AND CLADDING: Unless otherwise
specified the Work to be carried out as per Manufacturers specifications.

*****

105

SUB-HEAD 8.0

SPECIFICATION FOR STONE / BRICK / BLOCK WORK

106

Clause No.

Brief Description

Page No.

8.1

Scope of Work

8.2

Size Stone Masonry

8.3

Un-coursed Rubble Masonry

8.4

Random Rubble Masonry

8.5

Concrete Block Work

8.6

Workmanship for Block Work

8.7

Mode of Measurement for Stone Masonry

8.8

Mode of Measurement for Block Masonry

* * * * *

107

8.0 - SPECIFICATION FOR STONE MASONRY

8.1

SCOPE OF WORK :
The work covered under this specifications consists of supplying and erecting stone masonry
walls with available best quality of stone in strict compliance with this specifications and
applicable drawings.

8.2

SIZE STONE MASONRY:

Size stones shall be of hard granite, basalt or trap stone obtainable from approved quarry. The
stones shall be clean and wetted before they are used.
Height of course, shall not be less than 15 cms and all courses shall be of uniform height. Unless
otherwise instructed the depth of higher courses should not be more than the depth of lower
courses. Bed and sides shall be hammer or chisel dressed from the face 75mm and 35mm
respectively.
No face stone shall be less in depth than in height or shall tail into the work to a length less than
the height. Stones shall break joints at-least half the height of the course. Faces of stones shall
be hammer dressed and bushing not to be more than 25 mm thickness of joints shall not be
more than 20mm edges of face stones of exposed faces shall be dressed by using flat/ pointed
chistle true to both longitudinal and vertical lines. Exposed faces of corner stones to be 2 lines
dressed 50 mm wide.
Bond or through stones shall be provided not exceeding 2.0 Mtrs apart in each course and shall
be staggered. Bond stone shall be from the front to the back of the walls. For wall upto 60 cms
thick under, bond stones shall be in one piece and for walls over 60 cms thick they shall either
be in one piece (if available locally) or be in the series of headers, each header overlapping the
adjoining one by not less than 150 mm bond or through stones shall be marked as directed to
enable their being easily detected even after having been built in position. The interior or
filling shall be with flat bedded stones laid in mortar, chips, spalls shall be used to avoid thick
mortar joints and shall not exceed 10% of the quantity of stone masonry. Care is to be taken that
no dry work or hollow spaces shall be left any where in the masonry.

8.3

UNCOURSED RUBBLE MASONRY :

The stones as received from quarry are to be set in work after knocking off weak corners and
edges with mason's hammer. They are to be laid carefully so as to break joint as much as
possible and shall be solidly bedded in mortar. No joint shall exceed 20 mm, chips of stone and
spalls shall be wedged into the work wherever necessary to avoid thick beds or joints of mortar.
No dry work or hollow spaces shall be allowed, every stone whether large or small shall be set
flush in mortar, smaller stones used in filling being carefully selected to fit snugly the interstices
between the larger ones. The face stone shall be selected from the mass of quarry stones for
proper size good beds and uniform color and shall be laid as far as possible without pinning in
front. One through stone shall be provided for every Sqm. of facing and shall run back into work
at least 600mm or full depth of the work if it is less than 600mm. The quoins for exposed corners
unless otherwise specified shall be of selected stone neatly dressed with hammer and chisel to
form required angle and laid header and stretcher alternatively. The masonry has to be kept wet
for 10 days. In the case of cement mortar the proportion specified is on volumetric basis. But
cement shall be weighed on the assumption that one cubic meter of cement weighs 1440 kgs.
The architects may also require cement to be measured by volume but on same assumption.

8.4

RANDOM RUBBLE MASONRY

The face stone shall be laid absolutely without pinning on the face. Every stone shall be carefully
fitted so as to form neat and close joints and if necessary the edges shall be dressed with chisel
so as to ensure close joints work. The thickness of joint will be as specified for each work and in
no case more than 20mm. The thickness of joint should be uniform on the face variation being
within 25%. Mortar in joints should be scraped 12mm deep for pointing.
The stones shall be roughly chisel dressed to ensure equal size on face as far as possible. They

108

shall be of uniform color and they shall be carefully laid and solidly bedded in mortar and shall
tail back and bond well into the backing and shall not be of greater than either breadth of face or
length of tail into the work.
One header or through stone shall be inserted for every square meter of face and shall run right
through the wall be laid from face to back which shall overlap each other at least 150mm stones
shall be arranged to break joints as much as possible and long vertical lines of joining shall be
avoided in face work. The quoins unless otherwise specified shall be of selected stones neatly
dressed with hammer chisel to form required angle and laid header and stretcher alternatively.
The masonry has to be kept wet for 10 days.
In the case of cement mortar, the proportion specified is on volume basis. But cement shall be
weighed on the assumption that one cubic meter of cement weighs 1440 Kgs.
Architects may also require the cement to be measured by volume but on the same assumption.
8.5

SPECIFICATION FOR CONCRETE BLOCK WORK

Hollow or solid concrete blocks shall conform to IS 2185 and shall be regular in size and
shape and of the specified strength.
Blocks shall be properly cured before being brought to Site and shall have a texture such that
plaster and/or render will readily adhere to it.
The Contractor shall supply samples for the approval of the Engineer and all blocks supplied
shall conform strictly to the approved samples.
Half or three quarter size blocks may be used wherever required to make up lengths of walls
but broken blocks shall not be used.
Pre-cast concrete screen or special blocks or jalli work for decorative purposes shall be as
specified on the drawings or as directed by the Engineer. Sample blocks shall be submitted to
the Engineer for approval and blocks supplied shall strictly conform to the approved samples.
Mortar shall be prepared in accordance with IS 2250. Mixes for cement mortar shall be as
specified for the respective items of work. Cement shall be ordinary Portland cement as
described in Specification 2.2.
Sand shall be natural sand in accordance with IS 383, passing a 4.75mm size IS sieve, and
shall be free from clay, shale, loam, alkali, organic and other deleterious matter and shall be of
sound, hard, clean and durable particles. Sand shall be approved by the Engineer and, if so
directed, shall be thoroughly washed until it is free of any contamination.
Gauge boxes for sand shall be of such dimensions that one complete 50Kg bag of cement
forms one unit.
For the preparation of cement mortar the ingredients shall first be thoroughly mixed dry.
Water shall then be added and the mixing continued until a uniform mix of the required
consistency is achieved.
Cement mortar shall preferably be machine mixed, though hand mixing in troughs may be
allowed with the approval of the Engineer. Mortar so mixed shall be used within 25 (twenty
five) minutes of mixing. Mortar left unused within the specified period shall be rejected and
disposed of by Contractor to satisfaction of the Engineer. Re-tempering of mortar shall not be
permitted.
The Contractor shall arrange at his own cost for tests on mortar samples, if so directed by the
Engineer.

109

8.6

WORKMANSHIP FOR BLOCK WORK

Block work shall be plumb, square and properly bonded with broken joints. The thickness of
the courses shall be uniform with courses horizontal. All connected work shall be carried out
at one level and no portion of the work shall be left more than one course lower than the
adjacent work.
Blocks shall be laid so that all joints are well filled with mortar. Joined shall not be less than
6mm and not more than 8mm thick. Face joints shall be raked to a minimum depth of 10mm
by raking tools during the progress of work when the mortar is still green so as to provide a
proper key for pointing, plastering or rendering. When pointing, plastering or rendering is not
required joints shall be struck flush.
For pointed block work or block work without plaster or render approved, smooth textured
concrete blocks shall be used.
Faces of block work shall be cleaned daily and all mortar droppings cleaned off and removed.
Top surfaces of each course shall be thoroughly cleaned before other courses are laid. If
mortar in lower courses has begun to set joints shall be raked out to a depth of 12mm before
laying is continued.
Where blocks are to be used for load bearing walls the uppermost course of blocks supporting
slabs or other structural members shall be solid or treated as directed by the Engineer.
Miscellaneous inserts in block work, e.g. sleeves, wall ties, anchors, conduits, structural steel,
steel lintels and the like shall be installed by the Contractor and these items shall be deemed
to be included in the quoted rates for block work. The supply of such inserts by the Contractor
will be paid separately in accordance with the relevant items of the Bill of Quantities.
Openings, arches, chases, pockets and the like shall be provided as shown on the drawings to
receive windows, louvers, doors frames and the like.
Wall ties and flashings shall be built into block work in accordance with the drawings and
Specifications. It shall be clearly understood that the rates quoted by the Contractor shall be
deemed to include for leaving openings, Forming arches, cutting chases pockets and the like
in block work for various trades.

8.7

MODE OF MEASUREMENT FOR STONE MASONRY:

8.7.1

All stone masonry shall be measured in cubic meters as actually done. All openings for
windows, doors, lintels etc. shall be deducted to get the net quantity of actual work done.
Openings or chases required for P.H. and electrical inserts less than 0.1 Sqm. and bearings of
precast concrete members shall not be deducted. The unit rate for masonry shall include cost
of stones, dressing, mortar, simultaneous flush pointing, corner stones, bond stones,
scaffolding , labour, curing, forming or leaving holes for fixing or building in hold fasts, forming
chases and grooves and al operations including tools & appliances of any sort or kind
requisite for the completion of the work. etc.

8.8

MODE OF MEASUREMENT FOR BLOCK MASONRY:

8.8.1

All block masonry shall be measured in square meters as actually done. All openings for
windows, doors, lintels etc. shall be deducted to get the net quantity of actual work done.
Openings or chases required for P.H. and electrical inserts less than 0.1 Sqm. and bearings of
precast concrete members shall not be deducted. The unit rate for masonry shall include cost
of blocks, mortar, simultaneous flush pointing, scaffolding , labour, curing, forming or leaving
holes for fixing or building in hold fasts, forming chases and grooves and all operations
including tools & appliances of any sort or kind requisite for the completion of the work. etc.
*****

110

MORTARS
CONTENTS
Clause No.

Brief Description

List of Mandatory Tests

List of Bureau of Indian Standard Codes

General

3.1

Materials

3.2

Preparation of Mortars & its Grade

Page No.

Appendix A Test for Organic Impurities

Appendix B Test for Particle size (Sieve Analysis)
Appendix C Test for Silt Content
Appendix D Bulking of Fine Aggregates/ Sand (Field Methods)
Appendix E Physical Requirements & Chemical Requirements
of Fly Ash 80
Appendix F Criteria for Selection of Masonry Mortars 81

111

LIST OF MANDATORY TESTS

Material

Clause

Water

3.1.1

Test

Field/
Laboratory
Test

3
(i) pH Value
(ii) Limits of Acidity
(iii) Limits of Alkality
(iv) Percentage of solids
(a) Chlorides
(b) Suspended matter
(c) Sulphates
(d) Inorganic solids
(e) Organic solids

Test Procedure

Min. quantity
of material for
carrying out
test

Water from each source shall

be got tested before commencement of work and thereafter
once in every 3 months till
completion of work. Water from
municipal source need be
tested only once in six months.
Number of Tests for each
source shall be 3

Each lot

Every 50 tonnes or part thereof.

Each brand of cement brought
to site shall be tested as per this
frequency.

20 cum

Every 20 cum or part thereof or

more frequently as decided by
Engineer-in-charge

4
Lab
Lab
Lab

IS 3025

Lab
Lab
Lab

Frequency of testing

Lab
Lab
Lab

Cement

3.1.2

(a) Physical requirement

(i) Fineness
(ii) Soundness
(iii) Setting time (Initial &
Final) (iv) Compressive
strength
(v) Consistency of
standard cement paste

Lab
Lab
Lab
Lab
Lab

Sand

IS 4031
(Part II)
IS 4031 (Part III)
IS 4031 (Part V)
IS 4031 (Part VI)
IS 4031 (Part VI)

3.1.3.1

Organic impurities

Field

Appendix A

3.1.3.2
3.1.3.4

Silt Content
Particle size distribution a,
b, c, d & e

Field
Field or
Laboratory as
deci-ded by
the Engineerin-charge

Appendix C
Appendix B

Sand

3.1.3.5

Bulking of Sand

Field

Appendix D

20 cum

Every 20 cum or part thereof or

more frequently as decided by
Engineer-in-charge

Fly Ash

3.1.5 &
3.1.5.1

Total chloride in percent by

mass, max.

Lab

IS 12423

10 cum

Every 10 cum or part thereof or

more

Loss of ignition in percent

by mass, max.

Lab

IS 1727

10 cum

Frequency as decided by
Engineer-in-charge

Fineness, specific surface

in m/kg

Lab/field

Blaines
permeability
method

10 cum

-do-

Compressive strength at
28 days in N/mm, min

Lab.

10 cum

Only in cases when fly ash is

used as pozzolana in cement

20 cum
40 cum

-do40 cum or part thereof

112

LIST OF BUREAU OF INDIAN STANDARD CODES

S. No.

I.S. No.

Subject

IS 269

Specification for 33 grade ordinary Portland cement

IS 383

Specification for coarse and fine aggregate from natural

source for concrete.

IS 455

Specification for Portland slag cement.

IS 460 (Part I)

Specification for test sieves: wire cloth test sieves.

IS 650

Specification for standard sand for testing of cement

IS 1269

Specification for 53 grade ordinary Portland cement

IS 1344

Specification for calcined clay Pozzolana.

IS 1489

Specification for Portland pozzolana cement

IS 1542

Specification for sand for plaster

10

IS 1727

Methods of Test for Pozzolanic materials

11

IS 2116

Specification for sand for masonry mortar.

12

IS 2250

Code of practice for preparation and use of masonry

Mortar.

13

IS 2386 (Pt-I)

Method of test for aggregate for concrete (Particle size

and shape)

14

IS 2386 (Pt-II)

-Do- Estimation of deleterious materials and organic

impurities.

15

IS 2386 (Pt-III)

-Do- Specific gravity, density, voids, absorption and

bulking.

16

IS 3025

Method of sampling and test for water

17

IS 3406

Specification for masonry cement.

18

IS 3812 (Part I)

Specification for flyash for use as pozzolana in cement

mortar and concrete

19

IS 3812 (Part II)

Specification for flyash for use as admixture in cement

mortar and concrete

20

IS 4031 (Part I) to
(Part XIII)

Method of Physical test for hydraulic cement

21

IS 4032

Method of chemical analysis of Hydraulic cement.

22

IS 8041

Rapid hardening Portland cement.

23

IS 8042

Specification for white cement

24

IS 8043

Hydrophobic Portland cement

25

IS 8112

Specification for 43 grade ordinary Portland cement

113

26

IS 11652

Woven HDPE sacks for packing cement

27

IS 11653

Woven polypropylene sacks for packing cement

28

IS 12174

Jute synthetic union bags for packing cement

114

3.0 MORTARS
3.0 GENERAL
Desirable properties of mortars for use in masonry are:
(a)
(b)
(c)
(d)
(e)
(f)

Workability
Water retentivity
Rate of stiffing
Strength
Resistance to rain penetration
Durability

3.1 MATERIALS
3.1.1 Water
3.1.1.1 Water used for mixing and curing shall be clean and free from injurious quantities of alkalies,
acids, oils, salts, sugar, organic materials, vegetable growth or other substance that may be
deleterious to bricks, stone, concrete or steel. potable water is generally considered satisfactory for
mixing. The Ph value of water shall be not less than 6. The following concentrations represent the
maximum permissible values: (of deleterious materials in water).
(a) Limits of Acidity: To neutralize 100ml sample of water, using phenolphthalein as an indicator, it
should not require more than 5ml of 0.02 normal NaOH. The details of test shall be as given in IS
3025 (part 22).
(b) Limits of Alkalinity: To neturalise 100ml sample of water, using mixed indicator, it should not
require more than 25ml of 0.02 normal H2SO4. The details of tests shall be as given in IS 3025 (part
23).
(c) Percentage of Solids: Maximum permissible limits of solids when tested in accordance with IS
3025 shall be as under:
Organic
Inorganic
Sulphates
Chlorides
Suspended matter

200mg/ litre
3000 mg/ litre
400 mg/ litre
2000 mg/ litre.for concrete not containing embedded steel and 500
mg./ltr. for reinforced concrete work.
2000 mg/ litre

The physical and chemical properties of ground water shall be tested along with soil investigation and
if the water is not found conforming to the requirements of IS 456-2000, the tender documents shall
clearly specify that the contractor has to arrange good quality water for construction indicating the
source.
3.1.1.2 Water found satisfactory for mixing is also suitable for curing. However, water used for curing
shall not produce any objectionable stain or unsightly deposit on the surface.
3.1.1.3 Sea water shall not be used for mixing or curing
3.1.1.4 Water from each source shall be tested before the commencement of the work and thereafter
once in every three months till the completion of the work. In case of ground water, testing shall also
be done for different points of drawdown. Water from each source shall be got tested during the dry
season before monsoon and again after monsoon.

3.1.2 Cement
3.1.2.1 The cement used shall be any of the following grade and the type selected should be
115

appropriate for the intended use.

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)

33 grade ordinary Portland cement conforming to IS 269.

43 grade ordinary Portland cement conforming to IS 8112.
53 grade ordinary Portland cement conforming to IS 12269.
Rapid hardening Portland cement conforming to IS 8041.
Portland slag cement conforming to IS 455.
Portland Pozzolana cement (flyash based) conforming to IS 1489 (Part 1).
Portland Pozzolona cement (calcined clay based) conforming to IS 1489 (part 2).
Hydrophobic cement conforming to IS 8043
Low heat Portland cement conforming to IS 12600.
Sulphate resisting Portland cement conforming to IS 12330
White cement conforming to IS 8042

Different types of cement shall not be mixed together. In case more than one type of cement is used in
any work, a record shall be kept showing the location and the types of cement used.
3.1.2.2 Caution in Use of Cement Grade 53 in Construction: Because of the faster hydration
process, the concrete releases heat of hydration at a much faster rate initially and release of heat is
the higher in case of Grade. 53. The heat of hydration being higher, the chances of micro-cracking of
concrete is much greater. Thus, during initial setting period of concrete, the higher heat of hydration
can lead to damaging micro-cracking within the concrete which may not be visible at surface. This
cracking is different from shrinkage cracks which occurs due to faster drying of concrete in windy
conditions.
The situation can be worse when we tend to increase the quantity of the cement in the concrete with a
belief that such increases are better for both strength and durability of concrete. Thus, it is very
essential to be forewarned that higher grade cement specially grade 53 should be used only where
such use is warranted for making higher strength concrete and also where good Quality Assurance
measures are in place, by which proper precaution are taken to relieve the higher heat of hydration
through chilling of aggregates or by proper curing of concrete. There are instances where higher grade
cement is being used even for low strength concrete, as, mortar or even for plastering. This can lead
to unnecessary cracking of concrete/ surfaces.
Another issue to be cautioned against is the tendency of the manufacturers to project Grade 53
cement as stronger cement, whereas Grade 33 or 43 are enough to produce the concrete of desired
characteristic strength. The scenario of method of production of cement by various manufacturers
should also be kept in mind while ordering various grades of cement. The ability to produce cements
of particular fineness get fixed by the machinery installed by the manufacturers, and thus the ability to
produce other various grades of cement by a particular manufacturer also gets limited. Whereas
tendency today is to supply the consumer what he orders for by the manufacturers by simply stamping
such grades on the bags. Thus, it is often observed that cement bags marked as grade 33 or 43 may
really be containing cements of much higher grade.
3.1.2.3 Compressive Strength : Compressive strength requirement of each type of cement for
various grades when tested in accordance with IS 4031 (part 6) shall be as under:
Sample
Age at testing
72 + 1 hr
168 + 2 hrs
672 + 4 hrs

Strength in N/mm2 not less than for

Gr. 33
Gr.43
16
23
22
33
33
43

Gr. 53
27
37
53

3.1.2.4 Setting Time: Setting time of cement of any type of any grade when tested by Vicat apparatus
method described in IS 4031 shall conform to the following requirement:
(a) Initial setting time: Not less than 30 minutes
(b) Final setting time: Not more than 600 minutes

116

3.1.2.5 Supply : The cement shall be packed in jute sacking bags conforming to IS 2580, double
hessian bituminized (CRI type) or woven HDPE conforming to IS 11652. Woven polypropylene
conforming to IS 11653, jute synthetic union conforming to IS: 12174, or any other approved
composite bags, bearing the manufacturers name or his registered trade mark if any, with grade
batch no. and type of cement, with date of manufacturing of batch of cement. Every delivery of cement
shall be accompanied by a producers certificate conforming that the supplied cement conforms to
relevant specifications. These certificates shall be endorsed to the Engineer-in-Charge for his record.
Every consignment of cement must have identification marks on packages indicating date of
manufacturing grade and type of cement batch no. etc. Cemnt brought to works shall not be more than
6 weeks old from the date of manufacture.
Effective precautionary measures shall be taken to eliminate dust-nuisance during loading or
transferring cement.
3.1.2.6 Stacking and Storage : Cement in bags shall be stored and stacked in a shed which is dry,
leakproof and as moisture-proof as possible. Flooring of the shed shall consists of the two layers of
dry bricks laid on well consolidated earth to avoid contact of cement bags with the floor. Stacking shall
be done about 150 to 200 mm clear above the floor using wooden planks. Cement bags shall be
stacked at least 450 mm clear off the walls and in rows of two bags leaving in a space of atleast 600
mm between two consecutive rows. In each row the cement bags shall be kept close together so as to
reduce air circulation. Stacking shall not be more than 10 bags high to avoid lumping under pressure.
In stacks more than 8 bags high, the cement bags shall be arranged in header and stretcher fashion
i.e. alternately lengthwise and crosswise so as to tie the stacks together and minimise the danger of
toppling over.
A typical arrangement for storing and stacking of cement is shown in Fig. 1. of sub-head of Carriage of
Materials.
Different types of cement shall be stacked and stored separately.
Cement bags shall be stacked in a manner to facilitate their removal and use in the order in which they
are received.
For extra safety during monsoon, or when cement is expected to be stored for an unusually long
period, each stack shall be completely enclosed by a water proofing membrane, such as polyethylene,
which shall cover the top of the stack. Care shall be taken to see that the water proofing membrane is
not damaged at any time during use.
Storage of cement at the work site shall be at the contractors expense and risk. Any damage
occurring to cement due to faulty storage in contractors shed or on account of negligence on his part
shall be the liability of the contractor.
3.1.3 Fine Aggregate
3.1.3.1 Aggregate most of which passes through 4.75 mm IS sieve is known as fine aggregate. Fine
aggregate shall consist of natural sand, crushed stone sand, crushed gravel sand stone dust or
marble dust, fly ash and broken brick (Burnt clay). It shall be hard, durable, chemically inert, clean and
free from adherent coatings, organic matter etc. and shall not contain any appreciable amount of clay
balls or pellets and harmful impurities e.g. iron pyrites, alkalies, salts, coal, mica, shale or similar
laminated materials in such form or in such quantities as to cause corrosion of metal or affect
adversely the hardening, the strength, the durability or the appearance of mortar, plaster or concrete.
The sum of the percentages of all deleterious material shall not exceed 5%. Fine aggregate must be
checked for organic impurities such as decayed vegetation humps, coal dust etc. in accordance with
the procedure prescribed in Appendix A of Chapter 3.
3.1.3.2 Silt Content : The maximum quantity of silt in sand as determined by the method prescribed in
Appendix C of Chapter 3 shall not exceed 8%.
Fine aggregate containing more than allowable percentage of silt shall be washed as many times as

117

directed by Engineer-in-charge so as to bring the silt content within allowable limits for which nothing
extra shall be paid.
3.1.3.3 Grading : On the basis of particle size, fine aggregate is graded in to four zones. The grading
when determined in accordance with the procedure prescribed in Appendix B of Chapter 3 shall be
within the limits given in Table 3.1 below. Where the grading falls outside the limits of any particular
grading zone of sieves, other than 600 micron IS sieve, by a total amount not exceeding 5 per cent, it
shall be regarded as falling within that grading zone.
TABLE 3.1
Fine Aggregates

IS Sieve
Grading Zone I
10 mm
4.75 mm
2.36 mm
1.18 mm
600 microns
300 microns
150 microns

100
90-100
60-95
30-70
15-34
5-20
0-10

Percentage passing for

Grading Zone II
Grading Zone III
100
90-100
75-100
55-90
35-59
8-30
0-10

100
90-100
85-100
75-100
60-79
12-40
0-10

Grading Zone IV
100
95-100
95-100
90-100
80-100
15-50
0-15

Note 1: For crushed stone sands, the permissible limit on 150 micron sieve is increased to 20 per
cent. This does not affect the 5 per cent allowance permitted in 3.1.3.4 (e) (1) applying to other sieves.
Note 2: Allowance of 5% permitted in 3.1.3.4 (e) (1) can be split up, for example it could be 1% on
each of three sieves and 2% on another or 4% on one sieve and 1% on another.
Note 3: Fine aggregate conforming to Grading Zone IV shall not be used in reinforced cement
concrete unless tests have been made to ascertain the suitability of proposed mix proportions.
Note 4: Sand requiring use for mortar for plaster work shall conform to IS 1542 and for masonry work
shall conform to IS 2116.
3.1.3.4 Type and grading of fine aggregate to be used shall be specified. It shall be coarse sand, fine
sand, stone dust or marble dust, fly ash and surkhi. Use of sea sand shall not be allowed, unless
otherwise specified.
(a) Coarse sand shall be either river sand or pit sand or a combination of the two. It shall be clean,
sharp, angular, gritty to touch and composed of hard silicious material. Its grading shall fall within the
limits of grading zone I, II, III of Table 3.1. Grading of sand shall conform to IS 2116 for use in Masonry
work.

(b) Fine sand shall be either river sand or pit sand or a combination of the two. Its grading shall fall
within the limits of Grading zone IV of Table 3.1. Grading of sand shall conform to IS 1542 for use in
plaster work.
(c) Stone dust shall be obtained by crushing hard stones or gravel. Its grading shall fall within the limits
of grading Zone, I, II, or III of Table 3.1.
(d) Marble dust shall be obtained by crushing marble. Its grading shall fall within the limits of Grading
Zone IV of Table 3.1. Grading of Marble dust for use in Mortar shall be as per following table.

118

Grading of Marble Dust

IS Sieve

Percentage Passing

10 mm
4.75 mm
2.36 mm
1.18 mm
600 micron
300 micron
150 micron

100
95-100
95-100
90-100
80-100
15-50
0-15

(e) Sand for Masonry Mortar and for Plaster- Sand shall consist of natural sand, crushed stone sand or
crushed gravel sand or a combination of any of these. Sand shall be hard durable, clean and free from
adherent coating and organic matter and shall not contain the amount of clay, silt and fine dust more
than specified as under.
Deleterious Material: Sand shall not contain any harmful impurities such as iron, pyrites, alkalis,
salts, coal or other organic impurities, mica, shale or similar laminated materials, soft fragments, sea
shale in such form or in such quantities as to affect adversely the hardening, strength or durability of
the mortar.
The maximum quantities of clay, fine silt, fine dust and organic impurities in the sand / Marble dust
shall not exceed the following limits:
(1)

(2)
than

Clay, fine silt and fine dust when

determined in accordance within IS 2386
(Part II). In natural sand or crushed
gravel sand & crushed stone sand

Not more than 5% by mass

Organic impurities when determined in

Colour of the liquid shall be lighter

accordance with IS 2386 (Part II)

specified

that

indicated

by

the

standard

in IS 2386 (Part II).

Grading of sand for use in masonry mortar shall be conforming to IS 216 (Table 3.2 below).
Grading of sand for use in plaster shall be conforming to IS 1542 (Table 3.2 below):
TABLE 3.2
Grading of Sand for use in Masonry Mortar and Plaster

Grading of sand for use in masonry mortar

IS Sieve Designation
Pecentage passing by
mass
10 mm
4.75 mm
2.36 mm
1.18 mm
600 micron
300 micron
150 micron

100
100
90 to 100
70 to 100
40 to 100
5 to 70
0 to 15

Grading of sand for use in plaster

IS Sieve Designation
Pecentage passing by
mass
10 mm
4.75 mm
2.36 mm
1.18 mm
600 micron
300 micron
150 micron

100
95 to 100
95 to 100
90 to 100
80 to 100
20 to 65
0 to 50

Note: For crushed stone sands, the permissible limit on 150 micron IS Sieve is increased to 20%, this
does not affect the 5% allowance as per IS 2386 (Part 1).

119

3.1.3.5 Bulking: Fine aggregate, when dry or saturated, has almost the same Volume but dampness
causes increase in volume. In case fine aggregate is damp at the time of proportioning the ingredients
for mortar or concrete, its quantity shall be increased suitably to allow for bulkage, which shall be
determined by the method prescribed in Appendix D of Chapter 3.0 Table 3.3 gives the relation
between moisture content and percentage of bulking for guidance only.
TABLE 3.3

Moisture content % age

Bulking % age (by volume)

2
3
4
5

15
20
25
30

3.1.3.6 Stacking: Fine aggregate shall be so stacked as to prevent dust and foreign matter getting
mixed up with it as far as practically possible. Marble dust in dry condition shall be collected in bags
and properly staked so as not to form lumps, suitable arrangements shall be made to protect it from
moisture similar to those adopted for stacking of cement bags.
3.1.3.7 Measurements: As the fine aggregate bulks to a substantial extent when partially wet,
measurements shall be taken when the stacks are dry or appropriate allowance made for bulking.
3.1.4 Broken Brick (Burnt Clay) Fine Aggregate
3.1.4.1 Broken Brick (Burnt Clay) Fine Aggregate, also known as Surkhi, shall be made by grinding
well burnt (but not under or over burnt) broken bricks as specified in IS 3068-1986. It shall not contain
any harmful impurities, such as iron pyrites, salts, coal, mica, shale or similar laminated or other
materials in such form of quantity as to adversely affect hardening, strength, durability or appearance
of the mortar.
The maximum quantities of clay, fine silt, fine dust and organic impurities in surkhi (all taken together)
shall not exceed five per cent by weight. The particle size grading of surkhi for use in lime mortars
shall be within the limits specified in Table 3.4.
TABLE 3.4

IS Sieve Designation
4.75 mm
2.36 mm
1.18 mm
600 microns
300 microns
150 microns

Percentage passing (by

wt)
100
90-100
70-100
40-100
5-70
0-15

3.1.4.2 Stacking: Surkhi shall be stacked on a hard surface or platform so as to prevent the admixture
of clay, dust, vegetation and other foreign matter. It shall be also protected form rain and dampness
and kept under adequate coverings.
3.1.4.3 Measurements: Surkhi shall be measured in regular stacks in cubic metres. Alternatively it
may be measured by weight when supplied in bags.
3.1.5 Fly Ash
Fly ash is finely divided residue resulting from the combustion of pulverized coal in boilers. Fly ash is
the pulverized fuel ash extracted from the flue gases by any suitable process such as cyclone
separation or electrostatic precipitation. The ash collected from the bottom of boilers is termed as
bottom ash. Fly ash is finer than bottom ash. Siliceous fly ash (ASTM Class F) containing calcium
120

oxide less than 10% by mass is normally produced from burning anthracite or bituminous coal and
possesses pozzolanic properties. Calcareous fly ash (ASTM Class C) is poruduced by burning lignite
or sub-bituminous coal and contains calcium exide more than 10% by mass; the content could be as
high as 25%. This fly ash has both hydraulic and pozzolanic properties. It shall be clean and free from
any contamination of bottom ash, grit or small pieces of pebbles. It is obligatory on the part of supplier/
manufacture that the fly ash conforms to the requirements if mutually agreed upon & shall furnish a
certificate to this effect to the purchaser or his representative.
3.1.5.1 Characteristics: The physical requirements of fly-ash shall be as specified in Annexure E of
Chapter 3. The chemical properties of fly ash shall be as per IS 3812 (part 1 & 2) depending on the
usage.
3.1.5.2 Stacking: Fly ash shall be protected from dirt collecting on it.
3.1.5.3 Measurements: Fly ash shall be measured in regular stacks in cubic metres. Alternatively it
may be measured by weight when supplied in bags.
3.2 PREPARTATION OF MORTARS AND ITS GRADE
3.2.0 Grade of Masonry Mortar
The grade of masonry mortar will be defined by its compressive strength in N/mm2 at the age of 28
days as determined by the standard procedure detailed in IS 2250.
3.2.0.1 For proportioning the ingredients by volume, the conversion of weight into volume shall be
made on the following basis:
(a) Burnt Clay Pozzolana
860 Kg/cum
(b) Coarse Sand (dry)
1280 kg/cum
(c) Fine sand (dry)
1600 kg/ cum
(d) Fly Ash
590 kg/ cum
For details of grades and criteria for selection of Masonry mortars see Appendix F
3.2.1 Cement Mortar
3.2.1.1 This shall be prepared by mixing cement and sand with or without the addition of pozzolana in
specified proportions as per Appendix F.
3.2.1.2 Proportioning: Proportioning on weight basis shall be preferred taking into account specific
gravity of sand and moisture content . Boxes of suitable size shall be prepared to facilitate
proportioning on weight basis. Cement bag weighting 50 kg shall be taken as 0.035 cubic metre. Other
ingredients in specified proportion shall be measured using boxes of size 40 x 35 x 25 cm. Sand shall
be measured on the basis of its dry volume in the case of volumetric proportioning.
3.2.1.3 Mixing
3.2.1.3.1 The mixing of mortar shall be done in mechanical mixers operated manually or by power as
decided by Engineer-in-Charge. The Engineer-in-Charge may, however, permit hand mixing at his
discretion taking into account the nature, magnitude and location of the work and practicability of the
use of mechanical mixers or where item involving small quantities are to be done or if in his opinion
the use of mechanical mixer is not feasible. In cases, where mechanical mixers are not to be used,
The contractor shall take permission of the Engineer-in-Charge in writing before the commencement
of the work.
(a) Mechanical Mixing: Cement and sand in the specified proportions shall be mixed dry
thoroughly in a mixer. Water shall then be added gradually and wet mixing continued for at
least three minutes. only the required quantity of water shall be added which will produce
mortar of workable consistency but not stiff paste. Only the quantity of mortar, which can be
used within 30 minutes of its mixing shall be prepared at a time. Mixer shall be cleaned with
water each time before suspending the work.
121

(b) Hand Mixing: The measured quantity of sand shall be leveled on a clean masonry platform
and cement bags emptied on top. The cement and sand shall be thoroughly mixed dry by
being turned over and over, backwards and forwards, several times till the mixture is of a
uniform colour. The quantity of dry mix which can be used within 30 minutes shall then be
mixed in a masonry trough with just sufficient quantity of water to bring the mortar to a stiff
paste of necessary working consistency.
3.2.1.4 Precautions: mortar shall be used as soon as possible after mixing and before it begins to set,
and in any case within half hour, after the water is added to the dry mixture.
3.2.2 Cement Flyash Sand Mortar
3.2.2.1 This shall be prepared by mixing cement, flyash and sand in specified proportions as per
Appendix G. Mixing shall be done in a mechanical mixer (operated manually or by power) unless
otherwise permitted by the Engineer-in-Charge in writing. The Engineer-in-Charge may, however,
permit hand mixing at his discretion, taking into account the nature, magnitude and location of the
work and practicability of the use of mechanical mixer or where items involving small quantities are to
be done or if in his opinion the use of mechanical mixer is not feasible. In case, where mechanical
mixer is not to be used, the contractor shall take permission of the Engineer-in-Charge in writing
before the commencement of the work.
3.2.2.2 Proportioning: Proportioning on weight basis shall be preferred taking into account specific
gravity of Fly Ash, sand and moisture content. Boxes of suitable size shall be prepared to facilitate
proportioning on weight basis. Cement bag weighting 50 kg shall be taken as 0.035 cubic metre. Other
ingredients in the specified proportions shall be measured using boxes of suitable sizes. Sand and
flyash shall be measured on the basis of their dry volume in the case of volumetric proportioning.
3.2.2.3 Mixing
(a) Mechanical Mixing: Sand and flyash in the specified proportions shall be mixed dry in a mixer and
then the specified quantity of cement shall be added and mixed dry thoroughly. Water shall then be
added gradually and wet mixing continued for atleast one minute. Water shall be just sufficient to bring
the mortar to the consistency of a workable paste. Only the quantity of mortar which can be used
within 30 minutes of its mixing shall be prepared at a time.
(b) Hand Mixing: The measured quantity of sand and flyash shall be mixed dry on a clean masonry
platform before adding specified quantity of cement to it. The resulting mixture of cement, sand and
flyash shall then be mixed thoroughly being turned over and over, backward several times till the
mixture is of a uniform colour. The quantity of dry mix which can be used within 30 minutes shall then
be mixed in a clean watertight masonry trough with just sufficient quantity of water, to bring the mortar
to a stiff paste of necessary working consistency.
3.2.2.4 Precautions: Shall be same as specified in 3.2.1.4.
APPENDIX A
TEST FOR ORGANIC IMPURITIES
The aggregate must also be checked for organic impurities such as decayed vegetation humus, coal
dust etc.
What is called the colour test is reliable indicator of the presence of harmful organic matter in
aggregate, except in the area where there are deposits of lignite.
Fill a 350 ml clear glass medicine bottle upto 70 ml mark with a 3% solution of caustic soda or sodium
hydroxide. The sand is next added gradually until the volume measured by the sandy layer is 125 ml.
The volume is then made upto 200 ml by addition of more of solution. The bottle is then stoppered and
shaken vigorously and allowed to stand for 24 hours. At the end of this period, the colour of the liquid
will indicate whether the sand contains a dangerous amount of matter. A colourless liquid indicates a
clean sand free from organic matter. A straw coloured solution indicates some organic matter but not
enough to be seriously objectionable. Darker colour means that the sand contains injurious amounts
122

and should not be used unless it is washed, and a retest shows that it is satisfactory.
Add 2.5 ml of two per cent solution of tannic acid in 10 per cent alcohol, to 97.5 ml of three per cent
sodium hydroxide solution. Place in a 350 ml bottle, fix the stopper, shake vigorously and allow to
stand for 24 hours before comparison with the solution above the sand.
Note: A three per cent solution of caustic soda is made by dissolving 3 g of sodium hydroxide in 100
ml of water, preferably distilled. The solution should be kept in a glass of bottle tightly closed with a
rubber stopper. Handling sodium hydroxide with moist hands may result in serious burns. Care should
be taken not to spill the solution for it is highly injurious to clothing, leather, and other materials.
APPENDIX B
TEST FOR PARTICLE SIZE (SIEVE ANALYSIS)
Apparatus: Perforated plate sieves of designation 10 mm, 4.75 mm and fine mesh sieve of
designation 2.36 mm, 1.18 mm, 600 micron, 300 micron and 150 micron should be used.
The balance or scale shall be such that it is readable and accurate to 0.1 per cent of the weight of the
test sample.
Sample: The weight of sample available shall not be less than the weight given in the table below. The
sample of sieving shall be prepared from the larger sample either by quartering or by means of a
sample divider.
TABLE SHOWING MINIMUM WEIGHTS FOR SAMPLING
Maximum size present in
substantial proportions (mm)
10
4.75
2.36

Minimum weight of sample for

sieving (Kg)
0.5
0.2
0.1

Test Procedure: The sample shall be brought to an air-dry condition before weighing and sieving.
This may be achieved either by drying at room temperature or by heating at a temperature of 100
degree to 110 degree centigrade. The air dry sample shall be weighed and sieved successively on the
appropriate sieves starting with the largest. Care shall be taken to ensure that the sieves are clean
before use.
Each sieve shall be shaken separately over a clean tray until not more than a trace passes, but in any
case for a period of not less than two minutes. The shaking shall be done with a varied motion,
backwards and forwards, left to right, circular clockwise and anti-clockwise, and with frequent jarring,
so that the material is kept moving over the sieve surface in frequently changing directions. Materials
shall not be forced through the sieve by hand pressure, but on sieves coarser than 20 mm, placing of
particles is permitted, Lumps of fine material, if present may be broken by gentle pressure with fingers
against the side of the sieve. Light brushing of under side of the sieve with a soft brush may be used to
clear the sieve openings.
Light brushing with a fine camel hair brush may be used on the 150 micron IS sieve to prevent
segregation of powder and blinding of apertures. Stiff or worn out brushes shall not be used for this
purpose and pressure shall not be applied to the surface of the sieve to force particles through the
mesh.
On completion of sieving the material retained on each sieve, together with any material cleaned from
the mesh, shall be weighed.
Reporting of Results: The results shall be calculated and reported as:
(a) The cumulative percentage by weight of the total sample passing each of the sieves, to the
nearest whole number:

123

Or
(b) The percentage by weight of the total sample passing one sieve and retained on the next
smaller sieve, to the nearest 0.1 percent.
APPENDIX C
TEST FOR SILT CONTENT
The sand shall not contain more than 8% of silt as determined by field test with measuring cylinder.
The method of determining silt contents by field test is given below:
A sample of sand to be tested shall be placed without drying in a 200 ml measuring cylinder. The
volume of the sample shall be such that it fills the cylinder upto 100 ml mark
Clean water shall be added upto 150 ml mark. Dissolve a little salt in the water in the proportion one
tea spoon to half a litre. The mixture shall be shaken vigorously, the last few shakes being sidewise
direction to level off the sand and the contents allowed to settle for three hours.
The height of the silt visible as settled layer above the sand shall be expressed as a percentage of the
height of sand below. The sand containing more than the above allowable percentage of silt, shall be
washed so as to bring the silt contents within allowable limits.
APPENDIX D
BULKING OF FINE AGGREGATES/SAND (FIELD METHODS)
Two methods are suggested for determining the bulking of sand/fine aggregate. The procedure may
be suitably varied, if necessary. Both depend on the fact that the volume of inundated sand/fine
aggregate is the same if the sand/fine aggregate were dry.
Method -1: Put sufficient quantity of sand loosely into a container until it is about two-third full. Level
off the top of the sand and push a steel rule vertically down through the sand at the middle to bottom,
measure the height. Suppose this is X cm.
Empty the sand out of the container into another container where none of it is lost. Half fill the first
container with water. Put back about half the sand and rod it with a steel rod, about 6 mm in diameter,
so that its volume is reduced to a minimum. Then add the remainder and level the top surface of the
inundated sand. Measure its depth at the middle with the steel rule. Suppose this is Y cm.
The percentage of bulking of the sand due to moisture shall be calculated from the formula:
Percentage bulking = (X/Y -1) X 100
Method-2: In a 250 ml measuring cylinder, pour the damp sand, consolidate it by staking until it
reached the 200 ml mark.
Then fill the cylinder with the water and stir the sand well (the water shall be sufficient to submerge the
sand completely). It will be seen that the sand surface is now below its original level. Suppose the
surface is at the mark of Yml, the percentage of bulking of sand due to moisture shall be calculated
from the formula.
Percentage bulking= (200/Y 1) x 100

124

APPENDIX E
PHYSICAL REQUIREMENTS OF FLY ASH
Sl. No

1
(i)
(ii)
(iii)

(iv)
(v)

Characteristics

2
Fineness- Specific surface in m2/kg by Blaines
permeability method, min
Lime reactivity average compressive strength
in N/mm2 Min
Compressive strength at 28 days in N/ mm2

Soundness of autoclave test expansion of

specimens, per cent, max
Particles retained on 45 micron IS sieve (wet
sieving) in percent maximum

Requirement of Fly Ash

For use as
Pozzolana

For use as
Admixture in
Cement Mortar and
concrete

320

200

4.5

Not less than 80 per

cent of the strength of
corresponding mortar
cubes.
0.8

0.8

34

APPENDIX F
CRITERIA FOR SELECTION OF MASONRY MORTARS
(a) The selection of masonry mortars from durability consideration will have to cover both the loading
and exposure condition of the masonry. The masonry mortar shall generally be as specified below in
(b) to (g).
(b) In case of masonry exposed frequent to rain and where there is further protection by way of
plastering or rendering or other finishes, the grade of mortar shall not be less than 0.7 MM but shall
preferably be of grade MM2. Where no protection is provided, the grade of mortar for external wall
shall not be less than MM2.
(c) In case of load bearing internal walls, the grade of mortar shall preferably be MM 0.702 or more for
high durability but in no case less than MM 0.5.
(d) In the case of masonry work in foundations laid below damp proof course, the grade of mortar for
use in masonry shall be as specified below.
(i) Where soil has little moisture, masonry mortar of grade not less than MM 0.7 shall be used.
(ii) Where soil is very damp, masonry mortar of grade preferably MM 2 or more shall be used. But
in no case shall the grade of mortar be less than MM 2.
(e) For masonry in building subject to vibration of machinery, the grade of mortar shall not be less than
MM 3.
(f) For parapets, where the height is greater than thrice the thickness, the grade of masonry mortar
shall not be less than MM3. In case of low parapets the grade of mortar shall be the same as used in
the wall masonry.
(g) The grade of mortar for bedding joints in masonry with large concrete blocks shall not be less than
MM 3.
(h) The compressive strength shall be determined in accordance with the procedure given in IS 2250.
(i) While mixing the pozzolanic material like fly ash in mortars Ordinary Portland cement only shall be
use.

125

Grade of Masonry Mortar (IS 2250 )

Sl. No.

Grade

Compressive strength
at 28 days in N/mm2

Cement

Pozzolana (Fly
Ash)

Sand

1
2

MM 0.7

0.7 to 1.5

1
1

--0.4*

8
10

3
4
5
6
7
8
9
10
11
12
13
14

MM 1.5

1.5 to 2.0

MM 3

3.0 to 5.0

MM 5

5.0 to 7.5

MM 7.5

7.5 & above

1
1
1
1**
1
1
1
1
1
1**
1
1

--0.4*
---0.21
0.4*
---0.4
0.4
---0.2*
--0.4

7
8.75
6
4.2
7.5
5
6.25
5
4
2.1
3
3.75

Note:
* Pozzolana of minimum lime reactivity of 4 N/MM2
** This ratio by volume correspondence approximately to cement pozzolana ratio of 0.8:0.2 by weight.
In this case, only ordinary portland cement is to be used (see IS 269). Specifications for ordinary rapid
hardening and low heat Portland Cement (Third revision).
Note : Compressive strength shall be determined in accordance with the Appendix A-IS 2550.
Mortar for Masonary Works
Base concrete on which the slabs are to be laid shall be cleaned, wetted and mopped. The bedding for
the slabs shall be with cement mortar 1:5 (1 cement : 5 coarse sand) or as given in the description of
the item.
Sl. No.
Masonary Type
Mortar Grade
1
2

Stone Manonary
Brick Masonary
230 thick
115 thick
Block Masonary
200 thick
150 thick
100 thick

1:6

(1 cement : 6 coarse sand)

1:6
1:4

(1 cement : 6 coarse sand)

(1 cement : 4 coarse sand)

1:6
1:4
1:4

(1 cement : 6 coarse sand)

(1 cement : 4 coarse sand)
(1 cement : 4 coarse sand)

Mortar for flooring Works

Base concrete on which the slabs are to be laid shall be cleaned, wetted and mopped. The bedding for
the slabs shall be with cement mortar 1:5 (1 cement : 5 coarse sand) or as given in the description of
the item.
Sl. No.
Thickness
1
2
3

Flooring / Wall Tile

Natural Stone
Ceramic Tile
Vetrified Tile

Mortar Grade

1:4
1:3
1:4

(1 cement : 4 coarse sand)

(1 cement : 3 coarse sand)
(1 cement : 4 coarse sand)

Minimum

20mm
12mm
12mm

The average thickness of the bedding mortar under the slabs shall be 20 mm and the thickness at any

126

place under the slabs shall not be less than 12 mm.

Mortar for Plastering Works
The mortar of the specified mix using the type of sand described in the item shall be used. It shall be
as specified in Subhead 3.0. For external work and under coat work, the fine aggregate shall conform
to grading IV. For finishing coat work the fine aggregate conforming to grading zone V shall be used.
Sl. No.

Location
1

Type

Masonary Wall
Internal
With lime rendering
External (In Two Coat) Without Lime rendering

Water Proof plaster

2

Mortar Grade

1:4 (1 cement : 4 Fine sand)

1:3 (1 cement : 3 Fine sand)
Base Coat
1:4 (1 cement : 4 Fine sand)
Top Coat
1:3 (1 cement : 3 Fine sand)

Concrete Wall
Internal
With / without lime rendering
External (In Two Coat) With out Lime rendering

Water Proofing

1:3 (1 cement : 3 Fine sand)

1:3 (1 cement : 3 Fine sand)
Base Coat
1:4 (1 cement : 4 Fine sand)
Top Coat
1:3 (1 cement : 3 Fine

sand)
Ceiling

With / without lime rendering

1:3

(1 cement : 3 Fine

sand)

127

SUB-HEAD 9.0

SPECIFICATION FOR FLOORING WORK

128

CONTENTS

Clause No.

Brief Description

9.1

List of Mandatory Tests

9.2

List of Bureau of Indian Standard Codes

9.3

Specification for Rubble Stone Hard Core Soling

9.8

Cement Concrete Flooring (IPS) /Granolithic Flooring

Page

129

9.1.0

LIST OF MANDATORY TESTS

Material

Clause

Marble

8.3
(Table
8.2)

(i)
Moisture
Absorption
(ii)
Hardness
Test
(iii)
Specific
Gravity
(i)
Moisture
(ii)
Specific
Gravity

Granite

9.2

Test

Field/
Laboratory
Test

Test
Procedure

Minimum
quantity
of
material/
work
for
carrying
out
the
test

Frequency
of
testing

Laboratory

IS 1124

50 Sqm.

-do-

Mhos
Scale

-do-

-do-

-do-

IS 1122

-do-

-do-

-do-

IS 1124

-do-

-do-

-do-

IS 1122

-do-

-do-

100 Sqm.
Or
part
thereof.

LIST OF BUREAU OF INDIAN STANDARDS CODES

S. No.

IS. No.

Subject

1.

IS 1122

Method of test for determination of true specific gravity of

natural building stones.

2.
apparent

IS 1124

Method of test for determination of water absorption,

Specific gravity and porosity of natural building stones.

3.

IS 1130

Marble (blocks, slabs and tiles).

4.

IS 4101 (Part 1)

Code of practice for external facing and veneers: Stone

facing.

5.

IS 3316

Specifications for structural granite

6.

IS 14223 (Part 1)

Polished Building Stones (Part-1) Granite

130

9.3

SPECIFICATIONS FOR (RUBBLE STONE HARD CORE - SOLING)

9.3.1

SCOPE :
The work covered under this specification includes all type of soling work by rubble stone laid
under floor or foundations.

9.3.2

RUBBLE SOLING :

9.3.2.1 Rubble used for soling under floors, foundations etc. shall be hard, durable rock, free from
veins, flaws and other defects. The quality and size of the ruble shall be subject to the
approval of the Engineer-In-charge.
9.3.2.2 Rubble shall be hand packed as directed by Engineer-In-charge. This shall be laid closely in
position on the well prepared sub grade. All interstices between the stones shall be wedged in
with smaller stones of suitable size well driven to ensure tight packing and complete filling of
interstices. Such filling shall be carried out simultaneously with the placing in position of rubble
stones and shall not lag behind.
Small interstices shall be filled with murrum and well watered and rammed with mechanical
(heavy) rammer or hand rammer as approved by the Engineer-In-charge. Care shall be
exercised to avoid damage to the grade beams and columns and trench wall edges while
ramming.
9.3.3

MEASUREMENT :

9.3.3.1 The unit rate measurement shall be cubic meter for the specified thickness of rubble soling.
9.3.3.2 The linear dimensions shall be measured upto two places of decimals of a meter and are
worked out correct to the two places of decimals of a cubic meter.
9.3.3.3 Plan areas of soling work actually done and specified thickness to arrive at the volume of
soling limiting to the dimensions as per drawings shall be measured for payment.
9.3.3.4 The rate shall include all the materials, labour, preparation of surfaces, watering, consolidation
etc.

*****

131

9.8.0

SPECIFICATION FOR CEMENT CONCRETE FLOORING (IPS) / GRANOLITHIC

FLOORING

9.8.1.0 SCOPE:
The work covered under this specification consists of providing and laying at all levels and
floors cement concrete (IPS) flooring in accordance with these specifications and relevant
drawings.
9.8.2.0 APPLICABLE CODE & SPECIFICTIONS :
9.8.2.1 The relevant I.S. specifications, standards and codes given below are made a part of this
specification. All standards, specifications, code of practices referred to herein shall be the
latest edition including all applicable amendment, revisions and additional publications.
List of Indian Standards :
9.8.3.0 CEMENT CONCRETE FLOORING :
No.
1.
2.

I.S. No.
I.S. Particulars
I.S.
1200 Method of measurement of building and civil
(Part-XI)
engineering works.
I.S. 2571
Code of practice for laying in-situ cement concrete
flooring.

9.8.3.1 The flooring shall be of specified thickness and shall consist of 1:2:4 concrete base as
specified and 12mm thick granolithic wearing coat. The granolithic flooring shall be laid in
alternate panels. The size of panels shall be as decided by the architects.
9.8.3.2 The sand shall be screened and thoroughly washed to remove all dust and silt.
9.8.3.3 The coarse aggregate shall be of approved quality, well graded and shall not exceed 10 mm
size. The coarse aggregate shall be also washed thoroughly to remove all dust and dirt.
9.8.3.4 The surface to be paved shall be thoroughly hacked, cleaned of all mortar, loose materials
etc. and washed to remove the mud and dirt from the surface. Unless and until the surface is
approved by the Engineer-In-charge the paving shall not be started.
9.8.3.5 The surface to be paved shall then be wetted for at least 24 hours before the paving is taken
in hand. Before placing the concrete for flooring neat cement slurry shall be thoroughly
brushed into the prepared surface of the base concrete just ahead of the finish.
9.8.3.6 The 1:2:4 concrete base shall be of graded course aggregate of maximum size 10 mm and
course sand and cement. The ingredients shall be thoroughly mixed with sufficient water to
obtain the required plasticity.
9.8.3.7 The prepared 1:2:4 concrete shall be laid immediately after mixing on the fresh grouted base.
The concrete shall be spread evenly and leveled carefully. Low places shall be filled, humps
removed and the whole surface again leveled. The layer shall be compacted by ramming and
trowel led and allowed to set.
9.8.3.8 One part of cement in dry state shall be mixed with 1.5 parts by volume of well graded/crushed
granite chips of 6 mm maximum size. The ingredients shall be then mixed with sufficient water
as for ordinary concrete.
The wearing coat shall be laid 12mm thick over 1:2:4 cement concrete base immediately after it
has set compacted and leveled with a steel trowel. Just sufficient toweling shall be made to give
a level surface. The surface should not be over trowel led as excessive toweling will bring the
cement to the surface which shall be strictly avoided. When the initial set takes place further
compaction by steel toweling shall be done and final brushing shall be made before the topping
132

becomes too hard.

9.8.3.9 The paving shall be cured for at least 7 days and it shall be protected during this period with
hessian or other suitable material / means which will not stain the surface.
9.8.3.10 The laying and finishing shall conform to I.S. 2571.
The paving shall be laid in alternate bays of size as specified by the Engineer-in-charge. The
form work required for setting the bays shall not be paid extra.
9.8.4.0 MODE OF MEASUREMENT :
9.8.4.1 Measurement for flooring shall be for the actual area covered between the faces of skirting.
9.8.4.2 Deductions will be made for columns, projections, equipment foundation, trenches, opening
etc.
9.8.4.3 Unit of measurement will be square meter.
*****

133

SUB-HEAD 9.0

SPECIFICATION FOR FLOORING WORK

134

CONTENTS

Clause No.

Brief Description

Page

9.1

List of Mandatory Tests

9.2

List of Bureau of Indian Standard Codes

9.3

Specification for Rubble Stone Hard Core Soling

9.4

Marble Work

9.5
Dado

Marble / Granite / Antique Finish Flooring, Treads, Risers, Sills, Cladding,

9.6

Terrazzo / Plain Tile Flooring, Skirting, Treads & Risers

9.7

Ceramic Tile Flooring and Dado

9.8

Cement Concrete Flooring (IPS) /Granolithic Flooring

9.9

Vitrified Tile Flooring / Dado / Skirting & Facia

135

9.2.0

LIST OF MANDATORY TESTS

Material

Clause

Marble

8.3
(Table
8.2)

Granite

Test

(i)
Moisture
Absorption
(ii)
Hardness
Test
(iii)
Specific
Gravity
(i)
Moisture
(ii)
Specific
Gravity

Field/
Laboratory
Test

Test
Procedure

Minimum
quantity
of
material/
work
for
carrying
out
the
test

Frequency
of
testing

Laboratory

IS 1124

50 Sqm.

-do-

Mhos
Scale

-do-

-do-

-do-

IS 1122

-do-

-do-

-do-

IS 1124

-do-

-do-

-do-

IS 1122

-do-

-do-

100 Sqm.
Or
part
thereof.

136

9.2

LIST OF BUREAU OF INDIAN STANDARDS CODES

S. No.

IS. No.

Subject

1.

IS 1122

Method of test for determination of true specific gravity of

natural building stones.

2.
apparent

IS 1124

Method of test for determination of water absorption,

Specific gravity and porosity of natural building stones.

3.

IS 1130

Marble (blocks, slabs and tiles).

4.

IS 4101 (Part 1)

Code of practice for external facing and veneers: Stone

facing.

5.

IS 3316

Specifications for structural granite

6.

IS 14223 (Part 1)

Polished Building Stones (Part-1) Granite

137

9.3

SPECIFICATIONS FOR (RUBBLE STONE HARD CORE - SOLING)

9.3.1

SCOPE :
The work covered under this specification includes all type of soling work by rubble stone laid
under floor or foundations.

9.3.2

RUBBLE SOLING :

9.3.2.1 Rubble used for soling under floors, foundations etc. shall be hard, durable rock, free from
veins, flaws and other defects. The quality and size of the ruble shall be subject to the
approval of the Engineer-In-charge.
9.3.2.2 Rubble shall be hand packed as directed by Engineer-In-charge. This shall be laid closely in
position on the well prepared sub grade. All interstices between the stones shall be wedged in
with smaller stones of suitable size well driven to ensure tight packing and complete filling of
interstices. Such filling shall be carried out simultaneously with the placing in position of rubble
stones and shall not lag behind.
Small interstices shall be filled with murrum and well watered and rammed with mechanical
(heavy) rammer or hand rammer as approved by the Engineer-In-charge. Care shall be
exercised to avoid damage to the grade beams and columns and trench wall edges while
ramming.
9.3.3

MEASUREMENT :

9.3.3.1 The unit rate measurement shall be cubic meter for the specified thickness of rubble soling.
9.3.3.2 The linear dimensions shall be measured upto two places of decimals of a meter and are
worked out correct to the two places of decimals of a cubic meter.
9.3.3.3 Plan areas of soling work actually done and specified thickness to arrive at the volume of
soling limiting to the dimensions as per drawings shall be measured for payment.
9.3.3.4 The rate shall include all the materials, labour, preparation of surfaces, watering, consolidation
etc.

*****

138

9.4

MARBLE WORK

9.4.1 GENERAL
Marble shall be hard, sound, dense and homogeneous in texture with crystalline texture as far as
possible. It shall generally be uniform in colour and free from stains, cracks, decay and weathering.
9.4.1.1 Marbles are metamorphic rocks capable of taking polish, formed from the re-crystallization of
lime stones or dolomitic lime stones and are distinguished from lime stone by even visibly crystalined
nature and non-flaggy stratification.
Note : Marble is a product of nature hence it is difficult to guarantee uniformity of colour, veining or
other characteristics that may be represented in any sample submitted. A sample will indicate only an
average of colour, veining and other general texture and specified finish.
All marbles and granites must be carefully selected from the best quarry beds, and utmost care must
be exercised to ensure that the maximum amount of adjacent marble matches accurately. All stone
shall be free from cracks, holes, scratches and other blemishes. No stooping will be allowed.
All stones shall be free from cracks, holes, scratches and other blemishes. All stones shall be of the
highest quality, durable with resistance to atmospheric agents and shall pass, all the strength test (
Compressive strength ) and shall have adequate tensile strength.
The contractor will be required immediately to produce representative samples of all the stones
intended to be supplied for the employer's representative's approval, and the whole of the supply shall
correspond with the approved samples. No other quality of stone will be accepted and the contractor
will be required to guarantee that the qualities will comply in all respect with specification and the
samples approved by the employer's representative.
Mocked up sample panels of stone work to indicate the range of color and texture . matching of vein,
workmanship, etc. shall also presented for the approval of the Employer's representative.
All stonework is to be accurately worked, dead-square and true and accurately placed in the definite
position with due respect to levels, alignments and verticality and perfectly jointed and fitted against
adjoining members . All visible edges will have to be rectified and gauged with a maximum tolerance
of 0,5mm on the gauging thickness ( and shall be finished to the same degree of that of adjoining
finished surfaces of tricone). And +/- 1.5mm in the thickness of slab in general The tolerance allowed
in the cut of the slab, for out of joint and precision of size and square-ness shall not exceed 0.5m per
500mm.
All Exposed faces of marble are to be finished to the degree indicated on drawings and described
thereon. The whole of the work will be inspected at the factory during working and upon arrival at the
site and the Employer's representative will reject any material or workmanship which does not conform
to the conditions and will require replacement to be made at the contractor's expense.
9.4.2 CLASSIFICATION
The marble blocks, slabs and tiles shall be classified broadly in the following two categories:
9.4.1.1 White Marble
Raj Nagar (plain white) Marble:
It shall be plain white marble with coarse grains predominantly showing mica particles giving reflection
in light.
9.4.1.2 Coloured Marble
(i) Plain Black Marble
Black marble sawn along veins locally known as Peta Pasu sawing available at Bhainslana. Black
Zebra Marble
a.
139

Bhainslana Black Zebra Marble: Black marble having grey or white veins available at Bhainslana.
(Kishangarh Black Zebra Marble: Black marble with grey and/or white veins available at Kishangarh.
b.
Abu Black Zebra Marble: Black marble having white patches and streaks available at Abu.
c.
Narnaul Black Zebra Marbles: Black marble with thin white veins available at Narnaul.
d.
Makrana Dhobi Doongri Zebra Marble: Greyish black marble with white flowery pattern available at
Dhobi Doongri.
a)
(ii) Green Marble
Baroda Green Marble: Dark green marble with flowery pattern available at Baroda.
19
Abu Green Marble: Light green marble with green and/or brown streaks on white ground available at
Ambaji.
Falna Green Marble: Green marble with prominent yellowish pattern available at Falna.
Bundi Green Marble: Green marble with pinkish shades available at Umar, (Bundi).
(iii) Grey Marble
Kumari Grey Marble: Grey marble having light blue shades available at Makrana.
Bundi Grey Marble: Grey Marble with pink or green or black streaks available at Umar (Bundi).
(v) Brown Marble
Bar Brown Marble/Brown Marble with light and dark brown shades available at Bar.
Narnaul Brown Marble
Brown marble having teak wood shades available at Narnaul.
9.4.1.3 Granite Stone
It shall be of any colour and size as directed by Architect / Engineer-in-Charge . Granite shall be plain
machine cut and mirror polished. The stone shall be smooth and of even surface without holes or pits.
9.4.2 SIZES AND TOLERANCES
The size of marble blocks, slabs and tiles shall be as mentioned in Table 8.1.
TABLE 8.1
1.
2.
3.

Blocks
Slabs
Tiles

Length
30 to 250
70 to 250
10 to 60

Width
30 to 100
30 to 100
10 to 60

Thickness
30 to 90
2 to 15
0.8 to 2.4

Notes:
20.1.1.1All dimensions are in centimeter.
20.1.1.2The length and width, of the blocks shall be in multiple of 30 cm.
20.1.1.3Length and width of slab shall be in multiple of 10 cm. and thickness in multiple of 1 cm.
20.1.1.4Tiles shall be square cut and linear dimensions in multiple of 10 cm.
20.1.1.5Only slabs and tiles shall be machine cut and factory made.
20.1.1.6For 8 mm thick tiles, special precautions will be required for fixing them like using special
adhesive as per manufacturers specifications. Such tiles are not suitable for outside veneering work
exposed to rains/sun if used in large areas in continuous stretches. For tiles of thickness 20 mm and
above cramps may be provided if approved by Architect / Engineer-in-Charge .

140

Tolerance
The following tolerances shall be allowed in the dimension of blocks, slabs and tiles:
Blocks

Tolerance

(a) Length
(b) Width
(c) Thickness

+ 2 per cent
+ 2 per cent
+ 2 per cent

Slabs
(a) Length
(b) Width
(c) Thickness

+ 2 per cent
+ 2 per cent
+ 3 per cent

Tiles
(a) Linear dimension
(b) Thickness

+ 3 per cent
+ 1 per cent

The sizes other than those mentioned above may be provided as directed by the Architect / Engineerin-Charge and nothing extra shall be payable on this account.
9.4.3 PHYSICAL PROPERTIES
9.4.3.1 The physical properties of marble for blocks, slabs and tiles and method of tests are
mentioned in Table 8.2.
TABLE 8.2

Characteristic
(1)
Moisture
absorpTion after 24
hrs
immersion in
Cold water
(2) Hardness
(3)
Specific
Gravity

Marble
Marble
Method of
Requirements
test
Max. 0.4%

IS 1124

Granite
Granite
Method of
Requirement
test
Max. 0.50%

IS 1124

by weight

Min. 3

Mhos scale

Min. 2.5

IS 1122

__

__

Min. 2.6

IS 1122

9.4.3.2 Approval of Sample

Before starting the work, the contractor shall get samples of marble approved by the Architect /
Engineer-in-Charge . Approved samples shall be kept in the custody of the Architect / Engineer-inCharge and the marble supplied and used on the work shall conform to samples with regard to
soundness, colour, veining and general texture.
9.4.4 SAMPLING
In any consignment all the blocks/slabs/tiles of the same group, size and finish shall be grouped
together to constitute a lot. Sample shall be selected and tested separately for each lot for determining
its conformity or otherwise to the requirements of the specification. The number of blocks/slabs/tiles to
be selected for the samples shall depend upon the size of the lot and shall be in accordance with the
Table 8.3.

141

TABLE 8.3
Sample Size and Criteria for Conformity
Number of Blocks
slabs/Tiles
lot
(1)
Up to 25
26 to 100
101 to 200
201 to 500
501 to 1000

in

Number of blocks
the

slabs/ Tiles to
be
selected in
sample
(2)
3
5
8
13
20

Permissible
number
of defectives

Sub

sample

size

in no.

(3)
0
0
0
0
1

(4)
2
2
3
4
5

Note: The blocks/slabs/tiles in the sample shall be taken at random and in order to ensure to
randomness of selection, random tables may be used.
Explanation 1 : All the blocks/slabs/tiles, selected in the sample, shall be examined for dimensions
workmanship and general requirements.
Any block/slab/tile failing in any one or more of the above requirements shall be considered as
defective.
A lot shall be considered as conforming to these requirements if the number of defectives obtained is
not more than permissible no. of defectives given in Col. 3 of table 8.3
Explanation 2 : The lot having been found satisfactory with respect to dimensions, workmanship and
general requirement shall be tested for physical properties of the marble. For this purpose a sub
sample of the size given in Col. 4 of Table 8.3 shall be selected at random. These blocks/slabs/tiles in
the sub sample shall be tested for moisture absorption, hardness and specified gravity. The lot shall
be considered having satisfied the requirements of the physical properties if none of the
blocks/slabs/tiles tested for the requirements fails in any of these tests.
9.4.5 MARBLE WORK - TABLE RUBBED AND POLISHED (PLAIN WORK)
Marble work in steps, jambs, columns and other plain work shall be as specified below:
Joints in staircase treads, kitchen platforms shall be permitted only at curvature or when width/length
is more than 0.6/2 Mtrs. respectively. Number of joints in each direction shall not be more than one
number for every 2 Mtrs. length beyond the initial 2.00 m length. Additional joints due to curvature or
for providing fixture shall be provide judiciously as given in sketch A below.

142

9.4.5.1 Dressing, Cutting and Rubbing

Every marble stone shall be gang saw/machine cut to the required size and shape, chisel dressed
machine finished on all beds and joints, so as to be free from any waviness and to give truly vertical,
horizontal, radial or circular joints as required. The exposed faces and sides of stones forming joints
upto 6mm. from the face shall be fine tooled machine cut such that a straight edge laid along the face
of the stone is in contact with every point on it. All window sills, tread of steps, counters vanities
moulding edges etc. shall be machine cut & polished to give high gloss mirror finish as per direction of
Architect / Engineer-in-Charge . These surfaces shall then be rubbed smooth. All visible angles and
edges shall be true, square and free from chipping. Beyond the depth of 6 mm from face, the joints
shall be dressed with a slight splay so that the thickness of joint increases, in an inverted V shape as
shown in Fig. below. The surfaces of the stones coming in contact with backing need not be chisel
dressed.

INVERTED V-SHAPE JOINT

A sample of dressed and rubbed stone shall be prepared for approval and it shall be kept on worksite
after being approved by the Engineer-in Charge.
9.4.5.2 Mortar
The mortar used for jointing shall be as specified.
9.4.5.3 Laying
All marble stones shall be wetted before placing in position. These shall then be floated on mortar and
bedded properly in position with wooden mallets without the use of chips or under pinning of any sort.
The walls and pillars shall be carried up truly in plumb or battered as shown in the drawings. All
courses shall be laid truly horizontal and all vertical joints shall be truly vertical.
In case of work without backing of brick work or coursed rubble masonry, face stone shall be laid in
headers and stretchers alternatively unless otherwise directed. The headers shall be arranged to
come as nearly as possible in the middle of stretchers above and below. Stone shall be laid in regular
courses of not less than 15 cm in height and all courses shall be of the same height unless otherwise
specified.
For work facing with backing of brick work or coursed rubble masonry, face stone shall be laid in
alternate courses of header and stretchers unless otherwise directed. Face stone and bond stone
courses shall have break joint on the face of atleast half the height of the standard course and the
bond shall be carefully maintained through out. All the connected masonry in a structure shall be
carried up nearly at one uniform level throughout but where breaks are unavoidable the joints shall be
made in good long steps so as to prevent cracks developing between new and old work.
When necessary jib crane or other mechanical appliances shall be used to hoist the heavy pieces of
stones and place these in to correct positions, care being taken that the corners of the stone are not
damaged. Stone shall be covered with gunny bags, before putting chain or rope is passed over it, and
143

it shall be handled carefully. No piece which has been damaged shall be used in work. The matching
of grains shall be carried out as directed by the Architect / Engineer-in-Charge .
9.4.5.4 Bond Stone
Bond or through stones running right through the thickness of walls, shall be provided in walls upto 60
cm thick and in case of wall above 60 cm thickness a set of two or more bond stones overlapping
each other by atleast 15 cm shall be provided in a line from face to back.
At least one bond stone or a set of bond stones shall be provided for every 0.5 Sqm of the wall
surface. All bond stones shall be marked suitably as directed by the Architect / Engineer-in-Charge .
9.4.5.5 Joints
The depth of joints 6 mm from the face shall be uniform and as fine as possible but shall be not more
than 1.5 mm thick on the exposed face. Beyond the depth of 6 mm from face, the thickness of joints
shall increase in an inverted V shape so as to give good mortar bond between two stones. The
inverted portion of the joints shall be filled with bedding mortar and the face 6 mm portion with pointing
mortar.
9.4.5.6 Curing
The work shall be kept constantly moist on all faces for a period of atleast seven days.
9.4.5.7 Finishing
After the marble work is cured, it shall be rubbed with carborandum stone of different grades no. 60,
120 and 320 in succession or with electrical rubbing machines rubbed with carborandum items 0 to 6
nos. in succession, so as to give a plane true and highly smooth surface. It shall then be cleaned with
a solution of oxalic acid, washed and finished clean.
9.4.5.8 Protection
Green work shall be protected from rain by suitable coverings. The work shall also be suitably
protected from damage during construction.
9.4.5.9 Scaffolding
Double scaffolding having two sets of vertical supports shall be provided where necessary. The
supports shall be sound and strong, tied together by horizontal pieces over which the scaffolding plank
shall be fixed.
9.4.5.10 Tolerances
As per Para 9.4.2
Note: The above Para 9.4.5. also applies to the Ashlars masonry referred in Stone Work
specifications.
9.4.5.11 Measurements
For plain work: Measurements shall be taken correct to a cm in length and breadth and correct to 0.5
cm in thickness.
9.4.5.11.1 In the case of radially dressed or circular stone used in the work, the dimensions of the
circumscribing rectangle of the dressed stone, shall be measured correct to a centimeter and
thickness, correct to 0.5 cm.
The cubical contents shall be calculated in cubic decimeter nearest to two places of decimal.
9.4.5.11.2 The marble work in arches and domes shall be measured as for plain work, but extra shall
144

be allowed for such work over the rate for plain work.
9.4.5.11.3 Sunk or moulded work in marble shall be measured by volume as per plain marble work or
work in arches or domes as the case may be on the basis of circumscribed rectangular block of the
finished work but extra shall be paid for such work over the rate for plain work for work in arches and
domes. For the purpose of extra payment, volume of every stone sunk or moulded shall be
considered.
9.4.5.12 Rate
The rate includes the cost of materials and labour required for all the operations i/c cutting of recesses
in wall cutting moulding corners edge rounding finishing & polishing as specified.
9.4.5.13 Use of Finished Marble Slabs and Tiles
In case such finished tiles are used, these shall be measured and paid for separately.
9.4.6 WALL LINING/VENEER WORK
9.4.6.1 Unless and otherwise specified in the nomenclature of the item, the marble slabs used for wall
lining/veneer work shall be gang saw cut (polished & machine cut) and conform to dimensions given in
Table 8.1 above.
Back shall not be polished/ cut in order to ensure a good grip with the hearting of backing. The cut
slabs shall be of the thickness as specified with a tolerance permissible under Para 9.4.2 above. The
tolerance in wall lining when straight edge of 3 m length is placed should not be more than 2 mm.
9.4.6.2 Laying
The stone shall be wetted before laying. They shall then be fixed with mortar in position without the
use of chips or under pinning of any sort. Care shall be taken to match the grains of veneer work as
directed by the Architect / Engineer-in-Charge . For purpose of matching the grains, the marble slabs
shall be selected judiciously having uniform pattern of veins/streaks. Preferably the slabs shall be
those got out of the same block from the quarry. The area to be veneered shall be reproduced on the
ground and the marble slabs laid in position and arranged in the manner to give the desired matching
of grains. Any adjustment needed for achieving the best results shall be then carried out by replacing
or interchanging the particular slabs. Special care shall be taken to achieve the continuity of grains
between the two slabs one above the other along the horizontal joints. This shall then be got approved
by the Architect / Engineer-in-Charge and each marble slabs numbered properly and the same
number shall be marked on a separate drawing as well as on the surface to be actually veneered, so
as to ensure the fixing of the particular slabs in the correct location.
For the facing of the columns also the same procedure as mentioned above shall be followed.
9.4.6.2.1 Where so desired, the adjoining stones shall be secured to each other by means of pins as
specified.
9.4.6.2.2 The stones shall be secured to the backing by means of cramps. The material for cramps
shall have high resistance to corrosion under conditions of dampness and against the chemical action
of mortar or concrete in which cramps are usually embedded.
Cramps shall be of as specified in case of backing of stone masonry walls and brick masonry walls
thicker than 230 mm. In case of backing with brick masonry walls 230 mm or less thick or RCC
members cramps shall be of specified length as per requirement made out of gun metal or any other
metal specified in design by consultants. Generally the outer length of cramp, typical shape & details
of cramps for such backing are as indicated in drawings for general guidance. This can be modified as
per the approved shop drawings as directed by the Architect / Engineer-in-Charge if so, required at
site. Cramps shall be spaced not more 60 cm apart horizontally.
9.4.6.2.3 The adjoining stones shall be secured to each other by means of cramps or pins of the
145

specified size. Cramps may be attached to its sides or top and bottom or sides, top and bottom. The
general arrangement of cramps required for fixing facing unit to the wall are as mentioned in approved
shop drawing. The actual number of cramps and their sections, however, shall be as per requirements
of design to carry the loads.
9.4.6.2.4 Where cramps are used to hold the unit in position only, the facings shall be provided with a
continuous support on which the stones rest at the ground level and other storey levels, the support
being in the form of projection from or recess into the concrete floor slab, or a beam between the
columns or a metal angle attached to the floor slab or beams. These supports shall preferably be at
vertical intervals not more than 3.5 m apart and also over the heads of all openings. Such supports
shall also be provided where there is transition from thin facing below to thick facings above.
9.4.6.2.5 Alternatively cramps may be used to hold the units in position and in addition to support the
units thus transferring the weight of the units to the backing. Such cramps should be properly designed
as per IS 4101 (Part 1).
9.4.6.2.6 The cramps may be of copper alloyed with zinc, tin, nickel, lead or stainless steel.
9.4.6.2.7 The pins, cramps and dowels shall be laid in cement mortar 1:2 (1 cement : 2 fine sand) and
their samples got approved by the Architect / Engineer-in-Charge and kept at site.
9.4.6.3 Joints
All joints shall be full of mortar. Special care shall be taken to see that groundings for veneer work are
full of mortar. If any hollow groundings are detected by tapping the face stones, these shall be taken
out and re-laid. The thickness of the face joints shall be uniform, straight and as fine as possible, not
more than 1.5 mm and in the face joint, the top 6 mm depth shall be filled with mortar specified for the
pointing.
9.4.6.4 Mortar
The mortar used for jointing slabs shall be as specified.
9.4.6.5 Curing, Finishing, Protection and Scaffolding
It shall be as specified under 9.4.5.6, 9.4.5.7, 9.4.5.8 and 9.4.5.9.
9.4.6.6 Measurements
The length and breadth shall be measured correct to a cm. In case of radially dressed or circular slabs
used in the work, the dimensions of the circumscribing rectangles of the dressed stone used in the
work, shall be measured & paid for. The area shall be calculated in Sqm nearest to two places of
decimal.
Marble work in lining upto 4 cm thickness shall be paid by area under veneer work and lining of
greater thickness paid by volume under plain marble work.
9.4.6.7 Rate
The rate includes the cost of materials and labour required for all the operations described above
except for the cost of providing and fixing of dowel and cramps which shall be paid for separately,
unless otherwise stipulated in the item of work.
When factory made finished slabs and tiles are used, no further finishing as mentioned in Para 8.5.7
shall be required nor anything extra shall be payable.
9.4.7 MARBLE STONE FLOORING AND MARBLE STONE IN RISERS OF STEPS AND SKIRTING
Refer to relevant clause in subhead of flooring.
9.4.7.0 Marble Slab Urinal Partitions
The partitions shall be of marble slab embedded in the wall. The size and shape of the marbles slab
146

shall be as per direction of Architect / Engineer-in-Charge . The finished thickness shall be 18 mm.
The specifications for marble/granite stone work, in general, shall be as specified. The marble granite
stone shall be cut into slabs of required thickness and shall be one piece as per the detailed drawing.
9.4.7.1 Finishing
The partition of the slab to be embedded in the masonry shall be rough dressed. Dressing and rubbing
of the exposed portion of the slab shall be as described. The dressed slab shall be of the thickness as
specified with a tolerance of + 1.5mm. The slab shall be got approved from the Architect / Engineer-inCharge before fixing.
9.4.7.2 Fixing shall be as specified except that the recess shall be 7.5 cm wide. Fixing shall be done
by cutting chase with chase cutter/fine tools in a recess of 7.5 cm X 7.5 cm filled with cement concrete
1:2:4 (1 cement : 2 coarse sand : 4 graded stone aggregate 6mm nominal size). Fixing can also be
done by epoxy grout in a chase of 2.0 X 7.5 cm as per direction of Architect / Engineer-in-Charge .
9.4.7.3 Measurement shall be as per Para 8.6.6.
9.4.7.4 Rate shall include the cost of labour and materials involved in all the operations described
above including the leaving/cutting of recess in the wall, moulding, curves, edge rounding, finishing
and polishing as specified.
9.5.0

SPECIFICATION FOR MARBLE / GRANITE / ANTIQUE FINISH FLOORING, TREADS,

RISERS, SILLS, CLADDING, DADO

9.5.1.0 MARBLE STONE SLABS :

9.5.1.1 The colour and quality of marble slabs shall be of the kind of marble specified in
item/drawings/as directed by the Engineer-in-charge. The marble from which the slabs are
made, shall be of selected quality, hard, sound, dense and homogenous in texture, free from
cracks, decay, weathering and flaws. Before starting the work, the contractor shall get the
samples of marble slabs approved by the Engineer-in-charge. All slabs which goes into work
shall strictly conform to the samples, failing which the entire materials are likely to be rejected.
The slabs shall be machine polished and machine cut to the dimensions specified in items of
schedules of quantities/drawings and as directed by the Engineer-in-charge.
9.5.2

DRESSING OF SLABS:

9.5.2.1 Every stone shall be cut to the required size and shape, fine dressed on all sides to the full
depth so that a straight edge laid along the side of the stone is full in contact with it. The top
surface shall also be fine dressed to remove all waviness. The top surface of slabs shall be
machine polished and exposed edges machine cut, or as specified in the item and as
directed by the Engineer-in-charge. All visible angles and edges of the slabs shall be true,
square or as required, and free from chippings and the surface shall be true and plane.
9.5.2.2 The thickness of the slabs shall be specified in the description of item. The minimum size of
stone to be used for various items shall be as mentioned in the schedule of
quantities/drawings of this tender. Marble stones of approved smaller sizes other than
mentioned in the schedule of quantities, if required for bands, borders, flooring etc. shall be
provided and laid as directed by the Engineer-in-charge.
Any opening of required size and shape at any desired place in flooring, bands, borders etc.
shall be made in such a way that marble bounded by number of marble stones/slabs. No
broken or defaced stone shall be permitted in the work.
9.5.3.0 BEDDING/BACKING MORTAR:
9.5.3.1 The bedding/backing shall be of cement mortar/lime mortar of mix and thickness as specified
147

in the description of the item.

9.5.3.1.1 Mixing : The mixing of mortar shall be done in mechanical mixer or hand mixing as
specified/as directed by the Engineer-in-Charge.
9.5.3.1.1.1 Mixing in Mechanical Mixer : Cement and sand in the specified proportion shall be
mixed dry thoroughly in a mixer. Water shall then be added gradually and wet mixing
continued for at least one minute. Care shall be taken not to add more water than that
which shall bring the mortar to the consistency of stiff paste.
9.5.3.1.1.2 Only the quantity of mortar, which can be used within 30 minutes of its mixing shall be
prepared at a time.
9.5.3.1.1.3 Mixer shall be cleaned with water each time, before suspending the work.
9.5.3.1.2 Hand Mixing : If approved by Engineer-in-Charge, hand mixing shall be allowed. The
measured quantity of sand shall be leveled on clean masonry platform and cement bags
emptied on top. In hand mixing, the quantity of cement shall be increased by 5% over the
approved constant, with no extra cost to the Department. The cement and sand shall be
thoroughly mixed dry by being turned over and over, backwards and forwards, several times
till the mixture gives an uniform colour. The quantity or dry mix which can be used within 30
minutes shall then be mixed on masonry through with just sufficient quantity of water to bring
the mortar to the consistency of stiff paste.
General : Mortar shall be used as soon as possible after mixing and before it has begun to
set, and in any case within 30 minutes after the water is added to the dry mixture. Mortar
unused for more than 30 minutes shall be rejected and removed from the site of work
immediately.
9.5.4.0 LAYING - FLOORING:
9.5.4.1 Before laying the cement mortar bedding/backing, the concrete/brick, floor/wall surfaces shall
be thoroughly hacked, cleaned of all mortar scales, concrete lumps etc., brushed, washed
with water to remove mud, dirt etc. from the surface and shall be thoroughly wetted. Until and
unless the surface is approved by the Engineer-in-Charge, the flooring shall not be started.
A bedding of cement mortar of 20 mm. average thickness with the minimum thickness at any
place under the slab not less than 13mm. shall be laid evenly and to the required slopes as
directed / specified. The marble slabs shall be thoroughly washed and cleaned and then be
laid on the bedding/ backing with cement floating at the rate of 4.39 kg./sqcm. All slabs shall
be truly and evenly set in a thick cement slurry or paste like consistency applied to the sides
and bottom and over the prepared base. The slabs shall then be tamped down with a wooden
mallet until they are exactly in true plane and line with adjacent slabs. All slabs shall be
extended upto the unplastered surface of masonry walls/RCC columns/RCC walls. The slabs
shall be close jointed in matching cement slurry and the cement slurry coming out through
the thin joints shall be immediately wiped clean. The grains of marble stone shall be
matched as shown in drawing or as directed by the Engineer-in-Charge. All slabs shall be so
laid as to have continuous lines from various rooms to the corridors. No change of lines shall
be permitted at junction between rooms and corridor, if the same flooring is specified in both
the places.
9.5.5.0 MARBLE SILLS, TREADS ETC. :
9.5.5.1 Marble stone for sills shall be of approved quality. Dressing of stone slab, mortar mix. for
bedding/backing, laying etc. shall be similar to as described above as far as applicable.
Marble slabs of specified thickness and width shall only be provided. The length of the each
slab required for the sill shall be of the pattern which shall coincide with the lines of the
mullions of windows where it is laid or as directed by the Engineer-in-Charge. Normally it
shall not be less than 1.0 m. length.
9.5.6.0 MARBLE STONE DADO & CLADDING :
9.5.6.1 Only machine cut and machine polished marble stone will be used. Brass cramps and brass
148

pins of approved quality, size and make shall be provided. The brass pins shall be provided at
the meeting of two marble slabs both ways horizontally and vertically. The brass cramps
shall be provided at the places approved by the Engineer-in-Charge. Marble to be used shall
be of approved size, colour, type of veins and laid as specified in schedule of quantities or to
the pattern shown in drawings or as directed by the Engineer-in-Charge. Laying of marble
stone shall be similar as stated above as far as applicable.
9.5.7.0 POLISHING AND FINISHING :
9.5.7.1 The polishing and finishing shall be carried out in the similar manner as specified under the
chapter TERRAZZO/CEMENT TILES FLOORING, SKIRTING/DADO ETC. as far as it is
applicable.
9.5.8.0 MEASUREMENT :
9.5.8.1 Marble stone flooring, sills, treads, risers, dado cladding etc. shall be measured in square
meter correct to two places of decimal. The length and breadth shall be measured between
the finished faces correct to two places of decimal of meter. No deduction shall be made nor
extra paid for any opening of area upto 0.05 Sqm. Nothing extra shall be paid for working at
different levels.
NOTE : Wastage in marble slab cutting to get the required dimensions, as specified in drawing or
as directed by the Engineer-in-Charge shall be deemed to be considered by the contractor
while quoting the rate for work. The work shall be measured as above and no extra claim will
be entertained on this account.
9.5.9.0 RATE :
The rate shall include the cost of all materials, transport tools, plants, scaffolding and labour
involved in all operations described above.
9.5.10.0 GRANITE STONE FLOORING, TREADS, RISERS, SILLS, CLADDING, DADO ETC. :
9.5.10.1The specifications mentioned for Marble stone flooring shall be generally applicable for this
item. In case of granite stones available in different shades, the samples shall be submitted
for approval of Engineer-in-Charge.

*****
9.6.0

SPECIFICATIONS FOR TERRAZZO/ PLAIN TILE FLOORING, SKIRTING, TREADS &

RISERS

9.6.1.0 SCOPE :
The work covered under this specification consists of providing and laying at all levels and
floors terrazzo tiles in flooring and skirting in accordance with these specifications and relevant
drawings.
9.6.2.0 APPLICABLE CODES & SPECIFICATIONS :
9.6.2.1 The relevant I.S. specifications, standards and codes given below are made a part of this
specification. All standards, specifications, code of practices referred to herein shall be the
latest edition including all applicable amendment, revisions and additional publications.
List of Indian Standards :

149

9.6.3.0 TERRAZZO TILE FLOORING :

No.
1.
2.

I.S. No.
I.S. 1130
I.S.
1200
(Par
t-XI)

I.S. Particulars
Specification for marble (Block, slab & tiles)
Method of measurement building and civil engineering
work (paving, floor finish, dado and skirting).

3.

I.S. 2114

Code of practice for laying in-situ terrazzo floor finish.

4.
5.

I.S. 1237
I.S. 1443

Specifications for cement concrete flooring tiles

Code of practice for laying and finishing of cement
concrete flooring tiles

9.6.3.1 Terrazzo tiles shall be of size specified in the item hydraulically pressed and shall be best
quality obtained from approved manufacturers. The tiles shall be uniform in size, true and
square, free from twist, cracks, depressions or any other defects. The wearing surface of the
coloured terrazzo tiles shall consist of coloured terrazzo finish of not less than 7 mm thickness
using marble chips of best available variety. The tiles shall be perfectly smooth finished and
machine polished on the wearing surface and roughened or keyed on the bedding face.
9.6.3.2 The design and shade of the tile shall be as approved by the Engineer-In-charge. Samples of
different varieties of tiles shall be first submitted to the Engineer-In charge and got approved
by him prior to placing the order for bulk supply. All tiles which go into the work shall strictly
conform to the sample approved by the Engineer-In-charge, failing which the entire material is
likely to be rejected.
9.6.3.3 Before laying the cement mortar bedding, the concrete floor surface shall be thoroughly
hacked, cleaned of all mortar scales and concrete lumps etc. and washed to remove mud, dirt
etc. from the surface and shall be thoroughly wetted. Unless and until the surface is approved
by the Engineer-In-charge the flooring work shall not be started. A bedding of cement mortar
(1:4) and of specified thickness shall then be laid evenly and to the required slope as directed.
The terrazzo tiles shall then be laid on the bedding with cement floating. All tiles shall be truly
and evenly set in a thick slurry of neat cement applied to the sides and bottom and over the
prepared base. The tiles shall then be tamped down with a wooden mallet until they are
exactly in true plane and line with the adjacent tiles. All tiles shall be extended up to the
masonry wall and underside of plaster. The tiles shall be close jointed and the cement slurry
oozing out through the thin joints shall be immediately wiped clean. The joints shall then be
pointed with matching cement and finished neatly.
The flooring shall be kept wet and protected for at least 15 days before starting of polishing.
When the flooring is ready for polishing the joints shall be rubbed with carborandum stones so
that slight projections or edges rising above the surface are leveled properly. The entire
flooring shall be machined polished in 3 stages with different grades of polishing stones in the
machine. The finished flooring shall be perfectly smooth, uniform and with luster on the
surface. The polishing treatment shall also include a coat of grouting of tiles with matching
cement after the first stage of polish. After the final polish oxalic acid crystals ground into
powder shall be dusted over the surface at the rate of 32.5 gm/m2 sprinkled with water and
rubbed hard with a pad of woolen rags by means of polishing machine. The finished floor shall
give a uniform shade of tiles and any defective tiles or scratches in tiles etc. are observed the
same shall be made good at contractors own cost.
9.6.4.0 TERRAZZO TILE SKIRTING :
9.6.4.1 Terrazzo tiles in skirting shall be of specified sizes in the item hydraulically pressed and shall
be obtained from the same source as for the terrazzo tiles for flooring. The design and shade
of the skirting tiles shall be exactly similar to that of the flooring tiles. The specifications for
materials and workmanship shall be same as for flooring except that the skirting tiles shall be
laid against 20 mm thick bedding of cement mortar (1:3) to the full height of skirting. The
skirting tiles shall be in true plane, level and plumb. The skirting shall be laid projected beyond
150

the finished plastered surfaces. The continuous horizontal grooves at the top of the skirting
shall be provided if required as per drawing or as directed by the Engineer-In-charge. No
extra will be paid for such grooves.
9.6.4.2 The skirting shall be cured for 7 days.
9.6.4.3 The skirting shall be polished with hand to attain the same finish as for the flooring.
The specifications for dados will be the same as for skirting. The tile size however, will be 250
mm x 500 mm x 20 mm or as specified.
9.6.5.0 TERRAZZO TILE TREADS & RISERS:
The specifications mentioned for Terrazzo stone flooring shall be generally applicable for this
item.
9.6.6.0 MODE OF MEASUREMENT :
9.6.6.1 Measurement for flooring shall be clear distance between the finished (skirting) surfaces.
Deduction shall be made for columns, projections, equipment foundations, trenches, openings
etc. Unit of measurement shall be square meter.
The measurement shall be the actual area of skirting, dado etc. and deduction shall be made
for the areas not covered by the same. Unit of measurement shall be square meter.
9.6.7.0 PLAIN CEMENT TILE FLOORING & SKIRTING :
The specifications, mode of measurements etc. in respect of terrazzo tiles in flooring and
skirting shall be applicable in general to plain cement tiles except that no marble chips & white
cement shall be used in tile manufacture.
9.6.8.0 IN-SITU TERRAZZO FLOORS,SKIRTING, TREADS OF STAIRCASE, WINDOW SILLS,
ETC.
9.6.8.1 FLOORING :
9.6.8.1.1 In situ terrazzo flooring, the under layer shall consists of cement concrete mix 1:2:4 (the
maximum size of aggregate used shall not exceed 10 mm.) the thickness of which shall be
as specified in item of schedule of quantities.
9.6.8.1.2 The terrazzo topping shall consist of white cement or grey cement wherever specified in the
schedule of quantity with or without pigment and marble chips of best approved quality,
shade and grade all mixed in proper proportion as provided in I.S. 2114 and/ or approved by
the Engineer-in-charge. The total combined thickness of the under layer and topping shall as
provided in the I.S. Specification and as specified and approved by the Engineer-in-Charge.
9.6.8.1.3 The floor surface shall be thoroughly cleaned of all dirt, dust, laitance and loose material,
thoroughly wet with water and then smeared with cement slurry. Cement concrete under layer
immediately be laid in regular bays not exceeding 1.5 sq.m. in area or as directed and allowed
to harden. The surface of screed shall be well scratched whilst it is not sufficiently hard to
form key for terrazzo topping. 25 x 1.5 mm. aluminium dividing strips or 3mm. thick glass
dividing strips or whichever specified in the item of schedule of quantities shall be placed to
form bays as directed. When the screed has sufficiently hardened but not later than 24 hours,
it shall be thoroughly cleaned down, washed with water and brushed over with neat cement
slurry of about the consistency of thick cream. Terrazzo top layer shall then be laid in
alternative bays in plastic condition, well troweled into position. Surplus moisture and cement
slurry from surface shall be removed and allowed to set sufficiently hard to stand machine or
hand grinding, thoroughly cleaned to reveal surface voids, and grouted with neat cement of
the same tint as used in terrazzo. When dry and hard, machine grinding with grit blocks as
per specifications for terrazzo tiles shall be done with 3 to 5 days between successive

151

grinding during which the terrazzo shall be cured and grouted with neat cement of same tint, if
required. The entire surface shall then be kept wet for at least seven days. The edges of
treads and window sills shall have straight edges and corners properly rounded up. In case
of window sills, only top layers is covered under the relevant item and concrete base layer
under RCC item. The window sills and treads of staircase shall be hand polished instead of
machine polished.
9.6.8.1.4 Cleaning and applying oxalic acid shall be same as specified for terrazzo tile flooring.
9.6.8.2 IN-SITU SKIRTING & DADO ETC. :
9.6.8.2.1 In situ skirting and dado shall be as specified in the schedule of finishes.
9.6.8.2.2 The surface shall be prepared as per plastering work where required by the architects, the
dado or skirting shall be sectionalized as for in situ floor. If shown and required, the junction
of the floor and dado shall be rounded to a proper, neat and uniform round to the satisfaction
of the Engineer-in-charge. After the work is complete, the surface shall be kept continuously
wet for 7 days. Unless otherwise specified, skirting and dado shall match the floor.
9.6.8.2.3 Terrazzo skirting and dado shall consist of under coat of 1:4 cement- sand plaster of the
thickness specified. This shall be laid simultaneously with the borders of the flooring and
same joints as in the floor shall continue. The topping shall be terrazzo as per specifications
for in-situ terrazzo flooring except that in-situ polishing shall be done by hand to the
satisfaction of Engineer-in-charge. 1.5 mm. thick aluminium strip joint ( wherever mentioned
3mm. glass strips or as specified shall be fixed) shall be provided in situ terrazzo in both
direction or as directed. Care shall be taken to see that the terrazzo in skirting and dado
matches the floors. The dado work in columns shall be done in one operation for the full
height of the column. The shape of the finished surface shall be uniform for all such columns
treated and checked for its accuracy during the progress of work.
9.6.8.3 MODE OF MEASUREMENT :
9.6.8.3.1 Mode of measurement for cast-in-situ terrazzo flooring and dado shall be same as per
terrazzo tile flooring and skirting.
9.6.8.3.2 The rate shall include all materials, curing, rounding of junctions, labour, scaffoldings etc.

*****

152

9.7.0

SPECIFICATIONSFORCERAMIC TILE FLOORING AND DADO

9.7.1.0 SCOPE :
The work covered under this specification consists of providing and laying at all levels and
floors ceramic tiles in flooring, skirting and dado in accordance with these specifications and
relevant drawings.
9.7.2.0 APPLICABLE CODES AND SPECIFICATIONS :
9.7.2.1 The relevant I.S. specifications, standards and codes given below are made a part of this
specification. All standards, specifications, code of practices referred to herein shall be latest
edition including all applicable amendments, revisions and additional publications.
List of Indian Standards.
9.7.3.0 CERAMIC TILE FLOORING :
No.
1.
2.

3.
4.
5.
6.

I.S. No.
I.S. 777
I.S.
1200
(Par
t-XI)
I.S. 13753
I.S. 13754
I.S. 13755
I.S. 13756

I.S. Particulars
Specification glazed earthen ware wall tiles.
Method of measurement building and civil engineering
works.
Specification glazed earthen ware wall tiles.
Specification glazed earthen ware wall tiles.
Specification glazed earthen ware wall tiles.
Specification glazed earthen ware wall tiles.

9.7.3.1 Ceramic tiles shall be of specified size, best quality and of approved make and colour.
9.7.3.2 All the material shall be obtained form one source only. The tiles shall be sound hard well and
evenly glazed, free from twist and with fine and sharp edges.
9.7.3.3 Specified makes of tiles shall be brought for the approval and samples of tiles shall be first got
approved by the Engineer-In-charge and all the tiles which shall be used in the work shall
strictly conform to the approved sample otherwise all the tiles will be rejected.
9.7.3.4 The surfaces where the tiles are to be laid shall be thoroughly hacked, joints of masonry
raked, cleaned of all mortar scales, concrete lumps, loose materials etc. and washed to
remove mud, dirt etc. from the surfaces.
9.7.3.5 Unless and until the surface is approved by Engineer-In-charge laying of tiles in flooring or
dado shall not be started.
9.7.3.6 The prepared surface shall be thoroughly drenched with water. The glazed tiles and all
specials shall be soaked in water for a minimum period of 6 hours before use.
9.7.3.7 A bedding of cement mortar (1:3) and 20 mm thick for flooring shall be laid evenly to levels or
slope as directed.
9.7.3.8 The glazed tiles shall then be laid on the bedding with a backing of thin cement paste. All tiles
shall be truly and evenly set and pressed in position to obtain uniform plane surface. The tiles
shall be close jointed and all joints shall be uniform and run in perfect straight lines. The joints
shall be staggered or continuous as directed.
9.7.3.9 The other specials like corner edges, elephant foots, bull eyes etc. shall be used at the proper
place wherever required and as directed.
9.7.3.10 The entire finished surface shall thoroughly be cleaned to remove all cement stains etc.
153

9.7.3.11 The joints shall be then pointed with a neat cement of matching colour.
9.7.3.12 The flooring shall be kept wet for 7 days.
The flooring shall be thoroughly cleaned with suitable hydrochloric acid before handing over.
9.7.4.0 DADO :
9.7.4.1 The prepared surface-shall be plastered with cement mortar (1:3) to get a backing of 20 mm
thick. The plastered surface shall be even, uniform and true to plumb.
9.7.4.2 The white glazed / ceramic tiles shall be fixed in position with a backing of cement paste.
The specifications for workmanship regarding joints, specials, cleanings, paintings, curing etc.
shall be exactly similar to ceramic tile flooring.
9.7.5.0 MODE OF MEASUREMENT :
9.7.5.1 Length and breadth of flooring shall be measured correct to a centimeter before laying
skirting, dado or wall plaster.
9.7.5.2 In flooring wherever coves are used at the junctions the length and breadth shall be measured
between the lower edges of the coves.
9.7.5.3 No deductions shall be made for opening not exceeding 0.2 square meter.
9.7.5.4 Length and height of skirting/ dado shall be measured along the finished face of the skirting/
dado correct to a centimeter.
9.7.5.5 In case of skirting height shall be measured correct to 5 mm.
9.7.5.6 The area of flooring / skirting/ dado shall be calculated in square meter correct to two places
of decimal.
9.7.5.7 The specials such as coves, cornices, beads etc. shall be measured separately and paid for in
running meter.
9.7.5.8 The rates shall include the cost all material and labour involved in all the operations described
above.
*****

154

9.8.0

SPECIFICATION FOR CEMENT CONCRETE FLOORING (IPS) / GRANOLITHIC

FLOORING

9.8.1.0 SCOPE:
The work covered under this specification consists of providing and laying at all levels and
floors cement concrete (IPS) flooring in accordance with these specifications and relevant
drawings.
9.8.2.0 APPLICABLE CODE & SPECIFICTIONS :
9.8.2.1 The relevant I.S. specifications, standards and codes given below are made a part of this
specification. All standards, specifications, code of practices referred to herein shall be the
latest edition including all applicable amendment, revisions and additional publications.
List of Indian Standards :
9.8.3.0 CEMENT CONCRETE FLOORING :
No.
1.
2.

I.S. No.
I.S. Particulars
I.S.
1200 Method of measurement of building and civil
(Part-XI)
engineering works.
I.S. 2571
Code of practice for laying in-situ cement concrete
flooring.

9.8.3.1 The flooring shall be of specified thickness and shall consist of 1:2:4 concrete base as
specified and 12mm thick granolithic wearing coat. The granolithic flooring shall be laid in
alternate panels. The size of panels shall be as decided by the architects.
9.8.3.2 The sand shall be screened and thoroughly washed to remove all dust and silt.
9.8.3.3 The coarse aggregate shall be of approved quality, well graded and shall not exceed 10 mm
size. The coarse aggregate shall be also washed thoroughly to remove all dust and dirt.
9.8.3.4 The surface to be paved shall be thoroughly hacked, cleaned of all mortar, loose materials
etc. and washed to remove the mud and dirt from the surface. Unless and until the surface is
approved by the Engineer-In-charge the paving shall not be started.
9.8.3.5 The surface to be paved shall then be wetted for at least 24 hours before the paving is taken
in hand. Before placing the concrete for flooring neat cement slurry shall be thoroughly
brushed into the prepared surface of the base concrete just ahead of the finish.
9.8.3.6 The 1:2:4 concrete base shall be of graded course aggregate of maximum size 10 mm and
course sand and cement. The ingredients shall be thoroughly mixed with sufficient water to
obtain the required plasticity.
9.8.3.7 The prepared 1:2:4 concrete shall be laid immediately after mixing on the fresh grouted base.
The concrete shall be spread evenly and leveled carefully. Low places shall be filled, humps
removed and the whole surface again leveled. The layer shall be compacted by ramming and
trowel led and allowed to set.
9.8.3.8 One part of cement in dry state shall be mixed with 1.5 parts by volume of well graded/crushed
granite chips of 6 mm maximum size. The ingredients shall be then mixed with sufficient water
as for ordinary concrete.
The wearing coat shall be laid 12mm thick over 1:2:4 cement concrete base immediately after it
has set compacted and leveled with a steel trowel. Just sufficient toweling shall be made to give
a level surface. The surface should not be over trowel led as excessive toweling will bring the
cement to the surface which shall be strictly avoided. When the initial set takes place further
compaction by steel toweling shall be done and final brushing shall be made before the topping
155

becomes too hard.

9.8.3.9 The paving shall be cured for at least 7 days and it shall be protected during this period with
hessian or other suitable material / means which will not stain the surface.
9.8.3.10 The laying and finishing shall conform to I.S. 2571.
The paving shall be laid in alternate bays of size as specified by the Engineer-in-charge. The
form work required for setting the bays shall not be paid extra.
9.8.4.0 MODE OF MEASUREMENT :
9.8.4.1 Measurement for flooring shall be for the actual area covered between the faces of skirting.
9.8.4.2 Deductions will be made for columns, projections, equipment foundation, trenches, opening
etc.
9.8.4.3 Unit of measurement will be square meter.
*****
9.9.0

SPECIFICATIONS FOR VITRIFIED TILE FLOORING, DADO / SKIRTING / FACIA

9.9.1

MATERIALS:
Vitrified Tiles: The tiles shall be of approved make and shall generally conform to the
approved standards. They shall be flat and true to shape, free from cracks, crazing spots,
chipped edges and corners. Unless otherwise specified, the nominal sizes of tiles shall be as
under:
The tiles shall be square or rectangular of nominal sizes such as: 600 x 600 mm; 900 x 900
mm or as per tender schedule / drawings or as directed by the Engineer-in-Charge. Thickness
shall be as per recommendations of the approved manufacturers.
Technical specifications of the tiles shall be generally conforming to the following standards:

NO
1
2
3
4
5
6
7
8
9
10

TECHNICAL SPECIFICATIONS FOR VITRIFIED TILES

PROPERTY
EXPECTED STANDARDS
Deviation in length
(+/-) 0.6%
Straightness of sides
(+/-) 0.5%
Rectangularity
(+/-) 0.6%
Surface flatness
(+/-) 0.5%
Water absorption
< 0.50%
Mohs. hardness
>6
> 27 N / mm2
Flexural strength
< 204 mm2
Abrasion resistance
Skid resistance (friction coefficient)
> 0.4
Glossiness
Min. 85% reflection
The tiles shall conform to the relevant standards in all respects. Samples of tiles shall be got
approved from the Engineer-in-charge before bulk procurement for incorporation in the work.

9.9.2.0 PREPARATION OF SURFACE FOR FLOORING:

Following procedure shall be followed:
Sub grade concrete or RCC slab or side brick / block wall / or plastered surfaces on which
tiles are to be laid shall be cleaned, wetted and mopped.
156

Mortar and bedding: Cement mortar for bedding shall be prepared of mix 1:4 or as specified in
the schedule of items, to a consistent paste and shall conform to the specification for
materials, preparations etc. as specified under cement mortar. The amount of water added
while preparing mortar shall be the minimum necessary to give sufficient plasticity for laying.
Care shall be taken in preparation of the mortar to ensure that there are no hard lumps that
would interfere with even bedding of the tiles. Before spreading the mortar bed the base shall
be cleaned off all dirt, scum or laitance and loose materials and well wetted without forming
any pools of water on the surface. The mortar of specified proportion and thickness shall then
be evenly and smoothly spread over the base by use of screed battens to proper level or
slope.
Once the mix is prepared, no further water be added and the same shall be used within one
hour of adding water. Apply on an average 20 mm thick bedding of mortar over an area of 1
Sqm. at a time over surface of the area for laying tiles, in proper level and allowed to harden
sufficiently to offer a fairly good cushion for the tiles to set.
9.9.3.0 LAYING OF TILES FOR FLOORING:
The tiling work shall be done as per the pattern shown in the drawing or as directed by the
Engineer-in-Charge. As a general practice laying of tiles shall be commenced from the centre
of the area and advanced towards the walls. Cut tiles, if any, shall be laid along wall with
necessary border /pattern as shown / directed by the Engineer-in-Charge. Tiling work shall be
completed by pressing tiles firmly into place along the wall / floor. A white cement slurry to the
back of the tile to be applied to ensure proper and full bedding. The tiles shall be laid on the
bedding mortar when it is still plastic but has become sufficiently stiff to offer a fairly firm
cushion for the tiles. Tiles, which are fixed on the flooring adjoining the wall, shall be so
arranged that the surface on the round edge tiles shall correspond to the skirting or dado.
Press gently the tile with wooden mallet for even adherence at the back of the tile. Do not use
an iron hammer or some heavy material to press the tile.
The edges of the tiles shall be smeared with neat white cement slurry and fixed in this grout
one after the other, each tile being well pressed and gently tapped with a wooden mallet till it is
properly bedded and in level with the adjoining tiles. There shall be no hollows in bed or joints.
The joints shall be kept as close as possible and in straight line. Unless otherwise specified,
joint-less tiling shall be done butting the tiles with each other. If joint is specified, the same
shall be as specified by the Engineer-in-charge. The joint shall be grouted with white /
matching colour cement slurry. After fixing the tiles, finally in an even plane or slope, the
flooring shall be covered with wet sand and allowed undisturbed for 14 days.
9.9.4.0 FIXING TILES FOR DADO & SKIRTING / FACIA:
The fixing of tiles on wall surfaces shall be done only after completing fixing of the tiles on the
floor. Following procedure shall be followed:
The back of tiles shall be cleaned off and covered with layer of cement paste or approved
adhesive like BAL-ENDURA or equivalent with proper toweling as per manufacturers
recommendations.
The edges of the tiles shall be smeared with cement paste or adhesive and fixed on the wall
one after the other, each tile being well pressed and gently tapped with a wooden mallet till it is
properly fixed in level with the adjoining tiles. There shall be no hollows on the back or in
joints. Unless otherwise specified, joint-less tiling shall be done butting the tiles with each
other. If joint is specified by the Engineer-in-charge, the joint shall be grouted with approved
white / matching colour cement slurry cement or adhesive. The joints shall be kept in straight
line or as per the approved pattern.
While fixing tiles in dado / skirting work, care shall be taken to break the joints vertically. The
top line shall be touched up neatly with the rest of the plaster above. If doors, windows,
sanitary fittings or other openings are located within the dado area, the corners, sills, jambs
etc. shall be provided with true right angles without any specials. The contractor will not be
entitled to any extra claims on this account for cutting of tiles if required.
157

The fixing shall be done from bottom of wall to upward without any hollows in the bed of joints.
Each tile shall be as close as possible to one adjoining. All tiles faces shall be in one vertical
plane.
9.9.5.0 GROUTING OF JOINTS IN FLOOR / SKIRTING / DADO:
The joints, if specified, shall be cleaned off and all dust and loose particles removed. Joints
shall then be filled with approved adhesive like BAL-ENDURA or equivalent grouts. After
finishing the grouting process, after 15 minute, wipe off excess grout with a damp sponge and
polish the tiles with a soft & dry cloth for a clean surface. The Finished work shall not sound
hollow when tapped with a wooden mallet.
9.9.6.0 CLEANING:
As directed by the Engineer-in-Charge, the tiles shall be cleaned by mild acid (However,
Hydrofluoric acid and its derivatives should not be used). After the tiles have been laid in a
room or the days fixing work is completed, the surplus cement grout / adhesive that may have
come out of the joints shall be cleaned off before it sets. The dado / skirting shall be
thoroughly cleaned. In the case of flooring, once the floor has set, the floor shall be carefully
washed clean and dried. When drying, the floor shall be covered with oil free dry sawdust. It
shall be removed only after completion of the construction work and just before the floor is
used.
9.9.7.0 MODE OF MEASUREMENT AND RATE:
Dado / flooring / skirting shall be measured in Sqm correct to two places of decimal. Length
and breadth shall be measured correct to 1 cm. between the exposed surfaces of skirting or
dado. No deductions shall be made nor extra paid for any opening of area upto 0.1 Sqm. The
rate shall include all the cost of labour and materials involved.
9.9.8.0 CLEANING AGENTS FOR VITRIFIED TILES:
Vitrified tiles are resistant to all chemicals (except hydrofluoric acid and its derivatives), hence
commercially available detergents and cleaning agents can also be used for regular
maintenance. Any spills and stains must be removed immediately. If left dry they may leave
stains, which may be difficult to remove completely.
9.9.9.0 CLEANING AGENTS FOR VITRIFIED TILES
STAINS
CLEANING AGENT
Robin Blue
Household detergent / Warm water
Marker ink
Turpentine / Acetone / Trichloroethylene
Pen ink
Acetone / Isopropyl alcohol
Methylene blue
Isopropyl alcohol / Acetone
Sauce
Ammonia solution
Cement
Turpentine / Acetone / Trichloroethylene / Conc. HCL
Tea
Hydrochloric acid / Bleaching powder
Coffee
Sodium hydroxide / Potassium hydroxide
Beer
Sodium hydroxide / Potassium hydroxide
Diesel
Acetone / Petrol
Lab indicator
Acetone / Isopropyl alcohol
Cement and grouting
Hydrochloric acid
Pencil mark
Benzene or Toluene or Xylene
Plaster of Paris (POP)
Ammonium sulphate solution
Iodine (Tincture iodine)
Sodium hydroxide / Potassium hydroxide
Hair dye
Per chloric acid
Paan
Lemon juice or citric acid
Marker pen
Acetone
158

SUB-HEAD 12.0

SPECIFICATION FOR PLASTERING WORK

159

CONTENTS

Clause No.

Brief Description

Page No.

List of Bureau of Indian Standards Codes

12.1

Cement Plaster 12 mm, 15 mm, or 20 mm

12.2

Cement Plaster with a Floating Coat of Neat Cement

12.3

18 mm Cement Plaster (Two Coat Work)

160

LIST OF BUREAU OF INDIAN STANDARD CODES

Sl.

BIS No.

Subject

1.
2.
3.
4.
5.
6.

IS
IS
IS
IS
IS
IS
IS

7.

IS 117

8.
9.

IS 133
IS 137

10.

IS 158

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

IS 217
IS 218
IS 290
IS 337
IS 341
IS 347
IS 348
IS 419
IS 427
IS 428
IS 524
IS 533
IS 712
IS 1200 (PtXII)
IS 1200
(Pt-XIII)

Shellac : Part : I Hand Made Shellac

Shellac : Part : II Machine Made Shellac
Linseed Oil Raw and Refined
Linseed Oil Boiled For Paints
Ready Mixed Paint, Brushing, Red Lead, Nonsetting, Priming
Specification for Ready Mixed Paint, Brushing, Zinc Chrome, Priming
Ready Mixed Paint, brushing, priming Plaster to Indian Standard Colour
No.361, 631 White and off White
Ready Mixed Paint, Brushing, Finishing Exterior, Semigloss for General
Purposes to Indian Standards Colours.
Enamel, Interior (a) Under Coating (b) Finishing
Ready Mixed Paint, Brushing, Matt Or Egg Shell Flat, Finishing Interior to
Indian Standard Colour as required
Ready Mixed Paint, Brushing, Bituminous Black, Lead Free, Acid, Alkali and
Heat Resisting
Specification for Cut Back Bitumen
Specification for Creosote and Anthracene Oil For Use As Wood Preservatives
Coal Tar Black Paint
Varnish, Finishing Interior
Black Japan, Types A, B & C
Varnish, Shellac for General Purposes
French Polish
Putty for Use On Window Frames
Distemper, Dry Colour as Required
Distemper, Oil Emulsion, Colour as Required
Varnish, Finishing, Exterior, Synthetic Air Drying
Gum Spirit of Turpentine (Oil of Turpentine)
Specification For Building Limes
Method of Measurements of Building and Civil Engineering Works : Part : XII
Plastering and Pointing
Method of Measurements of Building and Civil Engineering Works :
Part : XIII White Washing, Colour Washing Distempering and Painting of
Building Surfaces.

25.

26.
27.
28.
29.
30.
31.
32.
33.

16(Pt-I)
16(Pt-II)
75
77
102
104
109

IS 1200 (PtXV)
IS 2339
IS 2547 (PtII)
IS 2932
IS 2933
IS 5410
IS 5411
(Pt-1)
IS 6278

Methods of Measurements of Building and Civil Engineering Works : Part : XV

Painting, Polishing, Varnishing etc.
Aluminium Paint For General Purposes, in Dual Container
Gypsum Building Plasters Pt.II Premixed Light Weight Plasters
Enamel, Synthetic, Exterior (a) Undercoating, (b) Finishing
Enamel, Exterior (a) Undercoating (b) Finishing
Cement Paint
Plastic Emulsion : Paint Part I For Interior Use
Code of Practice For White Washing and Colour Washing

161

12.0 FINISHING
12.1 CEMENT PLASTERING FOR INTERNAL WALLS & CEILINGS WITH LIME RENDERING:
The cement plaster shall be 12 mm, 15 mm thick or as specified in the item.
12.1.1 Scaffolding
For all exposed block work, concrete surface scaffolding independent of the work having two sets of
vertical / horizontal supports shall be provided. The supports shall be sound and strong, tied together
with horizontal pieces over which scaffolding planks shall be fixed.
For all other work in buildings, single scaffolding shall be permitted. In such cases the inner end of the
horizontal scaffolding pole shall rest in a hole provided only in the header course for the purpose.
Only one header for each pole shall be left out. Such holes for scaffolding shall, however, not be
allowed in pillars/columns less than one metre in width or immediately near the skew backs of arches.
The holes left in masonry works for scaffolding purposes shall be filled and made good before
plastering.
12.1.2 Preparation of Surface
The joints shall be raked out properly. Dust and loose mortar shall be brushed out. Efflorescence if any
shall be removed by brushing and scrapping. The surface shall then be thoroughly washed with water,
cleaned and kept wet before plastering is commenced.
In case of concrete surface if a chemical retarder has been applied to the form work, the surface shall
be roughened by wire brushing and all the resulting dust and loose particles cleaned off and care shall
be taken that none of the retarders is left on the surface.
12.1.3 Mortar
The mortar of the specified mix using the type of sand described in the item shall be used. It shall be
as specified in Subhead 3.0. For external work and under coat work, the fine aggregate shall conform
to grading IV. For finishing coat work the fine aggregate conforming to grading zone V shall be used.
12.1.4 Application of Plaster
12.1.4.1 Ceiling plaster shall be completed before commencement of wall plaster.
12.1.4.2 Plastering shall be started from the top and worked down towards the floor. All putlog holes
shall be properly filled in advance of the plastering as the scaffolding is being taken down. To ensure
even thickness and a true surface, plaster about 15 15 cm shall be first applied, horizontally and
vertically, at not more than 2 metres intervals over the entire surface to serve as gauges. The surfaces
of these gauged areas shall be truly in the plane of the finished plaster surface. The mortar shall then
be laid on the wall, between the gauges with trowel. The mortar shall be applied in a uniform surface
slightly more than the specified thickness. This shall be brought to a true surface, by working a
wooden straight edge reaching across the gauges, with small upward and side ways movements at a
time. Finally the surface shall be finished off true with trowel or wooden float according as a smooth or
a sandy granular texture is required. Excessive trowelling or over working the float shall be avoided.
12.1.4.3 All corners, arrises, angles and junctions shall be truly vertical or horizontal as the case may
be and shall be carefully finished. Rounding or chamfering corners, arrises, provision of grooves at
junctions etc. where required shall be done without any extra payment. Such rounding, chamfering or
grooving shall be carried out with proper templates or battens to the sizes required.
12.1.4.4 When suspending work at the end of the day, the plaster shall be left, cut clean to line both
horizontally and vertically. When recommencing the plastering, the edge of the old work shall be
scrapped cleaned and wetted with cement slurry before plaster is applied to the adjacent areas, to
enable the two to properly join together. Plastering work shall be closed at the end of the day on the
body of wall and not nearer than 15 cm to any corners or arrises. It shall not be closed on the body of
the features such as plasters, bands and cornices, nor at the corners of arrises. Horizontal joints in
plaster work shall not also occur on parapet tops and copings as these invariably lead to leakages.
162

The plastering and finishing shall be completed within half an hour of adding water to the dry mortar.
No portion of the surface shall be left out initially to be patched up later on. The plastering and finishing
shall be completed within half an hour of adding water to the dry mortar.
Lime shall be prepared from best available hydraulic lime slaked with fresh water and sifted. The lime
shall be ground fine in a mortar mill and kept moist until used. A sample of lime to be used shall be
produced by the contractor for the approval of Engineer-In-charge. Samples of lime may be subjected
to tests as per relevant I.S. before final approval. All lime to be used on the work shall conform to the
approved sample.
12.1.5 Thickness
Where the average thickness required as per description of the item is 12mm, 15mm, 20mm, the
average thickness of the plaster shall not be less than specified above whether the wall treated is of
block or stone or concrete surface.
12.1.6 Curing
Curing shall be started as soon as the plaster has hardened sufficiently not to be damaged when
watered.
The plaster shall be kept wet for a period of at least 7 days. During this period, it shall be suitably
protected from all damages at the contractors expense by such means as the Architect / Engineer-incharge may approve. The dates on which the plastering is done shall be legibly marked on the various
sections plastered so that curing for the specified period thereafter can be watched.
12.1.7 Finish
The plaster shall be finished to a true and plumb surface and to the proper degree of smoothness as
required. The work shall be tested frequently as the work proceeds with a true straight edge not less
than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested with a level and
all jambs and corners with a plumb bob as the work proceeds.
12.1.8 Precaution
Any cracks which appear in the surface and all portions which sound hollow when tapped, or are found
to be soft or otherwise defective, shall be cut out in rectangular shape and redone as directed by the
Architect / Engineer-in-charge.
(i) When ceiling plaster is done, it shall be finished to chamfered edge at an angle at its junction
with a suitable tool when plaster is being done. Similarly when the wall plaster is being done, it
shall be kept separate from the ceiling plaster by a thin straight groove not deeper than 6mm
drawn with any suitable method with the wall while the plaster is green.
(ii) To prevent surface cracks appearing between junctions of column/beam and walls, 150mm
wide chicken wire mesh should be fixed with U nails 150mm centre to centre before plastering
the junction. The plastering of walls and beam/column in one vertical plane should be carried
out in one go. For providing and fixing chicken wire mesh with U nails payment shall be made
separately.
12.1.9 Measurements
12.1.9.1 Length and breadth shall be measured correct to a cm and its area shall be calculated in
square metres correct to two places of decimal.
12.1.9.2 Thickness of the plaster shall be exclusive of the thickness of the key i.e. grooves, or open
joints in brick work.
12.1.9.3 The measurement of wall plaster shall be taken between the walls or partitions (the
dimensions before the plaster shall be taken) for the length and from the top of the floor or skirting to
163

the ceiling for the height. Depth of coves or cornices if any shall be deducted.
12.1.9.4 Deductions in measurements, for opening etc. will be regulated as follows:
(a) No deduction will be made for openings or ends of joists, beams, posts, girders, steps etc.
upto 0.5 sqm in area and no additions shall be made either, for the jambs, soffits and sills of
such openings. The above procedure will apply to both faces of wall.
(b) Deduction for opening exceeding 0.5 sqm but not exceeding 3 sqm each shall be made for
reveals, jambs, soffits sills, sills, etc. of these openings.
(i) When both faces of walls are plastered with same plaster, deductions shall be made for
one face only.
(ii) When two faces of walls are plastered with different types of plaster or if one face is
plastered and other is pointed or one face is plastered and other is unplastered,
deduction shall be made from the plaster or pointing on the side of the frame for the
doors, windows etc. on which width of reveals is less than that on the other side but no
deduction shall be made on the other side.
Where width of reveals on both faces of wall are equal, deduction of 50% of area of
opening on each face shall be made from area of plaster and/or pointing as the case
may be.
(iii) For opening having door frame equal to or projecting beyond thickness of wall, full
deduction for opening shall be made from each plastered face of wall.
(c) For opening exceeding 3 sqm in area, deduction will be made in the measurements for the full
opening of the wall treatment on both faces, while at the same time, jambs, sills and soffits will
be measured for payment.
In measuring jambs, sills and soffits, deduction shall not be made for the area in contact with the
frame of doors, windows etc.
12.2.0 Rate
The rate shall include the cost of all labour and materials involved in all the operations described
above.
12.2.1 18MM THICK CEMENT PLASTER FOR EXTERNAL SURFACE (TWO COAT WORK)
12.2.1 The specification for scaffolding and preparation of surface shall be as described in 12.1
12.2.2 Mortar
The mix and type of fine aggregate specified in the description of the item shall be used for the
respective coats. Generally the mix of the finishing coat shall not be richer than the under coat unless
otherwise described in item.
Generally coarse sand shall be used for the under coat and fine sand for the finishing coat, unless
otherwise specified for external work and under coat work, the fine aggregate shall conform to grading
zone IV. For finishing coat work the fine aggregate conforming to grading zone V shall be used.
12.2.3 Application
12.2.3.1 The plaster shall be applied in two coats i.e. 12 mm under coat and then 6 mm finishing coat
and shall have an average total thickness of not less than 18 mm.
12.2.3.2 12mm Under Coat : This shall be applied as specified in 12.1.4 except that when the plaster
has been brought to a true surface a wooden straight edge and the surface shall be left rough and
164

furrowed 2 mm deep with a scratching tool diagonally both ways, to form key for the finishing coat. The
surface shall be kept wet till the finishing coat is applied.
12.2.3.3 6 mm Finishing Coat : The finishing coat shall be applied after the under coat has
sufficiently set but not dried and in any case within 48 hours and finished in the manner specified in
12.1.4.
12.2.4 Specifications for Curing, Finishing, Precautions, Measurements and Rate shall be as
described under 12.1.
12.3 CEMENT WATER PROOFING COMPOUND
It shall be used for cement mortar for plastering or concrete work.
12.3.1 Water Proofing Compound
Integral cement water proofing compound conforming to IS 2645 and of approved brand and
manufacture, enlisted by the Architect / Engineer-in-charge from time to time shall be used.
12.3.2 The contractor shall bring the materials to the site in their original packing. The containers will
be opened and the material mixed with dry cement in the proportion by weight, recommended by the
manufacturers or as specifically described in the description of the item. Care shall be taken in mixing,
to see that the water proofing material gets well and integrally mixed with the cement and does not run
out separately when water is added.
12.3.3 It shall be measured by weight.
12.3.4 The rate shall include the cost of all labour and materials involved in all the operations
described above.

165

SUB-HEAD 13.0

SPECIFICATION FOR PAINTING WORK

166

CONTENTS

Clause No.

Brief Description

13.1.0

Painting

13.2.0

Exterior Painting on Wall

13.3.0

Painting Priming Coat on Wood, Iron or Plastered Surfaces

13.4.0

Wall Painting with Plastic Emulsion Paint

13.5.0

Painting with Synthetic Enamel Paint

Page No.

167

13.1.0 PAINTING
13.1.1 Materials
Paints, oils, varnishes etc. of approved brand and manufacture shall be used. Only ready mixed Paint
(Exterior grade) as received from the manufacturer without any admixture shall be used.
If for any reason, thinning is necessary in case of ready mixed Paint, the brand of thinner
recommended by the manufacturer or as instructed by the Architect / Engineer-in-charge shall be
used.
Approved Paints, oil or varnishes shall be brought to the site of work by the contractor in their original
containers in sealed condition. The material shall be brought in at a time in adequate quantities to
suffice for the whole work or at least a fortnights work. The materials shall be kept in the joint custody
of the contractor and the Architect / Engineer-in-charge. The empties shall not be removed from the
site of work, till the relevant item of work has been completed and permission obtained from the
Architect / Engineer-in-charge.
13.1.2 Commencing Work
Painting shall not be started until the Architect / Engineer-in-charge has inspected the items of work to
be painted, satisfied himself about their proper quality and given his approval to commence the
painting work.
Painting of external surface should not be done in adverse weather condition like hail storm and dust
storm.
Painting, except the priming coat, shall generally be taken in hand after practically finishing all other
building work.
The rooms should be thoroughly swept out and the entire building cleaned up, at least one day in
advance of the Paint work being started.
13.1.3 Preparation of Surface
The surface shall be thoroughly cleaned and dusted off. All rust, dirt, scales, smoke splashes, mortar
droppings and grease shall be thoroughly removed before painting is started. The prepared surface
shall have received the approval of the Architect / Engineer-in-charge after inspection, before painting
is commenced.
13.1.4 Application
13.1.4.1 Before pouring into smaller containers for use, the Paint shall be stirred thoroughly in its
containers, when applying also, the Paint shall be continuously stirred in the smaller containers so that
its consistency is kept uniform.
13.1.4.2 The painting shall be laid on evenly and smoothly by means of crossing and laying off, the
latter in the direction of the grains of wood. The crossing and laying off consists of covering the area
over with Paint, brushing the surface hard for the first time over and then brushing alternately in
opposite direction, two or three times and then finally brushing lightly in a direction at right angles to
the same. In this process, no brush marks shall be left after the laying off is finished. The full process
of crossing and laying off will constitute one coat.
13.1.4.3 Where so stipulated, the painting shall be done by spraying. Spray machine used may be
(a) high pressure (small air aperture) type, or
(b) a low pressure (large air gap) type, depending on the nature and location of work to be carried
out. Skilled and experienced workmen shall be employed for this class of work. Paints used
shall be brought to the requisite consistency by adding a suitable thinner.

168

13.1.4.4 Spraying should be done only when dry condition prevails. Each coat shall be allowed to dry
out thoroughly and rubbed smooth before the next coat is applied. This should be facilitated by
thorough ventilation. Each coat except the last coat, shall be lightly rubbed down with sand paper or
fine pumice stone and cleaned off dust before the next coat is laid.
13.1.4.5 No left over Paint shall be put back into the stock tins. When not in use, the containers shall
be kept properly closed.
13.1.4.6 No hair marks from the brush or clogging of Paint puddles in the corners of panels, angles of
mouldings etc. shall be left on the work.
13.1.4.7 In painting doors and windows, the putty round the glass panes must also be painted but care
must be taken to see that no Paint stains etc. are left on the glass. Tops of shutters and surfaces in
similar hidden locations shall not be left out in painting. However, bottom edge of the shutters where
the painting is not practically possible, need not be done nor any deduction on this account will be
done but two coats of primer of approved make shall be done on the bottom edge before fixing the
shutters.
13.1.4.8 On painting steel work, special care shall be taken while painting over bolts, nuts, rivets
overlaps etc.
13.1.4.9 The additional specifications for primer and other coats of Paints shall be as according to the
detailed specifications under the respective headings.
13.1.5 Brushes and Containers
After work, the brushes shall be completely cleaned of Paint and linseed oil by rinsing with turpentine.
A brush in which Paint has dried up is ruined and shall on no account be used for painting work. The
containers when not in use, shall be kept closed and free from air so that Paint does not thicken and
also shall be kept safe from dust. When the Paint has been used, the containers shall be washed with
turpentine and wiped dry with soft clean cloth, so that they are clean, and can be used again.
13.1.6 Measurements
13.1.6.1 The length and breadth shall be measured correct to a cm. The area shall be calculated in
sqm (correct to two places of decimal), except otherwise stated.
13.1.6.2 Small articles not exceeding 10 sq decimetre (0.1sqm) of painted surfaces where not in
conjunction with similar painted work shall be enumerated.
13.1.6.3 Painting upto 10 cm in width or in girth and not in conjunction with similar painted work shall
be given in running metres and shall include cutting to line where so required.
Note : Components of trusses, compound girders, stanchions, lattices and similar work shall,
however, be given in sq. metres irrespective of the size or girth of members. Priming coat of painting
shall be included in the work of fabrication.
13.1.6.4 In measuring painting, varnishing, oiling etc. of joinery and steel work etc. The coefficients as
indicated in following tables shall be used to obtain the area payable. The coefficients shall be applied
to the areas measured flat and not girthed.

169

TABLE 13.1
Equivalent Plain Areas of Uneven Surface
S.
No.

Description of work

How measured

I. Wood work doors, windows

Etc.
1. Panelled or framed and braced
doors, windows etc.
2. Ledged and battened or ledged,
battened and braced doors,
windows etc.
3. Flush doors etc.
4. Part panelled and part glazed or
gauzed doors, window etc.
(Excluding painting of wire gauze
portion)
5. Fully glazed or gauzed doors,
windows etc. (Excluding painting of
wire gauze portion)
6. Fully venetioned or louvered
doors, windows etc.
7. Trellis (or Jaffri) work one way
or two way

Multiplying coefficients
4

Measured flat (not girthed

including)
Chowkhat or frame, Edges,
chocks, cleats, etc. shall be
deemed to be
included in the item.
-do-do-

-do-

1.30 (for each side)

- do -

1.20 (for each side)

1.00 (for each side)

0.80 (for each side)

1.80 (for each side)

Measured flat overall, no

deduction shall be made for open
spaces, sup-porting members
shall not be mea sured
separately

2 (for painting all over)

8. Carved or enriched work

Measured flat

2 (for each side)

9. Weather boarding

Measured flat (not girthed

supporting frame work shall not
be measured separately
Measured flat (not girthed)

1.20 (for each side)

10. Wood shingle roofing

11. Boarding with cover fillets
12. Tile and slate battening

II. Steel work doors, windows

Etc.
13. Plain sheeted steel doors or
windows including frame edges etc.
14. Fully glazed or gauzed steel
doors and windows (excluding
painting of wire gauze portion)
15. Partly panelled and partly
glazed or gauzed doors and
windows (excluding painting
of wire gauze portion)
16. Corrugated sheeted steel doors
or windows

Measured flat (not girthed) and

match boarding
Measured flat overall no
deductions shall be made for
open spaces

Measured flat (not girthed)

-do-

1.10 (for each side)

1.05 (for each side)
0.80 (for painting all
over)

1.10 (for each side)

0.50 (for each side)
0.80 (for each side)

-do-do-

1.25 (for each side)

170

17. Collapsible gates

18. Rolling shutters of interlocked
laths

Measured flat
Measured flat (size of opening) all
over; jamb guides, bottom rails
and
locking arrangement etc. shall be
included in the item (top cover shall
be measured separately)

1.50 (for painting

all over)
1.10 (for each side)

III. General
19. Expanded metal, hard drawn
steel wire fabric of approved quality,
grill works and gratings in guard
bars, balustrades, railing partitions
and MS Bars in windows frames.
20. Open palisade fencing and gates
including standards, braces, rails
stays etc. in timber or steel
21. Corrugated iron sheeting in
roofs, side cladding etc.
22. AC corrugated sheeting in roofs,
side cladding etc.
23. AC semi corrugated sheeting in
roofs, side cladding etc. or Nainital
pattern using plain sheets
24. Wire gauze shutters including
painting of wire gauze

Measured flat overall; no

deduction shall be made for open
spaces; supporting members shall
not be measured separately
-do- (see note No. 12)
-do- Measured flat (not girthed)
-do-do-do-

1 (for Paint all over)

1 (for Paint all over)

1.14 (for each side)
1.20 (for each side)
1.10 (for each side)
1.00 (for each side)

Explanatory Notes for Table 13.1

(1)

(2)

(3)
(4)
(5)

(6)

(7)

Measurements for doors windows etc., shall be taken flat (and not girthed) over all including
chowkhuts or frames, where provided. Where Chowkhuts or frames are not provided, the
shutter measurements shall be taken.
Where doors, windows etc., are of composite types other than those included in Table 1 the
different portion shall be measured separately with their appropriate coefficients, the centre
line of the common rail being taken as the dividing line between the two portions.
The coefficients for door and windows shall apply irrespective of the size of frames and
shutter members.
In case steel frames are used the area of doors, windows shutters shall be measured flat
excluding frames.
When the two faces of a door, window etc. are to be treated with different specified finishes,
measurable under separate items, the edges of frames and shutters shall be treated with the
one or the other type of finish as ordered by the Architect / Engineer-in-charge and
measurement of this will be deemed to be included in the measurement of the face treated
with that finish.
In the case where shutters are fixed on both faces of the frames, the measurement for the
door frame and shutter on one face shall be taken in the manner already described, while the
additional shutter on the other face will be measured for the shutter only excluding the frame.
Where shutters are provided with clearance at top or/and bottom each exceeding 15 cm
height, such openings shall be deducted from the overall measurements and relevant
coefficient shall be applied to obtain the area payable.

171

(8)

(9)

(10)
(11)

(12)

Collapsible gates shall be measured for width from outside to outside of gate in its expanded
position and for height from bottom to top of channel verticals. No separate measurements
shall be taken for the top and bottom guide rails rollers, fittings etc.
Coefficients for sliding doors shall be the same as for normal types of doors in the table.
Measurements shall be taken outside to outside of shutters, and no separate measurements
shall be taken for the painting guide rails, rollers, fittings etc.
Measurements of painting as above shall be deemed to include painting all iron fittings in the
same or different shade for which no extra will be paid.
The measurements of guard bars, expanded metal, hard drawn steel wire fabric of approved
quality, grill work and gratings, when fixed in frame work, painting of which is once measured
else where shall be taken exclusive of the frames. In other cases the measurements shall be
taken inclusive of the frames.
For painting open palisade fencing and gates etc., the height shall be measured from the
bottom of the lowest rail, if the palisades do not go below it, (or from the lower end of the
palisades, if they project below the lowest rail), upto the top of rails or palisades whichever are
higher, but not up to the top of standards when the latter are higher than the top rails or the
palisades.

13.1.6.5 Width of moulded work of all other kinds, as in hand rails, cornices, architraves shall be
measured by girth.
13.1.6.6 For trusses, compound girders, stanchions, lattice girders, and similar work, actual areas will
be measured in sq. metre and no extra shall be paid for painting on bolt heads, nuts, washers etc.
even when they are picked out in a different tint to the adjacent work.
13.1.6.7 Painting of rain water, soil, waste, vent and water pipes etc. shall be measured in running
metres of the particular diameter of the pipe concerned. Painting of specials such as bends, heads,
branches, junctions, shoes, etc. shall be included in the length and no separate measurements shall
be taken for these or for painting brackets, clamps etc.
13.1.6.8 Measurements of wall surfaces and wood and other work not referred to already shall be
recorded as per actual.
13.1.6.9 Flag staffs, steel chimneys, aerial masts, spires and other such objects requiring special
scaffolding shall be measured separately.

13.1.7 Precautions
All furnitures, fixtures, glazing, floors etc. shall be protected by covering and stains, smears,
splashings, if any shall be removed and any damages done shall be made good by the contractor at
his cost.
13.1.8 Rate
Rates shall include cost of all labour and materials involved in all the operations described above and
in the particular specifications given under the several items.
13.2 EXTERIOR PAINTING ON WALL
13.2.1 Material (Renova / Spectrum):
The paint shall be (Texured exterior paint/Acrylic smooth exterior paint/premium acrylic smooth
exterior paint) of approved brand and manufacture.
This paint shall be brought to the site of work by the contractor in its original containers in sealed
condition. The material shall be brought in at a time in adequate quantities to suffice for the whole
work or at least a fornights work. The materials shall be kept in the joint custody of the contractor and
the Architect / Engineer-in-charge. The empty containers shall not be removed from the site of work till
the relevant item of work has been completed and permission obtained from the Architect / Engineer172

in-charge.
13.2.2 Preparation of Surface
For new work, the surface shall be thoroughly cleaned off all mortar dropping, dirt dust, algae, fungus
or moth, grease and other foreign matter of brushing and washing, pitting in plaster shall make good,
surface imperfections such as cracks, holes etc. should be repaired using white cement. The prepared
surface shall have received the approval of the Engineer in charge after inspection before painting is
commenced.
13.2.3 Application
Base coat of water proofing cement paint
13.2.3.1 All specifications in respect of base coat of water proofing cement paint shall be as described
under 13.2.
13.2.3.2 Before pouring into smaller containers for use, the paint shall be stirred thoroughly in its
container, when applying also the paint shall be continuously stirred in the smaller containers so that
its consistency is kept uniform. Dilution ratio of paint with potable water can be altered taking into
consideration the nature of surface climate and as per recommended dilution given by manufacturer.
In all cases, the manufacturers instructions & directions of the Architect / Engineer-in-charge shall be
followed meticulously.
The lids of paint drums shall be kept tightly closed when not in use as by exposure to atmosphere the
paint may thicken and also be kept safe from dust.
13.2.3.3 Paint shall be applied with a brush on the cleaned and smooth surface. 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 uniformly as possible leaving no brush marks.
13.2.4 The specifications in respect of scaffolding, protective measures, measurements and rate shall
be as described under 13.14.
13.3

PAINTING PRIMING COAT ON WOOD, IRON OR PLASTERED SURFACES

13.3.1 Primer
13.3.1.1 The primer for wood work, iron work or plastered surface shall be as specified in the
description of item.
13.3.1.2 Primer for plaster/wood work/Iron & Steel/Aluminium surfaces shall be as specified below:
TABLE 13.2
S.No.

Surfaces

Primer to be used

1.
2.

Wood work (hard and soft wood)

Resinour wood and plywood

3.

(A) Aluminium and light alloys

Pink conforming to IS 3536

Aluminium primer conforming to IS
3585
Zinc chromate primer conforming to
IS 104
Red Oxide Zinc chromate Primer
conforming IS 2074
Cement primer conforming to IS 109

(B) Iron, Steel and Galvanized steel

4.

Cement/Conc/RCC/brick work, Plastered

surfaces, non-asbestos surfaces to
receive Oil bound distemper or Paint
finish.

173

13.3.1.3 The primer shall be ready mixed primer of approved brand and manufacture.
13.3.1.4 Where primer for wood work is specified to be mixed at site, it shall be prepared from a
mixture of red lead, white lead and double boiled linseed oil in the ratio of 0.7 kg : 0.7 kg : 1 litre.
13.3.1.5 Where primer for steel work is specified to be mixed at site, it shall be prepared from a
mixture of red lead, raw linseed oil and turpentine in the ratio of 2.8 kg : 1 litre : 1 litre.
13.3.1.6 The specifications for the base vehicle and thinner for mixed on site primer shall be as
follows:
(a) White Lead : The White lead shall be pure and free from adulterants like barium sulphate and
whiting. It shall conform to IS 103.
(b) Red Lead : This shall be in powder form and shall be pure and free from adulterants like brick
dust etc. It shall conform to IS 102.
(c) Raw Linseed Oil : Raw linseed oil shall be lightly viscous but clear and of yellowish colour with
light brown tinge. Its specific gravity at a temperature of 30 degree C shall be between 0.923
and 0.928.
Note : The oil shall be mellow and sweet to the taste with very little smell. The oil shall be of
sufficiently matured quality. Oil turbid or thick, with acid and bitter taste and rancid odour and
which remains sticky for a considerable time shall be rejected. The oil shall conform in all
respects to IS 75. The oil shall be of approved brand and manufacture.
(d) Double Boiled Linseed Oil : This shall be more viscous than the raw oil, have a deeper colour
and specific gravity between 0.931 and 0.945 at a temperature of 30 degree C. It shall dry with
a glossy surface. It shall conform in all respects to IS 77. The oil shall be of approved brand
and manufacture.
Turpentine : Mineral turpentine i.e. petroleum distillate which has the same rate of evaporation as
vegetable turpentine (distillate product of oleeresin of conifers) shall be used. It shall have no grease
or other residue when allowed to evaporate. It shall conform to IS 533.
13.3.1.7 All the above materials shall be of approved manufacture and brought to site in their original
packing in sealed condition.
13.3.2 Preparation of Surface
13.3.2.1 Wooden Surface : The wood work to be painted shall be dry and free from moisture.
The surface shall be thoroughly cleaned. All unevenness shall be rubbed down smooth with sand
paper and shall be well dusted. Knots, if any shall be covered with preparation of red lead made by
grinding red lead in water and mixing with strong glue sized and used hot. Appropriate filler material
conforming to IS 345 with same shade as Paint shall be used where specified. The surface treated for
knotting shall be dry before
Paint is applied. After obtaining approval of Architect / Engineer-in-charge for wood work, the priming
coat shall be applied before the wood work is fixed in position. After the priming coat is applied, the
holes and indentation on the surface shall be stopped with glaziers putty or wood putty.
Stopping shall not be done before the priming coat is applied as the wood will absorb the oil in
stopping and the latter is therefore liable to crack.
13.3.2.2 Iron & Steel Surface : All rust and scales shall be removed by scrapping or by brushing with
steel wire brushes. Hard skin of oxide formed on the surface of wrought iron during rolling which
becomes loose by rusting, shall be removed.
All dust and dirt shall be thoroughly wiped away from the surface.
If the surface is wet, it shall be dried before priming coat is undertaken.
174

13.4 WALL PAINTING WITH PLASTIC EMULSION PAINT (FOR INTERNAL MASONRY WALLS
GYPSUM & RCC CEILINGS)
13.4.0 The plastic emulsion Paint is not suitable for application on external, wood and iron surface and
surfaces which are liable to heavy condensation. These Paints are to be used on internal surfaces
except wooden and steel.
13.4.1 Plastic Emulsion Paint as per IS 5411 of approved brand and manufacture and of the required
shade shall be used.
13.4.2 Painting on New Surface
13.4.2.1 The wall surface shall be prepared as specified in 13.1.0.
13.4.2.2 Application : The number of coats shall be as stipulated in the item. The Paint will be applied
in the usual manner with brush, spray or roller. The Paint dries by evaporation of the water content and
as soon as the water has evaporated the film gets hard and the next coat can be applied. The time of
drying varies from one hour on absorbent surfaces to 2 to 3 hours on non-absorbent surfaces.
The thinning of emulsion is to be done with water and not with turpentine. Thinning with water will be
particularly required for the under coat which is applied on the absorbent surface. The quantity of
water to be added shall be as per manufacturers instructions.
The surface on finishing shall present a flat velvety smooth finish. If necessary more coats will be
applied till the surface presents a uniform appearance.
13.4.2.3 Precautions
(a) Old brushes if they are to be used with emulsion Paints, should be completely dried of
turpentine or oil Paints by washing in warm soap water. Brushes should be quickly washed in
water immediately after use and kept immersed in water during break periods to prevent the
Paint from hardening on the brush.
(b) In the preparation of wall for plastic emulsion painting, no oil base putties shall be used in
filling cracks, holes etc.
(c) Splashes on floors etc. shall be cleaned out without delay as they will be difficult to remove
after hardening.
(d) Washing of surfaces treated with emulsion Paints shall not be done within 3 to 4 weeks of
application.
13.4.2.4 Other details shall be as specified in 13.1.0 as far as they are applicable.
13.5 PAINTING WITH SYNTHETIC ENAMEL PAINT ON WOOD WORK, M.S. SECTIONS, ETC.
13.5.1 Synthetic Enamel Paint (conforming to IS 2933) of approved brand and manufacture and of the
required colour shall be used for the top coat and an undercoat of ordinary Paint of shade to match the
top coat as recommended by the same manufacturer as far the top coat shall be used.
13.5.2 Painting on New Surface
13.5.2.1 Preparation of surface shall be as specified in 13.1.0 as the case may be.
13.5.2.2 Application : The number of coats including the undercoat shall be as stipulated in the item.
(a) Under Coat : One coat of the specified ordinary Paint of shade suited to the shade of the top
coat, shall be applied and allowed to dry overnight. It shall be rubbed next day with the finest
grade of wet abrasive paper to ensure a smooth and even surface, free from brush marks and
all loose particles dusted off.
(b) Top Coat : Top coats of synthetic enamel Paint of desired shade shall be applied after the
undercoat is thoroughly dry. Additional finishing coats shall be applied if found necessary to
ensure properly uniform glossy surface.
175

13.5.2.3 Other details shall be as specified in 13.2.0 as far as they are applicable.
13.5.2.4 Painting : The number of coats as stipulated in the item shall be applied with synthetic
enamel Paint. Each coat shall be allowed to dry and rubbed down smooth with very fine wet abrasive
paper, to get an even glossy surface. If however, the surface is not satisfactory additional coats as
required shall be applied to get correct finish.
13.5.2.5 Other details shall be specified in 13.2.0 as far as they are applicable.

176

SPECIFICATION FOR WATER PROOFING, ROOFING INSULATION & RAIN WATER PIPES

177

23

WATER PROOFING, ROOFING INSULATION & RAIN WATER PIPES

CONTENTS
Clause No.

Brief Description

Page No.

List of Bureau of Indian Standards Codes

23.0

Treatment for Concrete Roof Slab

23.1

Rain Water Spouts

23.2

Unplasticised Polyvinyl Chloride Pipes and Fittings

23.3

Thermal Insulation for Roofing

23.3a

With Resin Bonded Fibre Glass Wool (Bonded Mineral Wool)

23.3b

With Expanded Polystyrene

23.4

With Styrofoam Boards

23.4a

Flat roof insulation with FOAM BOARDS

23.4b

Insulation Drainage Panels / Boards

23.4c

Adhesives for Thermal Protection

23.5

Integral Cement Based Water Proofing Treatment With Brick Bat Coba

178

LIST OF BUREAU OF INDIAN STANDARDS CODES

Sl. No.

BIS Code

Subject

1.

IS 1200 (PT.IX)

2.

IS 1200 (PTX)

3.

IS 2645

4.
5.

IS 3144
IS 3346

6.
7.
8.

IS 3348
IS 4671
IS 13592

9.

IS 73

Method of measurements of building and civil engineering works: Part

9 Roof covering ( including cladding)
Method of measurements of building and civil engineering works: Part
-10 ceiling and lining
Specification for integral water proofing compounds for cement mortar
and concrete
Methods of test for mineral wool thermal insulation materials
Method of the determination of thermal conductivity of thermal
insulation materials
Specification for fibre insulation boards
Expanded polystyrene for thermal insulation purposes
Unplasticised polyvinyl chloride (UPVC) pipes for soil and Waste
discharge system for inside and outside building.
Paving Bitumen Specifications

10.

IS 702

Specifications for Industrial Bitumen

11.

IS 1322

Specifications for Bitumen felts for Water Proofing and Damp Proofing.

12.

IS 2645

Specifications for Integral Cement Water Proofing Compounds

13.

IS 3370 (Part -1)

Code of Practice for Concrete Structures for the Storage of Liquid:

Part -1 General Requirements.

14.

IS 3384

Specifications for Bitumen Primer for Water Proofing and Damp

Proofing

15.

IS 7193

Specification for Glass Fibre Bitumen Felts

16.

IS 12200

Provision of Water Stops at Transfers Construction Joints in Masonry

and Concrete Dams - Code of Practice.

17.

IS 12432 (Part-3)

Application for Spray Applied Insulation - Code of Practice Part-3

Polyurethane/ Polyisocyarurate

179

23.0 Treatment for Concrete Roof Slab

Poly coat application as per manufacturers specification
23.1 RAIN WATER SPOUTS
The sectional area of rain water spouts provided shall be generally at the rate of 1 square cm per 70 to
80 square decimetre of roof area drained. However in locations subject to excessive and high
intensities of rainfalls, the area of spouts provided may be suitably increased to suit local conditions.
No spout shall be less than 80 mm in diameter. The spacing of spouts shall be arranged to suit the
position of openings in the wall.
23.2 UNPLASTICISED POLYVINYL CHLORIDE PIPES AND FITTINGS
UPVC / PVC Pipes
Pipes shall conform to Type A pipes of IS 13592. The internal and external surfaces of the pipes shall
be smooth and clean and free from grooving and other defects. The end shall be clearly cut and shall
be square with the axis of the pipe. The end may be chamfered on the plain sides. Slight shallow
longitudinal grooves or irregularities in the wall thickness shall be permissible provided the wall
thickness remains within the permissible limit.
Colour of Pipe
Surface colour of the pipes shall be dark shade of grey or as specified.
Marking
Each pipe shall be clearly and indelibly marked with the following informations at intervals not more
than 3 meter.
(a) Manufacturers name or trade mark.
(b) Nominal outside dia of pipe.
(c) Type A
(d) Batch number.
Dimensions
Diameter and Wall Thickness: Mean outside diameter, outside diameter at any point and wall
thickness for type A manufactured plain or with socket shall be as given in Table- 1 of IS 13592.
UPVC rain water pipes shall be of the dia, specified in the description of the item and shall be in
nominal lengths of 2, 3, 4 or 6 metres either plain or with sliding/grooved socket unless shorter lengths
are required at junctions with fittings. Tolerances on specified length shall be + 10 mm and 0 mm.
Fixing and Jointing
Pipes shall be either fixed on face of wall or embedded in masonry as required in the description of the
item.
Plain pipes shall be secured to the walls at all joints with PVC Pipes clips by means of 50 x 50 x 50
mm hard wood plugs, screwed with M.S. screws of required length i/c cutting brick work and fixing in
cement mortar 1:4 (1 cement : 4 coarse sand ). The clips shall be kept about 25 mm clear off finished
face of wall, so as to facilitate cleaning of pipes. Pipes shall be fixed perfectly vertical or to the lines as
directed. The pipes shall be fitted to fittings with seal ring conforming to IS 5382 allowing 10 mm gap
for thermal expansion.
Installation in Wall/Concrete
The walls/concrete slots should allow for a stress free installation. Pipes and fittings to be inserted into
the slots without a cement base have to be applied first with a thin coat of PVC solvent cement
followed by sprinkling of dry sand (medium size). Allow it to dry. The process gives a sound base for
cement fixation. This process is repeated while joining PVC material to CI/AC materials.

180

Fittings
Fittings used shall be of the same make as that of the PVC pipes Injection moulded or fabricated by
the manufacturer and shall have a minimum wall thickness of 3.2 mm. The fittings shall be supplied
with grooved socketted ends with square grooves and provided with Rubber Gasket conforming to IS
5382.
The plain ends of the fittings should be chamfered. The fittings shall be joined with the help of Rubber
lubricant. The details of fittings refer IS 13592.
Measurements
The fittings shall be measured by numbers. The pipes shall be measured net when fixed correct to a
cm. excluding all fittings along its length.
Rate
The rate shall include the cost of all materials and labour involved in all the operations described
above including jointing but excluding the supply and fixing of wall plugs and PVC clips which shall be
paid for separately.
Note: These pipes shall be used only in shaft or unexposed location to avoid damage to these pipes
due to willful act.

23.3 THERMAL INSULATION FOR ROOFING

23.3a With Resin Bonded Fibre Glass Wool (Bonded Mineral Wool)
Material: The material shall be mineral wool made from rock slag or glass processed from a molten
state into fibrous form and shall be bonded with a suitable binder. Bonded mineral wool shall conform
to specifications of group I of IS 8183.
Dimensions: The bonded mineral wool shall be supplied in width of 50, 60, 75 and 100 cms, and
length of 100, 120 and 140 cms and the thickness of the bonded mineral wool shall be 25, 40, 50, 65
or 75 mm.
Tolerances: For width and length, the dimensional tolerances of the bonded mineral wool slabs shall
be -%. For nominal thickness in the range 25 to 75 mm the tolerance shall be -2 mm. An excess, in
all dimensions is permitted.
Requirements for Fibre Glass Wool as per the Table below
S.
No.
1.
2.

Characteristics
Bulk density
Recovery after compression

3.

Shot content max

4.

Moisture content
and absorption

5.
6.

Incombustibility
Thermal conductivity deg. C at
mean temperature 50 deg.C

7.

Sulphur content

Group I

Test Reference

12 to 15 kg/cum
not less than 90% of original
thickness
500 micron - 5%
250 micron - 15%
not more than 2%

IS 3144
Annex. A of IS 8183
IS 3144
IS 3144

Incombustible
0.49 mw/ cmoC

IS 3144
IS 3346

Not more than 0.6%

IS 3144

General: Bonded mineral wool insulation can be either laid over false ceiling or alternatively it can be
fixed to the ceiling when the space above false ceiling is being used for carrying return air. In the first
case the bonded mineral wool can either be fixed with suitable adhesive to the false ceiling board or
181

else it can simply be rolled over the suspended false ceiling.

In the second case when space above false ceiling is to be used for carrying return air 1.5" x 1.5"
slotted angle (3" length) shall be fixed to the ceiling by means of rawl plugs at 20" spacing. Draw 14
gauge tie wires from the slots. Make a mat of mineral wool insulation backed with scrim cloth with a
light coating of Plaster of Paris or polythene faced hessian and 24g x 1" wire mesh netting. The joints
of wire netting should be butted and tightly laced down with G.I. wire. Stretch the mat tightly across the
angles holding it in place by means of tie wires.
Measurements : Length and breadth of the roofing insulation shall be measured correct to a cm and
the surface area worked out in square metre of the finished work.
No deduction shall be made for openings of areas upto 40 square decimetre. No extra payment will be
made for any extra material or labour involved in forming such openings. For openings exceeding 40
square decimetre in area, deduction for the full opening will be made, but no extra will be paid for any
extra material or labour involved in forming such openings.
Boarding fixed to curved surfaces in narrow widths shall be measured and paid for separately. Circular
cutting and waste shall be measured and paid for separately in running metres.
Rate : The rate shall include the cost of all materials and labour required in providing bonded mineral
wool.
23.3b With Expanded Polystyrene
Material : Expanded polystyrene shall conform to IS 4671. It is of two types as given below:
(a) Type N - Normal
(b) Type SE - It shall be of self extinguishing type when tested in accordance with Appendix E of
IS 4671.
Dimensions : The size of the finished boards shall be 1.0 0.5 m or as specified and having a
thickness of 15, 20, 25, 40, 50, 60, 75 or 100 mm.
Tolerances : The tolerances on length, width and thickness of the finished board shall be 2 mm.
Requirements for Expanded Polystyrene for General Use as per the Table Below:
Sl.
No.
1.

2.

Characteristics

Thermal conductivity (K. value)

(a) at 0C
(b) at 10C

5.

Compressive strength at 10%

deformation in Kg/sq.cm Min.
Cross breaking strength in
kg/sq. cm Min.
Water vapour presence in g/sqm
24 hrs. Max.
Thermal stability Percent Max.

6.

Water absorption

3.
4.

Requirements at various
nominal apparent densities in
kg/cum
15
20
25
30
35
0.3
0.3
0.3
0.2
4
2
0
9
0.3
0.3
0.3
0.3 0.28
7
5
3
2
0.3
1.7

Test Reference

IS 3346

0.7

0.9

1.1

1.4

1.4

1.6

1.8

2.2

IS 4671 Appendix B

50
1

40
1

30
1

20
1

IS 4671 Appendix C
IS 4671 Appendix D

less than 0.5% by volume (after

24 hrs. immersion)

IS 4671 Appendix A

IS 4671 Appendix E

182

Sampling : In a single consignment all the items of the same type, shape and dimensions belonging
to the same batch of manufacture shall be grouped together to constitute a lot. For the purpose of
judging conformity to the requirements each lot shall be considered separately. The number of sample
items for this purpose shall depend on the size of the lot and shall be in accordance with col. 1 & 2 of
Table given below. The sample shall be taken at random from the lot.
No. of items in the lot

No. of sample items

1
Upto 25 26 to 100

2
35

Permissible number of
defective sample items
3
00

101 to 300
301 to 1000
1001 to 3000
3001 and above

8
13
20
32

0
0
1
2

All the sample items selected from the lot shall be tested for all requirements of the specifications.
Any item failing in one or more of the requirements shall be regarded as defective.
General : Expanded polystyrene can either be fixed with suitable adhesive to the false ceiling board or
else it can simply be rolled over the suspended false ceiling.
Measurements : Length and breadth of the roofing insulation shall be measured correct to a cm and
the surface area worked out in square metre of the finished work.
No deduction shall be made for openings of areas upto 40 square decimetre. No extra payment will be
made for any extra material or labour involved in forming such openings. For openings exceeding 40
square decimetre in area deduction for the full opening will be made, but nothing extra will be paid for
any extra material/labour involved in forming such openings.
Rate : The rate shall include the cost of material and labour in providing and fixing the polystyrene
boards.
23.4 STYROFOAM BOARDS
23.4a Flat roof insulation with FOAM BOARDS
The performance and longevity of flat roofs depends upon many factors, including the position of the
insulation within the construction. If insulation is placed below the structural deck (cold roof
construction) the structure remains cold and there is a considerable risk of condensation; for that
reason cold deck roofs are not recommended and are now seldom used.
Insulation placed above the structural deck and beneath the waterproof layer (warm roof construction)
reduces the risk of condensation but, because the waterproof layer is thermally isolated from the rest
of the roof construction, it is exposed to wide temperature fluctuations with consequent increased risk
of premature failure.
The inverted roof concept overcomes the problem by placing thermal insulation above the waterproof
layer, maintaining it at an even temperature close to that of the building interior and protecting it from
the damaging effects of UV radiation and from mechanical damage. The insulation protects the water
proof covering from:
wide temperature variations +80 to -20C
degradation from weathering
mechanical damage during construction, use and maintenance.
The waterproof layer acts as a total vapour control layer and, being on the warm side of the insulation,
is maintained above dew point temperature so the risk of condensation is minimised. The inverted roof
concept has other benefits. The insulation can be:
installed in any weather
183

added to, without stripping the waterproof layer

easily lifted and replaced/re-used if the building is altered.

The insulation for an inverted roof must:

resist water absorption

be unaffected by freeze/thaw cycling
withstand surface traffic
protect the waterproof layer long term
be ballasted to prevent flotation
be protected from UV and mechanical damage.

The approved boards should contain a flame retardant additive to inhibit accidental ignition from a
small fire source. The boards are, however, combustible and, if exposed to an intensive fire, may burn
rapidly.
Storage, Handling And Application
The boards should be stored outside, but should be protected against intense sunlight, preferably by
retention in their original packaging. The boards should not be exposed to other ignition sources.
Exposed to intense sunlight over prolonged periods, the surface of the boards degrades into fine dust.
The boards should be placed in position within the recommended temperature range. When exposed
to higher temperature than the recommended max. 75 C, the boards can either soften, undergo
irreversible dimensional changes and eventually melt or become brittle and lose its mechanical
properties. Under no circumstances boards should be installed under black membrane.
The boards should be resistant to most commonly occurring construction materials like solvent-free
bituminous compounds, water-based wood preservatives, lime, cement, plaster, anhydrous gypsum
as well as alcohols, acids and alkalis. Certain organic materials like solvent based wood preservatives,
coal tar and derivatives (aerosol etc.), paint thinners and common solvents such as acetone, ethyl
acetate, petrol toluene, white spirit can attack the XPS boards resulting in softening, shrinkage and
even dissolving with the consequent loss of performance. When bonding boards, the use of solvent
free adhesive is recommended.
Compatibility with polystyrene foam should be sought from the adhesive manufacturer prior to
application.
Properties
Density, min.

Standard
DIN 53420
ASTM D 1622

Unit
kg/m3
lb/ft3

32
2,0

Thermal conductivity at 10 C (50F)

mean
temperature of
test
mean
temperature 23,9 C (75F)

DIN 52612
DIN 52616
ASTM C 177-97
or
ASTM C 518-98

Compressive strength at 10%

deflection

DIN 53421
ASTM D 1621-95

kPa
psi

300
43

Water absorption by submersion

DIN 53428
ASTM D 2842
(1% by vol.
precision)

% by Vol.
% by Vol.

0,2

W/m .K
Btu . In/ft2 .
H . F

0,028
0,2

184

Water vapour diffusion resistance

factor

DIN 52615
ASTM E 96-00

-Perm-inch

100-200
0,4-0,6

Water vapour permeability 1)

Capillarity

--

--

none

Heat stability / compressive creep

DIN 18164

20 kPa, 80C
Type 2,8 psi,
176F 40
kPa, 70C
Type 5,6 psi,
158F

Linear coefficient
of thermal expansion and contraction
(heating soaking conditions)

DIN 52328

C-1
F-1

WD
WS

70.10-6
39.10-6

23.4b INSULATION DRAINAGE PANELS

General
Related Documents
Drawings and general provisions of Contract, including General and Supplementary Conditions and
Division-1 Specification Sections, apply to this Section.
Submittals
Manufacturer's product literature including specified physical properties.
Installation instructions.
Certification that product complies with specification requirements and is suitable for the use intended.
Manufacturer's thermal performance warranty.
Quality Assurance
Insulating Drainage Panels shall not be produced with, or contain, any of the United States EPA
regulated CFC compounds listed in the Montreal Protocol of the United Nations Environmental
Program.
Performance Characteristics
Cell Structure and Key Properties
Unique, tight closed cell structure of STYROFOAM brand insulation leaves no voids between the
cells. The result: high compressive strength and unequaled resistance to water penetration.
Beadboard
Molded Polystyrene voids between beads
Extruded Polystyrene
STYROFOAM brand insulation closed cell structure
Thermal Property Comparison
The heat conduction of STYROFOAM Brand is bad, besides, it is extremely stable, the temperature
and the change of temperature almost have no influence on it.

185

Compressive Strength Comparison

There are space between the cells of Expanded Polystryrene (EPS), and will be compressed under
pressure. The cells of EPS don't fully connect to each other. For unique extruded technology,
STYROFOAM products possess a rigid closed cell structure with lightweight and high compressive
strength property.
Product Handling
a. Protect insulating drainage panels from physical damage.
b. Comply with manufacturer's recommendations for handling, storage and protection.
c. Handle boards carefully so corners are not broken off or boards otherwise damaged.
Handling & Storage
STYROFOAM extruded polystyrene foam products should be stored on a clean, flat surface in an
area free from flammable or volatile materials. When large quantities of the boards are stored indoors,
it is recommended that the building be ventilated to allow a minimum of two air changes per hour.
When stored for long periods outside, the boards should be protected from exposure to direct sunlight
in order to avoid surface degradation. Light colored plastic sheeting is the recommended protective
cover. Avoid dark or transparent materials as they may cause excessively high temperatures to
develop underneath the cover.
Solvent attacks may occur if the extruded polystyrene products are used in direct contact with
materials containing volatile components.
Care should be taken to protect the boards from flames or other ignition sources during storage,
installation and in use.
Warranty
Provide written warranty that the actual thermal resistance of the extruded polystyrene foam insulation
will not vary by more than 10% from its published thermal resistance.
Warranty period is 15 years after date insulation is purchased.
Products
Drainage Board
Material Properties:
1. Rigid closed-cell extruded polystyrene foam board with vertical channels fabricated into one
side, with shiplap edges.
2. Compressive Strength (ASTM D 1621-94): 30 psi.
3. R-Value as per ASTM C 518-91: 5.0 (1.063" thick).
4. R-Value as per ASTM C 518-91: 10.0 (2.125" thick).
5. Water Absorption: Max. 0.3% by volume, ASTM C 272.
6. Surface Burning Characteristics:
a. Flame Spread: 5.
b. Smoke Developed: 165.
Acceptable manufacturers product: The Dow Chemical Company STYROFOAM Brand
PERIMATE Extruded Polystyrene Foam Insulation.
Adhesive
Adhesive: mastic type recommended by insulating drainage panel manufacturer as compatible with
drainage panel and the waterproofing.

186

Acceptable manufacturer's products:

1. ChemRex, Inc. "Contech Brand PL300 Foam Board Adhesive".
2. ChemRex, Inc. "Contech Brand Premium Foam Board Adhesive".
3. Dacar Products, Inc. "Foamgrab PS".
or other approved equivalent
Execution
Surface Preparation
a. Surface shall be smooth, monolithic and free of coarse aggregate.
b. Clean off debris from footings.
c. Waterproofing shall be cured and free of solvent.
Installation

Before backfilling, completely cover damp-proofed or waterproofed wall with insulation

drainage panels.
Apply mastic adhesive in six 2" diameter equally-spaced daubs on the smooth side of panels
to adhere them to the cured waterproofing temporarily until backfill is in place.
Install first panel vertically, with long edge flush with a comer.
a. Be sure shiplap on long edge of panel overlaps previous panel. Continue until a comer is
reached.
b. Cut and install comer panels, cutting off shiplap at corner.
When additional tiers are required, shiplap edges at both horizontal and vertical joints.
Seal off top edge of panels below grade to prevent soil entry, using a J or Z channel,
sheathing tape, or soil fabric.
Protect exposed panels above grade from physical damage and ultraviolet exposure with
protection panel, flashing, or latex coating.

Clean-Up
A. Remove and dispose of excess panels, wrappings and other waste materials.
23.4c ADHESIVES FOR THERMAL PROTECTION
Following are suggested specification paragraphs to be used when specifying sprayed-in-place
polyurethane adhesive. This product is typically considered an accessory type product for use with
roofing insulation, and may be included in Section - Roof and Deck Insulation.
General
Performance Requirements
select appropriate roof design (flat or sloped) and then select FM Class applicable to Project. FM
Approvals are for specific combinations of insulation materials and substrates. Please consult FM
Approvals to determine if the combination of roofing materials for a specific Project meets the desired
Class.
Factory Mutual - Flat Roof:
comply with FMG Fire / Windstorm Class [1-60][1-90][1-135][1-150][1-165][1-180][1-195][1-210][1225][1-240][1-270].
[OR]
Factory Mutual - Sloped Roof:
comply with FMG Fire / Windstorm Class [1-135][1-150][1-165][1-180][1-195][1-240][1-315].
Underwriters Laboratories:
comply with UL 1897 for uplift design criteria.

187

Delivery, Storage And Handling

a. Refer to manufacturers specification.
b. Deliver Products in manufacturers original, unopened, undamaged containers with
identification labels intact.
c. Store Products in a dry and adequately ventilated area, with an ambient temperature
maintained between [45 F and 75 F] [7 C and 24 C].
d. Keep containers tightly closed when not in use.
e. Protect containers from damage.
f. Keep Products away from direct sunlight.
Environmental Requirements
Apply products when ambient air temperature is greater than [33 F] [1 C] and less than [110 F] [43
C].
Do not apply Products during inclement weather, or to surfaces that are wet or have standing water,
frost, ice or snow present.
Warranty
Submit manufacturers extended warranty as described in the General Conditions of the Contract.
Manufacturers Warranty: [10][15][20] year extended warranty, covering adhesion of Product to
compatible materials and substrates.
Products
Accessories
Insulation Adhesive: single-component, moisture cured, solvent free polyurethane adhesive;
dispensed from a portable disposable pre-pressurized container; Insta-Stik Quik Set Commercial Roof
Adhesive by The Dow Chemical Company.
Execution
Examination
Ensure surfaces are free of debris, dirt, dust, grease, oil, diesel fuel and standing water.
Preparation

Steel Deck: Remove residual oil coating from steel substrate with a TSP, acetone, naptha or
comparable cleaner.
Re-Cover Over Built-Up Roofing: Completely remove existing roofing materials from existing
roof surface. Clean roof deck surface. Conduct field pull-test to determine material
compatibility when residual asphalt is present on deck surface.

Installation

Apply beads of insulation adhesive in accordance with manufacturer's installation guidelines.

Install additional adhesive at roof perimeter, roof penetrations and drains.
Adhere insulation boards in adhesive within 5 minutes after adhesive application.
Walk on insulation boards to help spread adhesive for maximum contact. Repeat every 5-7
minutes until insulation boards are firmly attached.

Cleaning
Remove excess Product from adjacent surfaces not intended to receive adhesive.

188

23.5 INTEGRAL CEMENT BASED WATER PROOFING TREATMENT WITH BRICK BAT COBA
Before taking up the water proofing work the construction of parapet walls, including finishing should
be completed. Similarly, the ancillary items like haunches, khurras, grooves to tack the fibre cloth
layer, fixing up of all down take pipes, water pipes and electric conduits etc. should be completed and
no such work should be allowed on the area to be treated during the progress of water proofing
treatment or even later.
Preparing the Surface
The surface of the slab should be roughened by scrapping when the slab concrete is still green,
however, the surface need not be hacked. In case the slab is already cast and surface fairly finished,
the same shall be cleaned neatly of all mortar droppings, loose materials etc with brooms/cloth.
Providing and Laying of Slurry under Base Coat
The consistency of the slurry should be such as to cover the desired area by using 0.488 kg of
blended cement per sqm of area.
On deciding the correct quantity of water required per sqm. area the required quantity of slurry should
be prepared which can be applied over the desired surface within half an hour of mixing with 0.488 kg.
of grey cement + 0.253 kg. water proofing compound as per manufacturer specifications + x litres of
water per sqm. area and the required quantity of slurry thus prepared should only be used for first
application.
The first layer shall be applied with painting brushes over the specified and dampened area carefully
including the corners, holes on the surfaces and joints of pipes in concrete etc. and the application
should continue at least upto 150 mm height of fixtures of pipes from the surface. The surface on
application shall be air cured for 4 hours.
The quantity of water required to prepare the slurry with 2.75 kg. of blended cement to be painted over
an area of 1 sqm. shall be calculated exactly as described above. Depending upon the area of surface
that has to be covered, the required quantity of slurry should be prepared using 2.75 kg. blended
cement + water per sqm. area to be covered, taking particular care to see that only that much quantity
of slurry shall be prepared which can be used within half an hour of preparation i.e. before the initial
setting time of cement.
The prepared slurry shall be applied over the dampened surface with brushes very carefully, including
the joints between the floor slab and the parapet wall, holes on the surfaces, joints of pipes,
masonry/concrete etc.
The application of the slurry should continue upto a height of 300 mm on the parapet wall and also the
groove. The slurry should also be applied upto a height of 150 mm over pipe projections etc.
Laying Base Coat 20 mm thick
Immediately after the application of slurry and when the application is still green, 20 mm thick cement
plaster as base coat with cement mortar 1:5 (1 blended cement : 5 coarse sand) shall be evenly
applied over the concrete surface taking particular care to see that all the corners and joints are
properly packed and the application of the base coat shall be continued upto a height of 300 mm over
the parapet wall.
Laying Brick Bat Coba
Brick bat of size 25 mm to 115 mm out of well burnt bricks shall be used for the purpose of brick bat
coba. The brick bats shall be properly dampened for six hours before laying. Brick bats shall be laid to
required slope/gradient over the base coat of mortar leaving 15-25 mm gap between two bats. Cement
mortar 1:5 (1 blended cement: 5 coarse sand) shall be poured over the brick bats and joints filled
properly. Under no circumstances dry brick bats should be laid over the base coat.
The haunches/gola at the junction of parapet wall and the roof shall be formed only with brick bat
coba.

189

In case the brick bat coba is laid on the base coat immediately on initial set there will be no necessity
of applying cement slurry over the base coat before laying the brick bat coba. However, if the brick bat
coba is to be laid on the subsequent day, cement slurry prepared as described below and shall be
applied over the top surface of the base coat, then only the brick bat coba shall be laid.
The quantity of water required to prepare the slurry with 2.75 kg. of blended cement to be painted over
an area of 1 sqm. shall be calculated exactly as described above. Depending upon the area of surface
that has to be covered, the required quantity of slurry should be prepared using 2.75 kg. blended
cement + water per sqm. area to be covered, taking particular care to see that only that much quantity
of slurry shall be prepared which can be used within half an hour of preparation i.e. before the initial
setting time of cement.
The prepared slurry shall be applied over the dampened surface with brushes very carefully, including
the joints between the floor slab and the parapet wall, holes on the surfaces, joints of pipes,
masonry/concrete etc.
The application of the slurry should continue upto a height of 300 mm on the parapet wall and also the
groove. The slurry should also be applied upto a height of 150 mm over pipe projections etc.
Application of Slurry over Brick Bat Coba
After two days of curing of brick bat coba cement slurry prepared as mentioned in above paragraph
and shall be applied on the surface of brick bat coba The application of slurry shall be the same as
described in clause laying of slurry in base coat which should cover the haunches/gola, and the
remaining small portion of parapet wall and also inside the groove as shown in the figure.
Laying Finishing Layer (Protective Coat)
Immediately on applying the cement slurry over the surface of the brick bat coba and when the slurry
applied is still green. The fibre glass cloth shall be of approved brand and shall be thin, flexible
uniformly bonded mat composed of chemically resistant borosilicate glass fibre distributed in random
open porous structure bonded together with a thermosetting resin.
The cloth shall be spread evenly on the surface without any kink & pressed to see that no air spaces
exist. The fibre glass cloth shall be taken up to a height of 300 mm on parapet walls & tucked in the
groove specially prepared at that height. 20 mm thick layer of cement plaster, without leaving any
joints shall be applied with cement mortar 1:4 (1 blended cement: 4 coarse sand) over the entire fibre
glass cloth including the haunches/gola and the small portion on the parapet wall. The groove in the
parapet wall over the haunches shall also be filled neatly packing the mortar firmly in the groove.
The surface of the finishing layer (protective coat) shall be neatly finished with cement slurry prepared
as per clause providing slurry for base coat. The finished surface shall be allowed to dry for a while
and then pattern of 300 mm x 300 mm groove, 8 mm deep shall be made over the entire surface.
Curing and Testing the Treatment
The entire surface thus treated shall be flooded with water by making kiaries with weak cement
mortar, for a minimum period of two weeks.
Measurement
The measurement shall be taken along the finished surface of treatment including the rounded and
tapered portion at junction of parapet wall. Length and breadth shall be measured correct to a cm and
area shall be worked out to nearest 0.01 sqm. No deduction in measurement shall be made for
openings or recesses or chimney stacks, roof lights or khurras of area upto 0.40 sqm., nor anything
extra shall be paid for making such openings, recesses etc. For areas exceeding 0.40 sqm., deduction
will be made in the measurements for the full openings and nothing extra shall be paid for making
such openings.
Rate
The rate shall include the cost of all labour and materials involved in all the operations described
above.

190

EXTERIOR COATINGS - POLYCOAT

Elastomeric Coating
DESCRIPTION
A synthetic single component elastomeric
concrete/plaster/metal/wood surfaces, etc.

polymerized

waterproofing

coating

for

USES
Waterproofing of external walls, chemical plants and machinery, overhead and underground
water tanks, synthetic wood etc.
Pipe joints (both) new and repaired.
Coating of concrete/steel pipelines carrying potable water, raw water or effluents.
Suitable grade POLYCOAT can be used as a coating for concrete, plaster, stone, masonary steel,
cast iron, mild steel water pipelines, wood, brick structures, general chemical plants, concrete
structures subjected to chemical attack or bacterial or other contamination, water tanks, jetties,
sewage plants or other installations permanently under water.
ADVANTAGES
Exteriors can be waterproofed and decorated simultaneously eliminating painting expenditure.
Does not attract fungus, moss, etc. during monsoons hence, exteriors look freshly painted for
years.
shade not affected by ultraviolet rays of sun.
Protects structures from salt penetration in marine environments.
Can be suitably modified to become a fire resistant / retardant coating.
Unaffected by a wide spectrum of chemicals including some dilute and concentrated acids
and alkalis.
Protects underground structures from attack by ground water sulphates and chlorides.
When suitably modified, it inhibits bacterial growth making it suitable for hospital interiors. Has a fairly
good resistance to abrasion due to normal wear and tear.
COLOUR
Ivory, white, grey, terracotta are best suited for exteriors. Available in slightly glossy or matt finish.
INSTRUCTIONS FOR USE

Clean the surface to remove dirt, loose particles, flaking paint etc.
Rub down to a original hard surface.
In the case of steel surfaces, all scales, rust and grease should be removed.
Mechanical means such as wire brushing, shot blasting can be used, and finally vacuum clean
all loose solids and liquids if required.
All surface cracks up to 5 mm width should be filled up with approved crack filler products.
The cracks more than 5 mm wide and all separation gaps should be filled up with URP
modified mortar or as specified.
Open the container of and stir the contents well for 15 minutes to attain even consistency.
Apply the coating by brush or spray.
If required or recommended, apply two or three coats with a minimum interval of 24 hours
between successive coats.

191

Application Procedure
For External Surfaces:
The surfaces should be primed with approved make elastomeric coat diluted with potable
water in the ratio of 2:1 by volume prior to application of finish coats and allow it to dry for at
least 2 to 3 hrs.
Apply 2 neat coats of elastomeric coat with an interval of 5 to 6 hrs.
Allow it to cure for 7 days.
DRYING TIME
Touch dry
Tack free dry
Hard dry
Cure time

: 30 minutes at ambient temperature

: 3 hours at ambient temperature
: 24 hours at ambient temperature
: 3 days

COVERAGE
Average 50 to 60 ft2/ L per coat. Actual coverage depends on the nature of the surface. The
coverage shall be as per manufacturers specification.
CURING
Self cures progressively over 3 days, attaining full strength after seven days.
CONFORMANCE
Waterproofing
Passes I.S. 3085/1965
U.V. resistance
Passes ASTM D-322
High Temperature stability
Passes ASTM D-794
Abrasion
Passes ASTM D-968/57
Salt spray test
I.S. 2074/1962
Acid /Alkali resistance
Unaffected over a period of 30days by Sulphuric acid pH 1 and
Sodium carbonate solution pH 13.5
PRECAUTIONS & LIMITATIONS
Life and performance of POLYCOAT is directly dependent on the extent and quality of cleaning.
Hence clean the surface thoroughly.
POLYCOAT is supplied in ready mixed form. However in case it is thickened due to long storage, use
specified thinner (upto 5% maximum)
Do not dilute by any means other than potable water.
Application of a primer is must for all types of surfaces.
Excess water on substrate prior to application must be removed by suitable means.
Do not apply below 10oC or above 45oC.
Do not apply during rains, or in direct sunlight.
PACKING
20 kg .in HDPE / MS containers
STORAGE AND SHELF LIFE
It has shelf life of 6 months when stored in original packing in a cool, dry place.

192

METAL-FRAMED SKYLIGHTS
APPLICABLE STANDARDS AND PUBLICATONS (APART FROM THE CODES MENTIONED IN ALUMINIUM
WORKS AND STRUCTURAL STEEL WORKS SECTION)
Sl. No

Code

Subject

American Architectural Manufacturers Association (AAMA):

501-05
503-03
2605-05
CW 10-04
CW 13-85

Methods of Test for Exterior Walls

Field Testing of Metal Storefronts, Curtain walls and Sloped
Glazing Systems
Superior Performing Organic Coatings on Architectural Aluminum
Extrusions and Panels
Curtain Wall Manual No. 10 Care and Handling of Architectural
Aluminum from Shop to Site
Curtain Wall Manual #13 Structural Sealant Glazing Systems

American Society for Testing and Materials (ASTM):

A36/A36M-05
Carbon Structural Steel
A123/A123M-02
Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
A193/A193M-07
Alloy-Steel and Stainless Steel Bolting Materials for High
Temperature Service
A307 REV-07
Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength
B209-07
Aluminum and Aluminum-Alloy Sheet and Plate
B211/B211M-03
Aluminum-Alloy Bar, Rod and Wire
B221/B221M-03
Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire,
Shapes, and Tubes
B316/B316M-02
Specification for Aluminum and Aluminum-Alloy Rivet and ColdHeading Wire and Rods
C864-05
Dense Elastomeric Compression Seal Gaskets, Setting Blocks
and Spacers
C920-05
Elastomeric Joint Sealants
E283-04
Determining Rate of Air Leakage Through Exterior Windows,
Curtain Walls, and Doors Under Specified Pressure Differences
Across the Specimen
E330-02
Structural Performance of Exterior Windows, Curtain Walls and
Doors by Uniform Static Air Pressure Difference
E331-00
Water Penetration of Exterior Windows, Curtain Walls, and
Doors by Uniform Static Air Pressure Difference
E548-94(E1995)
Guide for General Criteria Used for Evaluating Laboratory
Competence
E1105-00
Field Determination of Water Penetration of Installed Exterior
Windows, Curtain Walls, and Doors by Uniform or Cyclic Static
Air Pressure Differences
American Welding Society (AWS):
D1.2/D1.2M-03
Structural Welding Code-Aluminum
Glass Association of North America (GANA):
2004 Edition
GANA Glazing Manual
1990 Edition
FGMA Sealant Manual
2006 Edition
GANA Laminated Glazing Reference Manual
1999 Edition
GANA Fully Tempered Heavy Glass Door and Entrance Systems
Design Guide.
National Association of Architectural Metal Manufacturers (NAAMM):
AMP 500-505 (1988)
Metal Finishes Manual

193

PART 1 GENERAL
1.1 DESCRIPTION:
Section specifies field erected aluminum framed skylights.
1.2 RELATED WORK:
A. Field installed fabrication work in connection with metal framed skylights
B. Finish and Colour
C. Joint sealants works in connection with metal framed skylights:
D. Glazing works in connection with metal framed skylights:
For detailed technical specifications refer
For skylights with Aluminium Section Aluminium works, Colour and finish, Glazing, Joint Sealants
For skylights with Structural Steel Section Structural Steel works, Colour and finish, For Glazing and
sealants refer section Aluminium works.
1.3 QUALITY ASSURANCE:
A.

Qualifications:

1.

Approval is required of products or service of proposed manufacturer, suppliers and installers, and will
be based upon submission by Contractor of certification that:
a.

Manufacturers Qualifications: Manufacturer with five years continuous documented experience in

design, fabrication and installation of metal framed skylights of type and size required for that
project.

b.

Installer Qualifications: An experienced installer with five years continuous documented experience
who has specialized in installing metal-framed skylights similar to those indicated for this Project
and who is acceptable in writing to manufacturer.

c.

Manufacturer's product submitted has been in satisfactory and efficient use on minimum of three
installations similar and equivalent to this project for past three years.

d.

Testing Agency Qualifications: ASTM E548. Refer to Performance Requirements and Field Quality
Control articles for testing requirements.

e.

Product Options: Information on Drawings and in Specifications establishes requirements for

aesthetic effects and performance characteristics of metal-framed skylights. Aesthetic effects are
indicated by dimensions, arrangements, alignment, and profiles of components and assemblies as
they relate to sightlines, one another, and adjoining construction. Performance characteristics are
indicated by criteria subject to verification by one or more methods including preconstruction
testing, field testing, or in-service performance:
1)

Do not modify intended aesthetic effects. If modifications are proposed, submit

comprehensive explanatory data for review.

f.
B.

Welding: Welding shall be performed by certified welders qualified in accordance with AWSD1.2,
using procedures, materials and equipment of the type required for this work.
.
Pre-Installation Conference:
1.

Prior to starting installation of skylight system schedule conference with Contracting Officer to
ensure (1) a clear understanding of drawings and specifications; (2) onsite inspection and
acceptance of structural and pertinent structural details relating to skylight system; and (3)
coordination of work of various trades involved in providing related work. Conference shall be
attended by Contractor; personnel directly responsible for installation of skylight system, flashing
and sheet metal work and skylight manufacturer. Conflicts shall be resolved and confirmed in
writing.

1.4 SUBMITTALS:
A.

In accordance with relevant Section, SHOP DRAWINGS, PRODUCT DATA, and AND SAMPLES.

B.

Manufacturer's Literature and Product Data:

1.

Manufacturers standard details and fabrication methods.

194

C.

2.

Data on finishing, components, and accessories.

3.

Instructions: Submit detail specifications and instructions for installation, and adjustments.

4.

Recommendations for maintenance and cleaning of exterior surfaces.

Shop Drawings: Show elevations of skylights at 1:50 (1/4 inch) scale, metal gages, details of
construction, methods of anchorage, glazing details, and details of installation.

1.5 DELIVERY, STORAGE, AND HANDLING:

A.

Refer to AAMA CW 10 for care and handling of architectural aluminum from shop to site.

B.

Inspect materials delivered to site for damage. Unload and store with minimum handling. Provide
storage space in dry location with adequate ventilation, free from dust or water, and easily accessible
for inspection and handling. Stack materials on non-absorptive strips or wood platforms. Do not cover
frames with tarps, polyethylene film, or similar coverings. Protect finished surfaces during shipping and
handling using manufacturer's standard method, except that no coatings or lacquers shall be applied to
surfaces to which caulking and glazing compounds must adhere.

1.6 PROJECT CONDITIONS:

Field Measurements: Where metal-framed skylights are indicated to fit to other construction, verify
dimensions of other construction by field measurements before fabrication and indicate measurements
on Shop Drawings. Coordinate fabrication schedule with construction progress to avoid delaying Work.
1.7 APPLICABLE PUBLICATIONS:
A.

Publications listed below form a part of this specification to extent referenced. Publications are referred
to in text by basic designation only.

1.9 WARRANTY
Warranty metal skylight against leaks, and structural failure, and subject to terms of "Warranty of
Construction" as per the tender conditions and warranty period shall be extended to 5 years.
PART 2 - PRODUCTS
2.1 SYSTEM DESCRIPTION:
A.

Design Requirements:
1. System shall meet or exceed all performance requirements specified.
2. Extruded aluminum members with a system of alternate serrations for attachment of exterior caps and
glass supports.
3. Integral guttering system within skylight framing members for positive drainage of condensation. Integral
weeping system to drain to exterior.
4. Flush glazed exterior joints as indicated on contract drawings.
5. All structural silicone shall be factory applied.
6. Glazing Requirement: Refer to Section GLAZING for glazing requirements.

B.

Manufacturers Professional Engineer Qualifications: A professional engineer who is legally qualified to

practice in jurisdiction where Project is located and who is experienced in providing engineering services of
kind indicated. Engineering services are defined as those performed for installations of skylights that are
similar to those indicated for this Project in material, design, and extent.

C.

Performance Requirements:
1. Structural Members: Of sizes to support design loads as indicated on structural Contract Drawings and
as outlined below.
2. Deflection of framing member in a direction normal to plane of glass when subjected to a uniform load
deflection test in accordance with ASTM E330, Procedure B, and per above specified structural design

195

loads as indicated on structural contract drawings, shall not exceed 1/175 nor 25 mm (1 inch) of its clear
span for clear spans less than 6000 mm (20 feet) or 1/240 of clear spans greater than 6000 mm (20
feet).
3. Air Infiltration: When tested in accordance with ASTM E283, shall not exceed 0.03 L/S per sqm (0.06
cfm per square foot) of fixed skylight surface.
4. Water Penetration: No water shall penetrate when skylight is tested in accordance with ASTM E331 at a
differential static pressure of 20 percent of inward acting design wind pressure, with a minimum of 300Pa
(6.24 psf).
2.2 MATERIALS:
A.

Framework:
1. Principle Supporting Members: 2 mm minimum thickness extruded aluminum, alloy 6063-T5, 6063-T6, or
6061-T6 per ASTM B221M. Profiles as indicated on Contract Drawings.
2. Snap-on Covers and Miscellaneous Non-supporting Trim: 1.5 mm minimum thickness extruded
aluminum, alloy 6063-T5 per ASTM B221M.
3. Principle Formed Metal Members: 2 mm minimum thickness aluminum, alloy 5052, 5005, or 6061-T6 per
ASTM B209M.
4. Internal Reinforcement: ASTM A36M, steel shapes as required for strength and mullion size limitations,
hot-dip galvanized after fabrication in accordance with ASTM A123.

B.

Glazing Strips: ASTM C864:

1. Glass and glazing material as specified in Section GLAZING.
2. Extruded EDPM rubber designed to comply with the following specifications:
a.
b.
c.
d.

Hardness: 55+/-5 Durometer.

Tensile Strength: 12410 kPa (1800 psi) minimum.
Elongation: 500 percent minimum.
Color: Black

3. Heat Aging Characteristics:

a.
b.
c.
d.

70 hours at 100 degrees C (212 degrees F).

Hardness Change: +5 Durometer.
Tensile Change: -10 percent
Elongation Change: -20 percent

4. Weather resistance at 1 part ozone per million, 500 hours at 20% elongation: No cracks.
5. No visual checks, cracks or breaks after completion of tests.
C.

Setting Blocks:
1. Extruded Type II silicone rubber designed to permit adhesion and comply with the following
specifications; comply with ASTM C864:
a. Hardness: 80+/- Durometer
b. Color: Black

D.

Fasteners:
1. For Exterior Cap Retainers: ASTM A193 B8 300 series stainless steel screws.
2. For Framework Connections: ASTM B211M 2024-T4 aluminum, ASTM A193 B8 300 series stainless
steel, and ASTM B316 aluminum rivets, as required by connection.
3. For Anchoring Skylight to Support Structure: ASTM A307 zinc plated steel fasteners.

E.

Flashings: Comply with Section FLASHING AND SHEET METAL.

196

F.

Glass:
1. Refer to requirements of Section, GLAZING.
2. Glass Sizes and Clearances:
a. Accommodate up to 25 mm (1 inch) glazing.
b. Sizes indicated are nominal. Verify actual sizes required by measuring frames. Coordinate
dimensions for glass and glass holding members to meet applicable minimum clearances as
recommended by glass manufacturer. Do not nip glass to remove flares or to reduce oversized
dimensions. All cutting shall occur in factory.

2.3 FABRICATION
A.

Skylight components shall be of materials and thickness indicated or specified. Details indicated are
representative of required design and profiles. Unless specifically indicated or specified otherwise, methods
of fabrication and assembly shall be at discretion of manufacturer. Perform fitting and assembling of
components in shop to maximum extent practicable. Anchorage devices shall permit adjustment in three
directions. There shall be no exposed fasteners.

B.

Construct skylight(s) using a continuous aluminum curb with expansion joints as required.

C.

Insofar as practicable, fit and assemble work in manufacturer's shop. Work that cannot be permanently
assembled shall be shop-assembled, marked and disassembled before shipment to job site.

D.

Design rafter bars for snap-in type glazing strips.

E.

Attach snap-on cap retainers using stainless steel fasteners into a system of alternate serrations, at a
maximum spacing of 300 mm (12 inches) on center.

F.

Design snap-on cap retainer fasteners to provide not more than 187 g/mm (10 pounds per linear inch) of
compression on glazing strips and glass edge.

G. Use snap-on type caps to conceal snap-on cap retainer fasteners.

H.

Where applicable, shop rivet or weld aluminum clips to framing members or field bolt at installation.

I.

Set glass with exterior EDPM glazing strips.

J.

Use silicone setting blocks to support glass and to provide edge clearances and glass bites as outlined
below, in accordance with GANA recommendations:
1. Set blocks not less than 150 mm (6 inches) from edge of glass for support of unit.
2. Glass Bite: Not less than 13 mm (1/2 inch) nor more than 16 mm (5/8 inch) on any side of glass unit.
3. Maintain 6 mm (1/4 inch) edge clearance between glass and adjacent metal framework.
4. Use rubber spacers to maintain separation of glass and adjacent metal framework.

K.

Locate weep holes in curb to positively drain condensation to exterior of skylight at each rafter connection.

L.

Dissimilar Metals: Separate dissimilar metals with bituminous paint or other separator that will prevent
galvanic action.

M. Fasteners: Conceal fasteners wherever possible. Countersink heads of exposed fasteners.

2.4 METAL FINISHES:
A.

As specified in Section Aluminium Works.

B.

In accordance with NAAMM AMP 500-505 series.

C.

Anodized Aluminum:
1. Chemically etched medium matte, with clear anodic coating, Class 1 Architectural, 0.7-mil thick.
197

2. Chemically etched medium matte with electrolytically deposited metallic compound, integrally colored
coating Class 1 Architectural, 0.7-mil thick finish and colour. Dyes will not be accepted.
D.

Fluorocarbon Finish: AAMA 2605:

1. Color as selected.

E.

Sealants:
1. Structural Flush Glazed Joints: High performance silicone sealant applied in accordance with
manufacturer's recommendations.
2. Non-structural Flush Glazed Joints and Weather Seal Joints: Silicone sealants applied in accordance
with manufacturer's recommendations.
3. Structural silicone sealant performance requirements: ASTM C920.
a. Hardness: Type A, 30 Durometer.
b. Ultimate Tensile Strength: 1172.11 kPa (170 psi).
c. Tensile at 150 percent Elongation: 55.1580 kPa (80 psi).
d. Joint Movement Capability after 14-Day Cure: +/- 50 percent.
e. Peel Strength aluminum, after 21 Day Cure: 599 g/mm (32 pounds per inch).
4. Structural silicone shall not be used to support dead weight of vertical glass or panels.

PART 3 EXECUTION
3.1 EXAMINATION:
Prior to installation of skylight system, arrange for representative(s) of skylight manufacturer to examine
structure and substrate to determine that they are properly prepared, sized and ready to receive
skylight work included herein.
3.2 INSPECTION AND PREPARATION:
Contact between aluminum and dissimilar metals shall receive a protective coating of asphaltic paint for
prevention of electrolytic action and corrosion.
3.3 INSTALLATION:
A.

Install skylight frame, glass and accessory items as needed in accordance with manufacturer's instructions.

B.

Install skylight system by factory trained mechanics.

C.

Erect system plumb and true in proper alignment and relation to established lines and grades as shown on
approved shop drawings.

D.

Anchor skylight to structure in strict accordance with approved Shop Drawings.

E.

Use high-performance silicone sealants to seal horizontal joints between glass panels and silicone sealant
to wet seal joints between snap-on cap retainers and glass.

F.

Apply sealing materials in strict accordance with sealant manufacturer's instructions. Before application,
remove mortar dirt, dust, moisture and other foreign matter from surfaces it will contact. Mask adjoining
surfaces to maintain a clean, neat appearance. Tool sealing compounds to fill joint and provide a smooth
finish.

3.4 TOLERANCES:
A.

All parts of work, when completed, shall be within the following tolerances:
1. Maximum variation from plane or location shown on approved shop drawings: 3 mm per 3600 mm (1/8
inch per 12 feet) of length, or 10 mm (3/8 inch) in total length.
2. Maximum offset from true alignment between two members abutting end-to-end, edge-to-edge in line:
.75 mm (1/32 inch).
3. Allow minimum 6mm clearance between glass and other metal surfaces.

198

3.5 FIELD QUALITY CONTROL:

A.

Testing Agency: Engage a qualified independent testing and inspecting agency to perform field qualitycontrol tests and to prepare test reports.

B.

Sealant Adhesion Tests: Test installed sealant in a minimum of two areas and as follows:
1. Test structural silicone sealant according to field adhesion test method as described in Section
Aluminium works
2. Test weather seal sealant as recommended in writing by sealant manufacturer.

C.

Water-Spray Test: Test skylights for compliance with requirements as described in Section Aluminium
works.

D.

Water Penetration: Test skylights for compliance with requirements as described in Section Aluminium
works

E.

Repair or replace Work that does not meet requirements or that is damaged by testing; repair or replace to
comply with specifications.

3.6 CLEANING:
A.

Install skylight frame and associated metal to avoid soiling or smudging finish.

B.

Clean metal surfaces promptly after installation, exercising care to avoid damage to coatings.

C.

Remove excess glazing and sealant compounds, dirt, and other substances.

D.

Follow recommendations of skylight manufacturer in selection of cleaning agents. Do not use cleaning
agents containing ammonia or other compounds that might damage finished metal surfaces.

E.

Clean glass just prior to time of final acceptance of building, subsequent to completion of installation.

3.7 PROTECTION:
Protect finished surfaces from damage during erection, and after completion of work. Strippable plastic coatings
on colored anodized finish are not acceptable.
- - - END OF SECTION ALUMINIUM SKYLIGHTS - - -

Metal Framed Skylights

PART 1 - GENERAL
1.0 SCOPE
A.

Design, and fabrication of entire skylight system to include all MS framing, anchors, and flashing metals.

B.

Glazing and glazing materials including gaskets, sealants, setting blocks, backer rods, and related
materials.

C.

Finish on metal components.

D.

Installation of the metal framed skylight system.

1.02 RELATED WORK

A.

Section 007: Structural Steel and Metal Fabrication Works.

B.

Section: Sheet Metal Flashing and Trim given below.

C.

Section: Glazing and Sealant in Aluminium works.

1.03 REFERENCES

199

A.
B.
C.

American Architectural Manufacturers Association (AAMA).

American Society for Testing and Materials(ASTM).
Float Glass Manufacturers Association(FGMA).

1.04 PERFORMANCE REQUIREMENTS

A.

Skylight system shall be designed to support loads as specified by local building codes for the location of
the project, described and/or specified herein as:

B.

Design Wind Loads: As indicated on drawings Design Wind Pressures.

Design Snow Loads: As indicated, but not less than snow loads applicable to Project, required by ASCE 7,
"Minimum Design Loads for Buildings and Other Structures": Section 7, "Snow Loads."
1. Positive Live Loads:
a. Snow Load
b. Wind Load
c. Dead Load
2. Negative Live Loads:
a. Wind Load
3. Load Combinations:
a. Snow Load + Dead Load
b. Wind Load + Dead Load
4. The maximum allowable deflection of any framing member normal to the plane of the glass shall not
exceed L/175. Spans of 20' - 0" or greater shall not exceed a maximum allowable deflection of L/240.

C.

Manufacturer's system shall meet or exceed all performance standards as outlined by the following tests:
1. ASTM E283 (air infiltration 6.24 PSF)
2. ASTM E331 & AAMA 501(water penetration 8 PSF)
3. AAMA 1502.7 (condensation resistance)

D.

Thermal movement of system caused by ambient temperature ranges of + 70 degrees F without causing
buckling, undue stress on structural elements, stresses on glass, failure of seals, performance reduction or
other detrimental effects.

1.05 SUBMITTALS
A.

Shop drawings as required to fully describe the skylight system shall be submitted and approved by the
architect prior to starting any fabrication.

B.

Submit structural calculations (where applicable) by a licensed structural engineer (qualified in the design of
self supporting sloped glazed structures) in accordance with the relevant codes for Structural steel works.

C.

Finished samples (color charts or range samples), and glazing samples shall be submitted and approved by
the architect prior to starting any fabrication.

D.

Submit manufacturer's written warranty as outlined in paragraph 1.07 of this specification.

1.06 QUALITY ASSURANCE

A.

The skylight manufacturer shall be responsible for the design, fabrication, and installation of the skylight
assembly.

B.

Substitute manufacturer's will be considered only when all of the following conditions have been satisfied:
1. Alternate manufacturers must be approved by architect to bid not less than twenty (20) days prior to bid
date.
2. Detailed drawings for alternate skylight system are submitted to architect for review.

200

3. Structural calculations, showing sizes of framing members and loads applied to the support structure,
based on the design loads of this specification are submitted for review.
4. Prospective manufacturers must furnish evidence of their ability to perform, including a list of projects of
similar design and complexity within the last ten (10) years.
5. Prospective skylight systems must be manufactured by a firm with a minimum of ten (10) years
experience in the fabrication and installation of custom aluminum framed skylights.
1.07 WARRANTY
A.

The skylight system shall be warranted for a period of ( 5 ) year(s) after substantial completion against
defects in materials and workmanship.

B.

All glazing shall be warranted pursuant to the glazing manufacturer's standard warranties. Glass breakage
is not covered by these warranties.

C.

All aluminum finishes are warranted pursuant to the suppliers standard warranty.

D.

The structural sealant is warranted for ( 20 ) year(s) pursuant to the sealant manufacturer's standard
warranty of merchantable quality. Warranty shall certify that cured sealant:
1. Shall not become brittle or crack due to weathering or normal expansion and contraction of adjacent
surfaces.
2. Shall not harden nor soften beyond a Shore "A" durometer of 30 points.
3. Shall not change color significantly when used with compatible backup materials.
4. Shall not bleed significantly.

PART 2 PRODUCTS
2.01 MANUFACTURER
A.

Metal framed skylights shall be manufactured by a person / company as specified in the paragraph Quality
Control / Qualification above.

2.02 MATERIALS
A.

Framing members:
1. Extruded aluminum shall have minimum mechanical properties equal to or greater than 6063-T5 alloy
and temper.
2. Snap on covers and miscellaneous non-structural trim shall be the minimum thickness recommended by
the manufacturer.

B.

Flashing:
1. Shall be in confirmation with the section Sheet metal flashing given below

C.

Fasteners and Anchors:

1. Exposed fasteners shall be stainless steel or zinc coated or corrosion resistance, unless otherwise
noted.

D.

Glazing Material: Thickness to be determined by codes, glazing area loading conditions and manufacturers
recommendations.
2. Shall be in confirmation with the section Aluminium Works / Glazing F (in section 2.2 above for
Aluminium Skylight works)

E.

Glazing Gaskets:
1. Extruded black E.P.D.M. meeting or exceeding the following:
a. Hardness (Shore A)=50+durometer
201

b. Tensile strenght=2000psi
c. Elongation = 50%
F.

Sealants:
1. Selection of sealants shall be the responsibility of the skylight manufacturer.
2. All surfaces shall be cleaned and primed within the sealant manufacturers guidelines.
3. Also the specification as mentioned in the section Aluminium works and in section above for Aluminium
skylights

G. Finishes:
1. All exposed aluminum shall receive one or more of the following finishes (architect to select). Refer
section Aluminium works
a. anodized (Approved colour).
b. Powder Coated, (Approved color).
c. Acrylic enamel (custom color).
2.03 FABRICATION
1. Skylights shall be shop fabricated to the greatest extent possible.
2. All welding shall be done by inert gas process, exposed welds to be ground and sanded smooth.
3. System to be fabricated using integral condensate gutters and weep systems allowing any water
penetration to drain to the outside.
PART 3 - EXECUTION
3.01 INSTALLATION
A.

Metal framed skylights shall be installed by the selected agency / Person after tender process.

B.

Clients may authorize for a third party to check the installation of the skylight and validate.

C.

Prior to installation, installer, shall notify the general contractor of obvious deficiencies or dimensional errors
in the support system and/or construction. No installation work shall proceed until all errors and deviations
are corrected. Written authorization may be given to proceed with the as-built construction along with any
price corrections.

D.

ADJACENT AND SUPPORT CONSTRUCTION MUST SUPPORT FORCE IMPOSED BY SKYLIGHT

SYSTEM.

E.

Skylight materials shall be installed in strict accordance with manufacturer's installation instructions and
drawings.

F.

Install skylights plumb, level and true to line, without warp or rack of frames or panels and anchor securely
in place in accordance with approved shop drawings.

G. Contact areas between dissimilar metals shall be isolated with a protective coating or plastic strip to prevent
electrolytic corrosion.
H.

Upon completion of installation, installer shall remove all labels, part number markings and excess sealants
from skylight components. Weep system shall be clear of any and all obstructions.

3.02 FINAL CLEANING

A.

Final cleaning and physical protection of all installed materials shall be the responsibility of the general
contractor.
END OF SECTION STEEL SKYLIGHTS

202

ARCHITECTURAL ORNAMENTAL HANDRAILS AND RAILINGS (MODULAR)

PART 1 GENERAL
1.01
A.

WORK INCLUDED
Furnish and/or install supported glass stainless steel railings, glass and components.

1.02
A.

REFERENCE
American National Standards Institute (ANSI)
1. A17.1 Accessible and Usable Buildings and Facilities.
2. A21.l Safety Requirements for Floor and Wall Openings, Railings and Toe Boards.
3. A58.l Minimum Design Loads in Buildings and Other Structures.
4. Z97.l Safety Performance Specifications and Methods of Test for Safety Glazing Materials Used in
Buildings.

B.

American Society for Testing and Materials (ASTM)

1. A555 - Standard Specification for General Requirements for Stainless Steel Wire and Wire Rods.
2. A666 - Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip,
Plate, and Flat Bar.
3. C1048 - Standard Specification for Heat-Treated Flat Glass - Hind HS, Kind FT Coated and Uncoated
Glass.
4. E 894 - Standard Test Method for Anchorage of Permanent Metal Railing Systems and Rails for
Buildings.
5. E 935 - Standard Test Methods for Performance of Permanent Metal Railing Systems and Rails for
Buildings.
6. E 985 - Standard Specification for Permanent Metal Railing Systems and Rails for Buildings.

C.

Americans with Disabilities Act Accessibility Guidelines (ADA).

D.

National Association of Architectural Metal Manufacturers (NAAMM)

1. Metal Finishes Manual.
2. Pipe Railing Manual.
3. Stair Manual.

1.03
A.

STRUCTURAL REQUIREMENTS
Handrail, wall rail and Guardrail assemblies and attachments shall withstand a minimum concentrated load
of 200 pounds applied horizontally or vertically down at any point on the top rail. Infill area of guardrail
system capable of withstanding a horizontal concentrated load of 200 pounds applied to one square foot at
any point in the system. Load not to act concurrently with loads on top rail of system in determining stress
on guardrail. Handrail assemblies and guards shall be designed to resist a load of 50 pounds per linear foot
(pound per foot) (0.73 kN/m) applied in any direction at the top and to transfer this load through the supports
to the structure.

1.04

SUBMITTALS
A.

Submit under provisions of Section 01300.

B.

Shop Drawing: Manufacturer to submit approval drawings to include the following:

1.
2.
3.
4.

C.

Section-thru details.
Mounting methods.
Typical Elevations.
Key plan layouts

Shop Drawings: Drawings showing fabrication and installation of handrails including plans, elevations,
sections, details of components, anchor details, and attachment to adjoining units of work.

203

1.05

QUALITY ASSURANCE
A.

1.06

Source Limitations: Obtain each type of railing through one source from a single manufacturer. Railings
shall be from approved manufacturer
DELIVERY, STORAGE, AND HANDLING

A.

Materials to be delivered to the job site in good condition and adequately protected against damage as
handrails are a finished product.

B.

Store on site in a location and manner to avoid damage. Stacking should be done in a manner that will
prevent bending.

C.

Store material in a clean, dry location away from uncured concrete and masonry. Any protection on the
railings during transportation should remain until installed.

D.

Keep handling on site to a minimum. Exercise caution to avoid damage to finishes of material.

1.07

PROJECT CONDITIONS

A.

Field Measurements: Where handrails and railings are indicated to fit to other construction, check actual
dimensions of other construction by accurate field measurements before fabrication; show recorded
measurements on final shop drawings.

B.

Where field measurements cannot be made without delaying the railing fabrication and delivery, obtain
guaranteed dimensions in writing by the Contractor and proceed with fabrication of products to not delay
fabrication, delivery and installation.

C.

Coordinate fabrication and delivery schedule of handrails with construction progress and sequence to
avoid delay of railing installation.

PART 2 PRODUCTS
2.01 MATERIALS AND FINISHES
MATERIALS
A.

All stainless steel tube to be 304 or 316 welded stainless steel, ornamental tubing with approved dia
guard rail and hand rail finished with a polish.

B.

All fittings to be 304 or 316 stainless steel.

C.

Glass: Approved thick clear, tempered with beveled edges and all exposed edges ground smooth and
polished.

D.

Glass infill shall be offset from post-to-post centerline by use of point supported disks with overlapping
glass panels.

E.

Specify top rail as: approved dia stainless steel.

F.

Grip rail to be min 1 O.D. stainless steel.

FINISHES
A.

All machined stainless steel fittings will receive a # 8 polish.

B.

All stainless steel pipe and tubing to receive a #6 polish.

2.02 FASTENERS
A.
2.03
A.
B.
C.

All mechanical fasteners used shall be manufactured from stainless steel.

FABRICATION
All mitered and welded corners shall be ground smooth to match finish.
Make exposed joints butt tight and flush.
Interior sleeves shall be used for typical splices.
204

D.
E.

Fasteners are allowed at splice connection.

Verify dimensions on site prior to shop fabrication.

PART 3 EXECUTION
3.01 PREPARATION
A.

Coordinate post setting drawings, diagrams, templates, instructions, and directions for installation of
anchorages. These include items such as sleeves, concrete inserts, anchor bolts, and miscellaneous
items having integral anchors that are to be embedded in concrete and masonry construction.
1. Coordinate delivery of anchorages to project site.
2. Coordinate that blocking is in place for all mounting fasteners.

B.

Clean debris and dust from surfaces and embed holes thoroughly prior to installation.

C.

Prepare surfaces using the methods recommended by the manufacturer for achieving proper results
given the substrate and project conditions.

3.02 INSTALLATION
A.

Install in accordance with manufacturer's drawings and direction.

B.

Fit exposed connections accurately together to form tight joints except as necessary for expansion.

C.

Perform cutting, drilling, and fitting required for installation of handrails. Accurately set handrails in
location, alignment, and elevation, measured from established lines and levels.

D.

Set posts plumb within a tolerance of 1/8 inch (3 mm).

E.

When fastening to in-place construction, provide anchorage devices and fittings to properly secure rail to
in-place construction. Examples of such devices include threaded fittings (for concrete inserts), toggle
bolts and through-bolts. Separate dissimilar materials with bushings, grommets or washers to prevent
electrolytic corrosion.

3.03 PROTECTION
A.

Upon delivery railing may have protective wrapping. At completion of railing installation, immediately
remove any protective wrapping and clean all work for inspection and approval.

B.

After installation, General Contractor or Owner shall be responsible for protection of railings during the
balance of construction.

C.

When cleaning stainless steel surfaces use plain water containing a mild soap or detergent. No abrasive
agents or harsh chemicals shall be used

GENERAL INFORMATION ON STAINLESS STEEL

STAINLESS STEEL are iron-based alloys containing 10.5% or more chromium. Other elements are added and
the chromium content increased to improve the corrosion and heat resisting properties, enhance mechanical
properties, and/or improve fabricating characteristics.
Reference is often made to stainless steel in the singular sense as if it were one material. Actually there are well
over 100 stainless steel alloys. Three general classifications are used to identify stainless steels. They are:
1. Metallurgical Structure.
2. The AISI numbering system: namely 200, 300, and 400 Series numbers.
3. The Unified Numbering System, developed by the American Society for Testing Materials (ASTM) and
Society of Automotive Engineers (SAE), to apply to all commercial metals and alloys.
ALLOYS : The following grades of stainless steel are often used in structural applications:
SS 304 has an austenitic metallurgical structure. It is the basic 18-8 alloy (18% chromium, 8% nickel UNS
S30400), is the most readily available grade, and is often specified for all-purpose applications. It has excellent
corrosion resistance and unusually good formability.

205

SS 316 is basically a 304 grade with the addition of 2 to 3 percent molybdenum (UNS S31600). It has greater
corrosion resistance than 304 and is usually preferred for long-term service in aggressive industrial, chemical
and seacoast atmospheres.
SS 409 has a ferritic metallurgical structure. It is a straight chrome alloy (11% to 12% chromium UNS S40900). It
has good ductility and corrosion resistance. It is mainly used for internal applications.
SS 410-3 is a dual phase alloy (UNS S41003) with micro alloy element control that permits welding in up to 1 1/4
inches (30mm).
SS 2205 has a duplex structure which is typically about equal parts of austenite and ferrite (21% chromium,
4.5% nickel, 2.5% molybdenum UNS 32304). It has excellent corrosion resistance and exhibits about twice the
yield strength as conventional grades.
CONDITION
Stainless steel is usually available in the Hot Rolled and Annealed condition and has a yield strength of about
42 ksi. The austenitic grades can be hardened by cold working the material. 301 (UNS S30100), a modification
of 304, (with the chromium and nickel lowered slightly to increase the work hardening rate), can be supplied in
various tempers up to full hard with a yield strength of 140 ksi.
The American Society of Civil Engineers (ASCE) has a standard ANSI/ASCE 890, Specification for the Design
of Cold Formed Stainless Steel Structural Members, which details the design information on cold formed
stainless steel.
PRODUCT FORMS
The forms of stainless steel used in structural applications are: plate and sheet (often fabricated into structural
shapes), extrusions, forgings, preformed products (tubes and angles), bar and rod, wire, and castings.
PLATE : Plate is defined as material that has a thickness of 3/16" or greater (Table 1). It is usually available in
widths of 48, 60, 72 and 96 inches. It can be supplied as individual flat plates or in coil form (some limits on
thickness and width).
Many structural shapes are produced by fabricating the plate into beams, angles and other components.
SHEET : Sheet is defined as material that has a thickness of less than 3/16" (Table 1), and is usually supplied in
either 48 or 60 inch wide coils.
Table 1
ITEM

Sheet

CLASSIFICATION OF STAINLESS STEEL PRODUCT FORMS*

DESCRIPTION
DIMENSIONS

Coil and cut lengths:

Thickness

Width

Diameter
or Size

under 0.1875" (4.76mm)

24.000" (609.6mm) and

over

under 0.1875" (4.76mm)

24.000" (609.6mm) and

over

Hot Rolled No. 1

Cold Rolled No. 2D, 2B,
Bright Annealed, TR

Strip

Plate

Polished No. 3, 4, 6, 7 & 8

under 0.1875" (4.76mm)

Coils and cut lengths:

Hot Rolled No. 1
Cold Rolled No. 2D, 2B,
Bright Annealed, TR
Polished No. 3, 4, 6, 7 & 8

under 0.1875" (4.76mm)

24.000" (609.6mm) and

over
under 24.000" (609.6mm)

under 0.1875" (4.76mm)

under 24.000" (609.6mm)

under 0.1875" (4.76mm)

0.1875" (4.76mm) and
over

under 24.000" (609.6mm)

Coils and cut lengths:

over 10.000" (254mm)

Hot Rolled, annealed &

pickled
Polished available for

0.1875" (4.76mm) and

over

over 10.000" (254mm)

special applications
Bar

Straight lengths:
Hot
finished
squares,

rounds,

0.250"
(6.35mm)
and over

206

octagons and hexagons

0.125"
over

Hot finished flats

(3.18mm)

and

0.250" (6.35mm) to

10.000" (254mm)

Rod

Wire

Cold finished rounds,

squares,
octagons and hexagons
Cold finished flats
Hot Rolled coils may be
annealed
and/or descaled

0.375" (9.53mm) and over

Cold finishes only:

Rounds,
squares,
octagons
and hexagons
Flat wire (coils only)
Pipe &
Tube
Extrusions

0.062"
(1.59mm)
and over

0.200"
(5.54mm)
and over
0.500"
(12.7mm)
and
under

0.010" (0.254mm) to
0.062" (1.59mm) to
under 0.185" (4.76mm)
under 0.375" (9.53mm)
Several different classifications with differing specifications are available.
For information on standard sizes, consult your local Steel Service Center or the SSINA.
Not considered standard shapes, but available.
Currently limited in size to approximately 6.50" (165.1mm) diameter circle, or structural to 5.00"
(127mm) diameter.
END OF SECTION SS RAILING

FIXED HORIZONTAL LOUVER SYSTEM

HORIZONTAL LOUVER SYSTEM
1.0 GENERAL
1.1 RELATED SECTIONS:
a.
b.
c.

Section - Structural steel works

Section - Aluminum works
Section - Sealants in Aluminium Works

Products supplied by this section and installed by other trades:

Shall be co-ordinated this work with designated trades in other sections of these project specifications.
Operable Fabricated Aluminum Vertical louver system installed to the window wall as indicated on the
architectural drawings.
Steel or aluminum attachment brackets for fixed horizontal louver system
1.2 SUMMARY:
Provide fixed aluminum louver system with related specified hardware to complete the installation to the
locations as mentioned in the drawings.
1.3 QUALITY ASSURANCE:
All bidders submitting bids on the work of this section shall meet or exceed the quality of materials, components
and assemblies herein. Bidders who do not comply with these specifications shall refrain from submitting a bid
Manufacturer shall have a minimum of fifteen (15) years experience in the manufacture of the specified shading
system. All work specified under this section shall be supplied by one subcontractor
Conform to applicable Building Codes, relevant local codes and all other standards noted as per the relevant
sections like Aluminium works etc.,
Install one complete sample with accessories on site. Review the installation before proceeding with the
remainder of the work. Adjust sample installation, as required, to gain acceptance. Accepted work may
form part of the final installation

207

1.4 SUBMITTALS AND TEST REPORTS:

Submit fully detailed drawings prepared in AutoCAD 2000 version format showing all components, finishes and
other construction conditions, installation, controls and all applicable dimensions according to Section Submittals
in Aluminium Works
Submit structural calculations for local approval, taking account of maximum potential wind and snow loads
Submit duplicate samples of the key components of the specified fixed horizontal louver system with the
specified finish. Minimum size 40_ (1000mm) for review
Submit duplicate samples of the specified brackets and attachment methods
Submit duplicate copies of maintenance instructions including the name, address and other contact details of
local service company
1.5 INSPECTION / PREPARATION
Verify that the structure necessary to carry the horizontal louver system is a proper installation and secure
Notify general contractor in writing of any deficiencies in the work of other trades that would affect the fixed
horizontal louver system
Make accurate measurements at the site before fabrication.. Check layout of glazing framing sections, spans
and loading capabilities
1.6 DELIVERY, STORAGE AND HANDLING:
Do not deliver to site until areas to receive the fixed horizontal louver system are completely finished
Deliver materials in original protective wrappers or containers, with manufacturers labels and sealed intact
Handle and store materials in accordance with the manufacturers recommendations, protecting materials and
finishes from damage or soiling
1.7 WARRANTY:
Provide a limited manufacturers warranty from date of Substantial Completion covering the following periods:
Aluminum components and steel hardware Two (2) years
Aluminum and steel finishes Ten (10) years
Provide a limited installation warranty from date of Substantial Completion of one (1) year
2.0 PRODUCTS
SYSTEM:
System to comprise:
1. Operable vertical louvers attaching directly to the window wall, or
2. Operable vertical louvers attaching to a secondary steel structure
2.3 MATERIALS:
Aluminum and steel hardware and brackets:
As per the section Aluminium works and Structural Steel works specification
Mounting brackets:
1. System to be attached to steel or aluminum plates projecting from the window wall, supplied by the window
manufacturer,
2. System to be attached to mounting brackets to be supplied by the manufacturer of the fixed horizontal louver
system. Brackets to fix to:
208

a. Projecting studs supplied by the window wall manufacturer

b. Nosing of the window wall mullions
c. Brick or block work, using resin anchors or similar
d. Studs (provided by the structural steel contractor) projecting through the cladding
e. Steel work behind the cladding using engineered steel or aluminum spacers to take up the distance between
the steel structure and the cladding, or
3. System to be attached to horizontal steel posts supplied by the structural steel contractor. Mounting brackets
and / or vertical steel posts shall be manufactured from engineered wall thickness to support the full weight of
the system and applied wind and snow loads including the safety ratio as determined by the local building and
construction codes.
Mounting assembly will be equipped with attachment provision for cladding integration, as appropriate Method of
attaching to the structure to be coordinated with the structural steel contractor or the window wall contractor as
appropriate.
Louvers:
System shall incorporate single skin fabricated louvers.
a. The louvers shall be of approved shape, width and curvature.
b. The louvers shall comprise the following components:
- Extruded aluminum round tubing leading edges
- Perforated Sheet aluminum skin with holes spaced at a distance as mentioned in drawing.
- Aluminum screw attached, manufactured end caps to fit precisely to the profile of the fabricated louver
Material quality and coatings:
a. All extruded aluminum components shall be extruded from 6063-T6 quality aluminum
b. All aluminum components shall have the following finish:
- Two (2) coat Duracron finish to a standard color,
- Steel components shall be manufactured from mild steel of approved grade as mentioned in relevant sections,
while any stainless steel components shall be manufactured from Stainless SS 304 grade.
Steel components shall be hot dip galvanized or zinc plated,
Electrical Operation
System to be operated by means of linear actuators
Number and size / output torque of linear actuators to be determined by reference to the specific project
requirements
Linear actuators to be rated for external use
Linear actuators to be supplied with appropriate mounting brackets for fixing back to the structure
Each linear actuator to connect to an aluminum or steel operating strip which in turn connect the louvers in a
single bank together
Operating strips to be manufactured from material with engineered dimensions to sufficient to support the
applied loads
3.0 EXECUTION
FABRICATION:
Fixed horizontal louver system components manufactured and assembled allowing for custom installation
techniques to suit project requirements
Finished assemblies shall be square, true to size and free from twist or other defects that could affect
their strength or appearance. Factory applied finish should be uniform, smooth and without blemishes

209

INSTALLATION:
Install work using skilled tradesman and install in strict accordance with manufacturers recommendations.
All items installed, plumbed, squared and rigidly anchored maintaining uniform clearances and accurate
alignment measurements
The fixed horizontal louver system shall be pre-measured and manufactured off-site
ADJUSTING AND CLEANING:
Adjust components as required to ensure trouble free performance
Prior to Substantial Completion clean down once the fixed horizontal louver system
Replace work which cannot be satisfactorily repaired, adjusted or cleaned.
END OF SECTION LOUVERS

FLASHING AND SHEET METAL WORKS

CONTENTS
Clause No.

Brief Description

24.1.1
24.1.2

List of Bureau of Indian Standards Codes

Corrugated Galvanised Steel Sheet Roofing
Valley and Flashing of Plain Galvanised Steel Sheets 489

Page No.

210

LIST OF APPROVED MAKE OF MATERIALS

1.

CEMENT

ACC, L&T (ULTRATECH), RAJASREE, ZURAI,

COROMANDEL, BIRLA SUPER, DALMIA, BINANI.

2. REINFORCEMENT STEEL
BHUWALKA.

TISCO,

3.

STRUCTURAL STEEL

TISCO, IISCO, SAIL, VIZAG.

4.

TUBULAR STEEL

TATA, GUJARAT STEEL, ZENITH, APOLLO.

5.

ALUMINIUM ROOFING
& CLADDING SHEETS

INDAL, HINDALCO,

M.S ROOFING, DECKING

& CLADDING SHEETS

TI METAL, NIPPON DENRO, TRACDECK

6.

SAIL,

VIZAG,

GR

STEELS,

BRINDAVAN,

7. PREPAINTED SHEETS
METALI.

METACOLOR, NIPPON DENRO, TRACDECK, JAPAN

8.

POLYCARBONATE SHEETS

GE PLASTICS.

9.

ALUMINIUM EXTRUSIONS

INDAL, JINDAL, HINDALCO, BHORUKA.

10. VINYL FLOORING SHEETS

PREMIER VINYL, ARMSTRONG, BHOR, L.G.

11. CERAMIC TILES

CERAMICS,

KEDIA, KAJARIA, NITCO, NAVEEN, RESTILE, B. M.

VARAMORA, JOHNSON.

12. CEMENT TILES

EUROCON, ULTRA TILE, BASANTH BATON

13. GLASS (SHEET)

ATUL, SAINT GOBAIN, PILKINGTON, ASAHI.

14. GLASS (FLOAT)

MODIGLASS, SAINT GOBAIN, ATUL TUF, PILKINGTON.

15. POLYSULPHIDE SEALANT

TUFFSEAL, PEDILITE, CHOKSEY, FOSROC.

16. SILICONE SEALANT

GE SILICONES, DOW CORNING, RODOSIL, ANABOND.

17. READY MIX PAINTS

JHENSON &

ASIAN

PAINTS,

GOODLASS

NEROLAC,

BERGER,

NICKELSON.
18. CEMENT PAINTS

SUPER SNOWCEM, SANDTEX MATT, BERGER PAINTS.

19. INDUSTRIAL PAINTS

GOODLASS NEROLAC, BERGER, ASIAN, SHALIMAR.

20. DOOR CLOSER

DORMA / SEVAX.

21. FLOOR SPRING

DORMA / SEVAX.

22. MORTICE LOCKS

GODREJ, GOLDEN, YALE.

NOTE : PRIOR APPROVAL TO BE TAKEN FOR USE OF ANY OF THESE ITEMS.

211

LIST OF BUREAU OF INDIAN STANDARDS CODES

Sl. No.

BIS Code

Subject

1.
2.
3
4.
5.
6.

IS 73
IS 277
IS 651
IS 702
IS 1199
IS 1200 (PT.IX)

7.

IS 1200 (PTX)

8
9.

IS 1230
IS 1367 (PT -13)

10
11.
12.
13.

IS 2095 (PT-1)
IS 2115
IS 2633
IS 2645

14.

IS 3007 (PT.1)

15.

IS 3007 (PT.2)

16.

IS 3087

17.
18.

IS 3144
IS 3346

19.

IS 3348

20.

IS 3384

21.
22

IS 4671
IS 5382

23.

IS 5688

24.
25.

IS 6598
IS 7193

26.
27.

IS 8183
IS 10192

28.

IS 13592

29.
30
31

IS 14753
IS 14862
IS 14871

Specification for paving Bitumen

Galvanised steel sheets (plain and corrugated)
Glazed stoneware pipes and fittings
Specification for industrial bitumen
Methods of sampling and analysis of concrete
Method of measurements of building and civil engineering works:
Part 9 Roof covering ( including cladding)
Method of measurements of building and civil engineering works:
Part -10 ceiling and lining
Cast iron rain water pipes and fitting
Technical supply conditions for threaded steel fasteners pt.13 hot dip
galvanized coating on threaded fasteners
Gypsum plaster boards (Pt.1) plain Gypsum plaster boards
Code of practice for flat roof finish: mud phuska
Method of testing uniformity of coating on zinc coated articles
Specification for integral water proofing compounds for cement
mortar and concrete
Code of practice for laying of asbestos cement sheets: part- 1
corrugated sheets
Code of practice for laying of asbestos cement sheets part- 2 semicorrugated sheets
Particle boards of wood and other lignocellulogic materials (medium
density) for general purposes specifications
Methods of test for mineral wool thermal insulation materials
Method of the determination of thermal conductivity of thermal
insulation materials
Specification for fibre insulation boards
Specification for bitumen primer for water proofing and damp
proofing
Expanded polystyrene for thermal insulation purposes
Specification for rubber sealing rings for gas mains, water mains and
sewers
Methods of test of performed block type and pipe covering type
thermal insulations
Cellular concrete for thermal insulation
Specification for glass fibre base coal tarpitch & bitumen felts
(Amendment I)
Bonded mineral wool
Specifications for synthetic resin bonded glass fibre (SRBGF) for
electrical purposes.
Unplasticised polyvinyl chloride (UPVC) pipes for soil and Waste
discharge system for inside and outside building.
Specifications for polymethyl Methacrylate (PMMA) (Arylic) sheets
Fibre cement flat sheets specifications
Specifications for products in fibre reinforced cement Long
corrugated or Asymmetrical section sheets and fittings for roofing
and cladding.

212

24.1 GALVANISED STEEL SHEET ROOFING AND FLASHING

C.G.S. Sheets
These shall be of the thickness specified in the description of the item and shall conform to IS 277.
The sheets shall be of 275 grade of coating (See Appendix-A) unless otherwise specified in the
description of item.
The sheets shall be free from cracks, split edges, twists, surface flaws etc. They shall be clean, bright
and smooth. The galvanising shall be non-injured and in perfect condition. The sheets shall not show
signs of rust or white powdry deposits on the surface. The corrugations shall be uniform in depth and
pitch and parallel with the side.
Purlins
Purlins of the specified material or M.S. rolled sections of requisite size shall be fixed over the principal
rafters. These shall not be spaced at more than the following distances. (Table 12.1)
TABLE 24.1
Thickness of C.G.S. sheet Maximum spacing of purlins

Thickness of C.G.S. sheet

1.00 mm
0.80 mm
0.63 mm

Maximum spacing of purlins

2.00 metre
1.80 metre
1.60 metre

The top surfaces of the purlins shall be uniform and plane. They shall be painted before fixing on top.
Embedded portions of wooden purlins shall be coal tarred with two coats.
Slope
Slope shall not be pitched at a flatter slope than 1 vertical to 5 horizontal. The normal pitch adopted
shall usually be 1 vertical to 3 horizontal.
Laying and Fixing
The sheets shall be laid and fixed in the manner described below, unless otherwise shown in the
working drawings or directed by the Engineer-in-Charge.
The sheets shall be laid with a minimum lap of 15 cm at the ends. The above minimum end lap of 15
cm shall apply to slopes of 1 vertical to 2 horizontal and steeper slopes.
For flatter slopes the minimum permissible end lap shall be 20 cm. They shall be cut carefully with a
straight edge chisel to give a smooth and straight finish.
Lapping in G.S. sheets shall be painted with a coat of approved steel primer and two coats of painting
with approved paint suitable for G.S. sheet, before the sheets are fixed in place.
Flashing Sheets shall generally be fixed into gables and parapets. They shall be bent up along their
side edges close to the wall and the junction of masonary and flashing shall be protected by suitable
sealent or by a projecting drip course, the later to cover the junction by at least 7.5 cm.

The laying operation shall include all scaffolding work involved.

The galvanised coating should conform to IS 1367 (Pt. XIII) The mass of coating per square meter of
the surface shall be as under:

213

Mass and Equivalent Thickness of Coating

Minimum Mass
(g/m2)
375

Average Thickness
(m)
54

Minimum Mass
(g/m2)
300

Individual Thickness
(m)
43

Finish
The flashing when completed shall be true to lines, and slopes and shall be leak proof.
Measurements
The length and breadth shall be measured correct to a cm. Area shall be worked out in sqm correct to
two places of decimal.
The superficial area of roof covering shall be measured on the flat without allowance for laps and
corrugations.
Rate
The rate shall include the cost of all the materials and labour involved in all the operations described
above including a coat of approved steel primer and two coats of approved steel paint on overlapping
of G.S. sheets. This includes the cost of roof sheets, galvanised iron J or L hooks, bolts and nuts,
galvanised iron seam bolts and nuts, bituminous and galvanised iron limpet washers etc.
24.2 Valley and Flashing of Plain Galvanised Steel Sheets
Purpose made fittings, such as apron flashing pieces, barge boards, bottom glazing flashing, corner
piece (corner flashing), eaves filler pieces, expansion joints, hip capping, hip tile or cap, ridge capping,
ridge finials, roof lights, ventilators, with which the roof is furnished.
Eaves
The lower edge of the inclined roof.
Finial
A decorative fitting used at the Junction of ridges and hips to form a water proof covering and at the
top of conical, pyramidal, or dome roofs.
Flashing
A strip of impervious material, usually metal used to exclude water from the junction between a roof
covering and another part of the structure.

214

TECHNICAL SPECIFICATION
FOR WATER SUPPLY AND
SANITARY WORKS

215

CONTENTS
1.0

Intent of Specification

2.0

Codes and Standards

3.0

Scope

4.0

Site Utilities

5.0

Water Supply

5.1 External Water Supply

5.2 Internal Water Supply

6.0

Soil, Waste, rain water pipes and sewer appurtenances

7.0

Valves, Strainers and pressure gauges

8.0

Sanitary fixtures

216

1. INTENT OF SPECIFICATION
This specification is intended to cover design, engineering, manufacture, test and inspection of
works, delivery to site, properly packed for transportation, erection, testing, commissioning,
performance demonstration at site and handing over to client/consultant/ purchaser of plumbing
and Sanitary System as indicated in the schedule of Requirement and scope of work and as
required for reliable and effective Plumbing and Sanitary system at Proposed Class rooms in
IIM CAMPUS AT BANGALORE
1.1.This specification also includes complete earthwork, i.e. excavation and back filling for the
entire buried piping for plumbing & sewerage system.
1.2.The specification also includes the supply, erection and commissioning of spares as specified
with tools and tackles as required.
1.3.This specification also makes it obligatory for the contractor for arranging and obtaining
necessary clearance / approval from all Local / statutory authorities.
1.4.It is not the intent to completely specify all the details of design and construction herein.
Never the less the equipment and installation shall confirm to high standard of engineering,
design and workmanship in all respect and shall be capable of performing continuous satisfactory
operation acceptable to the client/consultant/purchaser as well as to the various statutory
authorities. In case of any violation of the above contract, the client/consultant/purchaser
reserves the right to change / reject / modify the equipment / system during detail engineering.
1.5.Wherever material or article is specified or described by the name of particular brand,
manufacturer or vendor, the specific item mentioned shall be understood as established type
function and quality desired. Other manufacturers product will be considered provided sufficient
information is furnished to allow the client/ purchaser to determine that the product proposed is
equivalent to that brand.
1.6.Supplies and services to be covered under this tender specification and the conditions thereof
are detailed in the subsequent sections of the specifications. In case of conflict among various
sections, subsections, documents, drawings the same shall be referred to
clients/consultant/purchaser whose decision shall be final and binding to the Bidder. In all cases,
the best advantages will go to the purchaser

217

2. APPLICABLE CODES AND STANDARDS

The installation shall conform in all respects to the following standards in general:
2008 UPC-I
:
2008 Uniform plumbing code India and
2008 Uniform Plumbing Code India Illustrated Training Manual
IS 651 1992
:
Specification for Salt Glazed stoneware pipes and fittings (fifth
revision).
IS 7558 1974
:
Code of practice for domestic hot water installation
IS 771
:
Part I to Part VII-Specification for vitreous china sanitary ware.
IS 771 (Part 3to
6)
IS 778

Specific requirements for urinals

Specification for gunmetal gate, globe and check valves for water,
steam and oil only.

IS5329 1983

Code of practice for sanitary pipe work above ground for buildings

IS 12251 1987
IS 800

:
:

Code of practice for drainage of building basements

Structural Steel Works

IS 2064 1973

IS 6924 1973

Code of practice for selection, installation and maintenance of

sanitary appliances
Code of practice for construction of refuse chutes in multistoried
buildings

IS 1200 (Part 1)
IS 1200 (Part 16)

:
:

IS 1200 ( Part 19)

IS 783 - 1959
IS 13592 1992

:
:
:

IS 2527 1984

IS 2685 1971

IS 6784 1984
IS 2373

:
:

Method of performance testing of water meters (Domestic type).

Specification for water meters (Bulk type).

IS 12235
( Parts 1 to 11)
IS 458 1988

IS 2692 - 1989
IS 12701 1989
IS 2548 ( Part 1&2
)
IS 3004 - 1979
IS 1711 - 1984
IS 1703 1977

:
:
:

Methods of test for un plasticized PVC pipes for portable water

supplies
Specification for precast concrete pipes (with or without
reinforcement).
Specification of ferrules for water services
Specification for rotational molded polyethylene water storage tanks
Specification for plastic seats and covers for water closets

IS 4038 - 1979
IS 1172 - 1983

:
:

IS 1239 - 1990
(Part I)

Specifications for mild steel tube, tubular and other steel pipe fittings.

IS 1239 - 1992
(PartII)

Specifications for mild steel tube, tubular and other steel pipe
fittings.

:
:
:

Method of measurement of building earthwork

Method of measurement of laying of water and sewer lines
including appurtenant
Method of measurement of Water supply, plumbing and drains
Code of practice for laying of concrete pipes
Specification for un plasticized PVC pipes for soil and waste discharge
system inside building including ventilation and rainwater.
Code of practice for fixing rainwater gutters and down pipes for roof
drainage.
Code of practice for selection, installation and maintenance of sluice
valves

Specification for plug cocks for water supply purposes

Specification for self closing taps for water supply
Specification for ball valves (Horizontal plunger type)including
floats for water supply purposes
Specification for foot valves for water works purposes
Code of basic requirements for water supply, drainage & sanitation
(revised).

218

IS 1726 1991
IS 1742 1983
IS 2064 1973

:
:
:

IS 2065 - 1983
IS 3114 1985
IS 4111 1986
IS 4127 - 1983
BS 4515
IS 4985 - 1988

:
:
:
:
:
:

IS 732 &
IS 2274 - 1963

IS 1536 1976

IS 1537 - 1976

IS 1538(part1to23)
- 1976
IS 1729 - 1979

IS 780 - 1984

Code for cast iron manhole frame and cover (third revision)
Code of practice for building drainage.( Second revision)
Code of practice for selection, installation and maintenance of
sanitary appliances
Code of practice for water supply to buildings
Code of practice for Laying of CI pipes
Code of practice for Ancillary structures in sewerage system
Code of Practice for laying glazed stone ware pipe
Specification for unplasticized PVC pipe fittings
Specification for unplasticized PVC pipes for portable water supplies
(second revision)
Indian Standard code of practice for electrical wiring & installation.

Specification for centrifugally cast (spun) iron pressure pipes for

water, gas
and sewage
Specification for vertically cast iron pressure pipes for water,gas and
sewage.
Specification for cast iron fittings for pressure pipes for water, gas and
sewage.
Specification for sand cast iron socket and spigot soil, waste and
ventilating pipes, fittings and accessories.
Specification for sluice valves for water works purposes

Note:
1) All IS Codes Latest year of Publication/ Revision to be considered.
2) National building Code for Water Supply, drainage and Sanitation - Part IX Plumbing
services - Section 1 and Section 2.
3) 2008 UPCI Code also can be considered for the system implementation. The installation shall also
be in conformity with the bylaws and requirements of the local authority so far as these become
applicable to the installation. Wherever this specification calls for, a higher standard of materials and/or
workmanship than those required by any of the above regulations and standards, then this specification
shall take precedence over the said regulations and standards.
Wherever the specifications and drawings require something that may conflict with the regulations,
the regulations shall govern. This shall be confirmed from Employer/OE&PMC/Consultants before
execution.
3.0

SCOPE
The general character and the scope of work to be carried out under this contract are illustrated in

the drawings and specifications. The contractor shall carry out and complete the said work under this
contract in every respect in conformity with the rules and regulations of the local authority.

The

Contractor shall furnish all labour, supply and install all materials, appliances, tools, equipments etc,
necessary for the complete provision and testing of the whole plumbing services installation as specified
herein as per the relevant ISI codes and shown on the drawings. This also includes any material,
appliances, equipment not specifically mentioned herein or noted on the drawings as being furnished or
installed but which are necessary and customary to make a complete installation as shown on the
drawings or described herein, properly connected and in working order. In general, the work to be
performed under this contract shall comprise of the following:

219

Following are the different items of work, which have to be designed, supplied, erected, tested,
commissioned, & obtain necessary approvals from Local statutory bodies wherever applicable.
a)

Internal Sanitary works, consist of supply, fixing, testing and commissioning of sanitary fixtures
like EWC, urinals, wash basins etc., complete as specified in the BOQ.

b)

Internal Domestic water piping work comprising of CPVC piping with fittings, isolation valves,
gauges etc. complete as specified in the BOQ.

c)

Internal Sewerage piping work comprising of UPVC piping with fittings etc. complete as specified
in the BOQ.

d)

External Domestic water piping work comprising of GI B Class piping with fittings, isolation
valves, gauges etc. complete as specified in the BOQ.

e)

External Sewerage piping work comprising of UPVC nu drain pipe with fittings etc. complete as
specified in the BOQ.

In general the work to be performed under this contract shall comprise of the following:
3.1.1 All incidental works connected with plumbing services installation such as excavation
of trenches and back filling, cutting & chasing in concrete and brick and making good,
cutting/drilling holes through walls, floors, and grouting for fixing of fixtures/equipment, etc.
3.1.2 Furnish and install a complete workable plumbing services installation as shown on the
drawings and described in this specification and as per the latest Bureau of Indian
Standards (BIS), Uniform Plumbing Code India & Illustrated Training Manual British
Standards (BS) specifications including all that which is reasonably inferred.
3.1.3
3.1.4

Complete installation of internal and external water supply system.

Complete installation of the sewerage and sewerage appurtenances internally as well as
around the building.

3.1.5

Complete installation of all sanitary and plumbing fixtures.

3.1.6

Co-operation with other crafts in putting the installation in place. Any work done without
regard or consultation with other trades, shall be removed by the contractor without additional
cost to the Client, to permit proper installation of all other work, as desired by the Architect
/Client.

3.1.7

Repair all damage done to the premises as a result of this installation and remove all debris
left by those engaged for this installation to the satisfaction of Client.

3.1.8

Cleaning of all plumbing and sanitary fixtures, testing and proving the satisfactory
performance of all fixtures at the time the building is handed over to the Client.

3.1.9

It is the responsibility of the contractor to take care of all the fixtu res fitted until the time of
handing over to the Client.

3.1.10 Painting of all concealed and exposed pipes as specified.

3.1.11 Assume full responsibility of all required applications and costs to connect to Industrial
board water mains, sewers and storm water drains, to the extent applicable to this
installation.
3.2.1 LICENSED PLUMBER
All work performed by the Plumbing and Sanitary Nominated Contractor shall be through licensed
plumbing supervisor possessing a valid Plumbing and Sanitary contractors license employing

220

Engineers, Technicians, Foremen, Plumbers, Masons, Helpers, etc., as required.

3.2.2 FEES, PERMITS AND NOTICES
Plumbing and Sanitary Nominated Contractor shall comply with all bye-laws and regulations of
local and other statutory authorities having jurisdiction over the works and shall be responsible for
the payment of all fees and other charges and giving and receiving of all necessary notices.
Plumbing and Sanitary Nominated Contractor shall keep the Employer / OE&PMC / Architects /
Consultants timely informed about regulations and requirements of statutory authorities and shall
obtain the final certificates of inspection and approval from the authorities.
3.2.3 DRAWINGS, SPECIFICATIONS & DEVIATIONS
The drawings and specifications lay down minimum standards of equipment and workmanship.
Should the Tenderer wish to deviate from the provisions of the specifications and drawings either
on account of manufacturing practice or from any other reasons, he should clearly draw attention
in his tender to the proposed points of departures and submit complete information on drawings
and specifications which will enable the consultants to evaluate the same on merits of the
deviations & come to a common conclusion. In the absence of any such deviation list, it will be
deemed that the Tenderer is fully satisfied with the intents of the specifications and the drawings
and their compliance with the statutory provisions and local codes. All any deviations or departures
not brought out to the notice of the consultants/clients shall be disregarded.
The tender drawings indicate the extent and general arrangement of the fixtures, drainage system,
etc. The drawings indicate the points of supply and termination of work shall be installed as
indicated in the drawings. However, any changes found essential to co-ordinate with this work and
other trades shall be made without any additional cost. The drawings and specifications are meant
for the assistance and guidance of the Plumbing and Sanitary Nominated Contractor, and exact
location, distance and levels will be governed by the individual building and site conditions.
Therefore, approval of the Employer/ OE & PMC/ Architects/ Consultants shall be obtained before
commencement of work on the following.
a.

Exact run and sizes of all piping on all floors and vertical stacks.

b.

Location of all mechanical equipment with layout and piping connections.

c.

Ground and invert levels of all drainage pipes together with location of all manholes and
connections up to outfall.

d.

Run of all water supply lines with diameters, location of control valves, access panels.

e.

Location of all mechanical equipment with layout and piping connections.

Plumbing and Sanitary Nominated Contractor shall provide six sets of catalogues, performance
data and list of spare parts together with the name and address of the manufacturer for all
electrical and mechanical equipment provided by him.
All Warranty Cards given by the manufacturers shall be handed over to the Employer/ OE &
PMC/ Architects/ Consultants.

221

3.2.4 TOOLS AND SPARE PARTS

All the tools and tackles, scaffolding and staging required for erection and assembly of the
installation covered by the contract shall be obtained by the Plumbing and Sanitary Nominated
Contractor himself. All other material such as foundation bolts, nuts etc, required for the installation
of the plant shall be supplied and included in the contract.
Tenderer shall include spares recommended by him for three years maintenance requirements
[commencing from the Date of Issue of the Certificate of Substantial Completion] for all items
covered by the specification.
3.2.5 MANUFACTURERS INSTRUCTIONS
Where manufacturers have furnished specific instructions relating to the materials used in this job
and methods of construction that are not specifically mentioned in these documents, such
instructions shall be followed in all cases. The Plumbing and Sanitary Nominated Contractor shall
also furnish six sets of the detailed instruction, operating and maintenance manuals including
detailed completion drawings and Fire Safety Plans on a bound copy to approved scale. Further it
is the responsibility of the Plumbing and Sanitary Nominated Contractor to train the Employer's/
Employers Authorized Representatives personnel in the operation and maintenance of the
system.
3.2.6

MATERIALS
Materials shall be of approved make and quality specified. They shall conform to the respective
Bureau of Indian Standards, British Standards Specifications, ASTM Standards and supported by
Manufacturing Certificate/ test certificate.
All materials shall be used as per the Technical specifications specified as well as relevant IS
Codes etc., and list of approved makes, however the final choice shall always remain with the
Employer/ OE & PMC/ Architects/ Consultants.
In any case of non-availability of materials in metric sizes, the nearest size of FPS units shall be
provided with prior approval of the Employer/ OE & PMC/ Architects/ Consultants at no extra cost.

3.2.7

GUARANTEE
The Plumbing and Sanitary Nominated Contractor shall guarantee both the material and
workmanship of first class quality corresponding to standard engineering practice for a period of 12
months from the date of issue of completion substantial. Any defective materials/ workmanship
shall be rejected and the Plumbing and Sanitary Nominated Contractor has to rectify/ replace at
his own cost. The Guarantee Certificates of the materials supplied shall be handed over to the
Employer/ OE & PMC/ Architects/ Consultants.

3.2.8 SHOP DRAWING, INSPECTION AND TESTING

3.2.8.1 Working and construction drawings
The Plumbing and Sanitary Nominated Contractor shall prepare shop drawings and all work shall
be according to approved working drawings. Shop drawings shall give all dimensions and shall
incorporate the requirements of the Employer/ OE & PMC/ Consultants. Approval of drawings
does not relieve the Plumbing and Sanitary Nominated Contractor of his responsibility to meet the
intents of the specifications. All such drawings for approval shall be submitted in 6 copies to the
222

OE & PMC/ Consultants. In addition, the Plumbing and Sanitary Nominated Sub-contractor shall
submit manufacturers details and get them approved before ordering. This has to be done
whether the materials/ equipment are one of the approved makes or not. The Plumbing and
Sanitary Nominated sub Contractor (PNSC) should make a mock up and get it approved from OE
& PMC/ Owners/ Architects/ Consultants before proceeding with the work in Full Scale.
3.2.8.2 Testing and Inspection
The Plumbing and Sanitary Nominated Contractor shall carry out tests on all different equipment
and system in total as specified in various sections of the tender in the presence of the Employer/
OE & PMC/ Architects/ Consultants in order to enable them to determine whether the plant,
equipment and installation in general comply with the specifications. All equipment shall be tested
after carrying out the necessary adjustments and balancing to establish equipment ratings and all
other design conditions. The test data shall be submitted in Acceptance Test Form.
3.2.8.3 Calibration of instruments and meters
Instruments required for testing shall be furnished by the Plumbing and Sanitary Nominated
Contractor for testing with initial requirements of all consumables. All the instruments, meters etc
to be used at site and on the system shall have a valid calibration certificate issued by the
competent authority. The Plumbing and Sanitary Nominated Contractor shall maintain and make
available all such calibration certificates.
3.3.

HANDING OVER REQUIREMENTS

The plant shall be submitted after satisfactory testing along with 6 sets of the following documents
submitted (HARD COPIES) along with 2 No,s CDs (Soft copy).
Detailed equipment data in the approved Performa

Manufactures maintenance and operating instructions manuals

Set of as built drawings, layouts, piping, ducting, cable routing, cable schedules etc

Approved test readings of all equipment and installations

Inspection certificates

Certificates of approval from statutory or Local Authorities for the operation and
maintenance of the installations, wherever such approval or certification is required. This
shall include Application filed along with enclosures and receipts of fees paid and deposits
made.

Warranty / guaranty certificate for all equipments

List of recommended spares together with list of suppliers and their contact details.

Certificate from the main civil contractor that he has cleared the site of all debris and litter
caused by him. However, Plumbing and Sanitary Nominated Contractor has also to
periodically clear the site from all the debris, which are generated from his part of scope.

223

Undertaking that all the materials supplied by him at site are fully tax paid and shall
produce all documentation for satisfaction of the Employer /OE&PMC / Architects /
Consultants or taxation authorities.

Submission of the above documentation shall form a precondition for final acceptance of the plant
and installation and final payments.
3.4.

STATUTORY APPROVALS INSPECTION

The Plumbing and Sanitary Nominated Contractor shall be fully responsible for meeting all the
statutory obligations and local inspectorates wherever applicable to the works carried out by them.
The Plumbing and Sanitary Nominated Contractor should prepare all working drawings and obtain
approval of competent authorities/consultants and also have the equipment and installation
inspected and got approved.
All documents for obtaining approval with fee and deposit towards statutory approval and
inspection paid against demand in writing from the appropriate authority will be reimbursed on
submission of original receipts. All other expenses for submission and approval of the various and
relevant statutory / bodies shall be embodied in the tender prices.
End of Section

4.0

SITE UTILITIES

4.1

UTILITIES TRENCHES

This specification establishes general criteria for efficient implementation of site utilities. The Plumbing
and Sanitary nominated sub contractor should coordinate with all other Nominated sub contractor to
complete trenches.
4.2

ALIGNMENTS AND GRADE

Drains are to be laid to correct alignment & grade shown in the drawings but subject to such
modifications as necessary to meet the requirements of the works. No deviations from the lines, depths
of cutting or gradients of Water supply, sewer Network & all, under scope of work as shown in the plans
and sections shall be permitted. If deviation is required then Prior Approval from the Employer/ OE &
PMC/ Architects/ Consultants is required in direction.
4.3

OPENING OUT TRENCHES

In excavating the trenches, the road metalling, pavement kerbing, etc., are to be placed on one side and
preserved for reinstatement and the trench or other excavation shall be filled up and laid back to original
condition at no extra cost. Before any road metal is replaced, it shall be carefully shifted. The surface of
all trenches and holes shall be restored and maintained to the satisfaction of the Employer/ OE & PMC/
Architects/ Consultants. The Plumbing and Sanitary Nominated Contractor shall not cut or break down
any live fence or trees in the line of the proposed works but shall tunnel under them unless the Employer/
OE & PMC/ Architects/ Consultants orders the contrary. The Plumbing and Sanitary Nominated
Contractor shall scrub and clear the surface over the trenches and other excavations of all stumps, roots
and other encumbrances affecting execution of work and shall remove the same from the site to the
approved dumping yards by local Authorities

224

4.4

EXCAVATION TO BE TAKEN TO PROPER DEPTH

Trenches shall be excavated in all conditions of soil and to such a depth that the sewers / or other pipes
shall rest as described in the several clauses relating thereto and so that the inverts may be at the levels
given on the section should the Plumbing and Sanitary Nominated Contractor excavate the trench to a
greater depth than is required the extra depth shall have to be filled up with concrete at the Plumbing and
Sanitary Nominated Contractors own cost to the requirements and satisfaction of the Employer/ OE &
PMC/ Architects/ Consultants.
4.5

REFILLING

After the sewer or other piping work has been laid and proved to be water-tight, the trench or other
excavation shall be refilled. Utmost care shall be taken in doing this so that no damage is caused to the
sewer and other permanent works.
4.6

BACK FILLING OF TRENCH (IS: 12288)

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 bottom level of trench to the level of the centerline of the pipe
ZONE B: From the level of the center line of the pipe to a level 30 cm above the top of the pipe, and
ZONE C: From a level 30 cm to the top of the trench by Good Earth.
4.6.1. BACKFILL MATERIALS
All backfill materials shall be free from cinders, ashes, slag, refuse, rubbish, vegetable or organic
materials, lumpy or frozen materials boulder, rocks or stone or other materials which in the opinion of the
Employer/OE&PMC/Architects/Consultants, is unsuitable & deleterious. River sand or good earth, can be
used for filling in zones A & B. However, material containing stones up to 20mm as their greatest
dimension may be used in zone C only unless otherwise specified by the Owner/ Employer / consultants.
Where excavated material is considered by the Employer/OE&PMC/Architects/Consultants as not
suitable for back filling, clean river sand shall be used for the same.
4.6.2. BACK FILL SAND
River sand used for back fill shall be natural sand complying with paragraph 5.6.1 graded from fine to
coarse. The total weight of clay in it shall not exceed 10 percent. All material shall pass through a sieve
of aperture size 20mm (IS-2405) and not more than 5 percent shall remain on IS sieve of aperture size
6.30mm.
4.6.3. BACK-FILL GRAVEL
Gravel used for back fill shall be natural gravel and having durable particles graded from fine to coarse in
a reasonably uniform combination with no boulders or stone larger than 50mm in size. It shall not contain
excessive amount of loam and clay and not more than 15 percent shall remain on a sieve of aperture
size 75 micron.

Back filling in zone A shall be done by hand with river sand, fine gravel or other approved
materials placed in layers of 8cm and compacted by tamping. The back filling material shall be

225

deposited in the trench for its full width of each side of the pipe, fittings and appurtenances
simultaneously.

Back-filling in zone B using fine selected material shall be done by hand or approved mechanical
methods using the fine excavated material special care being taken to tamping and to avoid
injuring or moving the pipe. If excavated material is not suitable, the type of back-fill material
shall be as per section 5.6.

Back filling in zone C shall be done by hand or approved mechanical methods and well
compacted. Selected good earth having stones of size not exceeding 20mm can be used for
zone C. If the excavated earth is unsuitable for back fill the filling material shall be as in section
5.6.

4.6.4. Backfill With Excavated Materials

Where the excavation is made through permanent pavements, curbs, paved footpaths, or where
such structures are undercut by the excavation, the entire back fill to the sub-grade of the
structures shall be made with sand or cement concrete in accordance with paragraph 5.6.1. The
method of placing and consolidating the back fill material shall be as in section 5.6
4.7

CONCRETE SLABS OVER PIPES

When pipes are laid under roads and pavements subjected to heavy traffic loads the trenches
may be covered with reinforced concrete slabs of suitable dimension, supported on edges to
relieve the load on pipes to the adjoining earth as mentioned in the drawing.

4.8

SITE CLEANING ON COMPLETION OF WORK

All surplus pipes and fittings, valves, etc., and all tools and temporary structures shall be
removed from the site as suitable to contractor himself. All dirt rubbish and excess earth from
the excavation shall be removed and transported and disposed to approved dumping yards by
local authorities and the construction site left clean to the satisfaction of the Employer/ OE &
PMC/ Architects/ Consultants.

4.9

PLUMBING AND SANITARY NOMINATED CONTRACTOR SHALL RESTORE SETTLEMENT

AND DAMAGES
The Plumbing and Sanitary Nominated Contractor shall at his own cost make good promptly,
during the whole period that the works are in hand, any settlement that may occur on the
surfaces of roads, beams, footpaths, gardens, open spaces, etc. whether public or private
caused by his trenches or his other excavations and he shall be liable for any accidents caused
thereby. He also shall, at his own expense and charge, repair and make good any damage done
to the buildings and other properties.

4.10 DISPOSAL OF SURPLUS SOIL

The Plumbing and Sanitary Nominated Contractor shall at his own cost dispose all surplus
excavated materials outside the site at the dumping yards approved by local Authorities.

226

4.11 TIMBERING
The Plumbing and Sanitary Nominated Contractor shall at all times support efficiently and
effectively the sides of trenches and other excavations by finest selected timbering, piling,
sheeting material, etc., at his own cost. The trenches shall be closed in timbered at loose or
sandy strata and below the surface of the sub-soil table. All timbering, sheeting and piling with
their walls and supports shall be of adequate dimensions and strength and fully braced and
strutted so that there is no risk of collapse or subsidence of the walls of the trench. The
Plumbing and Sanitary Nominated Contractor shall be held accountable and responsible for the
adequacy of all timbering, bracing, sheeting and piling used and for all damages to persons and
property resulting from the improper quality, strength, placing, maintenance, or removing of the
same.
4.12 REMOVAL OF WATER
The Plumbing and Sanitary Nominated Contractor shall at all times during the progress of work
keep the trenches and excavations free from water at his own expense which shall be disposed
off by him in a manner as will neither cause injury to public health nor to public or private
property, to the work completed or in progress, to the surface of any roads or streets and cause
any interference with the use of the same.
4.13 TRENCH WIDTH
The width of excavated trenches shall be as per the table given below:
Width at bottom
Excavation upto:

Up to 100 mm

Up to 150 mm

Up to 300 mm

dia pipe

dia pipe

dia pipe

900 mm depth

300 mm

300 mm

600 mm

900 to 1500 mm depth

600 mm

600 mm

900 mm

1500 to 3000 mm depth

750 mm

750 mm

1100 mm

3000 to 5000 mm depth

900 mm

1000 mm

1300 mm

4.14 PROTECTION OF EXISTING SERVICES

All pipes, water mains, cables, etc. met with during the course of excavation shall be carefully
protected and supported.
4.15 ROAD CROSSINGS
All pipelines laid below roads shall be taken through suitable underground trenches/RC pipes.
The size of trenches /RC pipes shall be as per drawings.
4.16 CONSTRUCTION ACROSS ROADS
All works across roads shall be carried out as per layout given in the drawings given.

227

5.0 WATER SUPPLY SYSTEM

5.1 CHLO RINAT ED PVC PIPES ( CPVC)

Scope
This specification covers requirements, test methods and methods of marking for chlorinated
poly vinyl chloride plastic hot-and cold-water distribution system components made in one
standard dimension ratio and intended for water service. These components comprise pipe and
tubing, socket-type fittings, street fittings, plastic-to-metal transition fittings, solvent cements, and
adhesives. Requirements and methods of test are included for materials, workmanship,
dimensions and tolerances, hydrostatic sustained pressure strength, and thermo-cycling
resistance. The components covered by this specification are intended for use in hot and cold
potable water distribution systems.
Referenced Documents
ASTM Standards:
D 1598 Test Method for Time-to-Failure of Plastic Pipe Under Constant Internal Pressure
D1399 Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing and
Fittings.
D1784 Specification for Rigid PoIy (VinyI Chloride) (PVC) Compounds and Chlorinated
Poly(Vinyi Chloride) (CPVC) Compounds
D 1898 Practice for Sampling of Plastics
D2122 Test Method for Determining Dimensions of Thermoplastic Pipe and Fittings2
D2444 Test Method for Impact Resistance of Thermoplastic Pipe and Fittings by Means of a
Tup (Failing Weight)2
D2837 Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials2
F 402 Practices for Safe Handling of Solvent Cements, Primers, and Cleaners Used for Joining
Thermoplastic Pipe and Fittings2
F 412 Terminologies Relating to Plastic Piping Systems
F 493 Specification for Solvent Cements for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic
Pipe and Fittines2
ANSI Standards:
ANSI B2.I-1968 Pipe Threads
ANSI Z17.1-1958 Preferred Numbers4
Federal Standard:
Fed. Std. No. 123 Marking for Shipments (Civil Agencies)5
Military Standard:
MIL-STD-129 Marking for Shipment and Storage
NSF Standards:
Standard No. 14 for Plastic Piping Components and Related Materials6
Standard No. 61 for Drinking Water Systems ComponentsHealth Effects

228

Classification
Pipe, Tubing, and FittingsThis specification classifies CPVC 4120 pipe, tubing, and fittings by
a single standard dimension ratio which shall be SDR II, by a maximum continuous use
temperature which shall be 1800F [820C] and by nominal pipe or tubing diameters from 3/8
in.[9.5 mm] through 2 in. [50 mm].
Plastic-to-Metal Transition FiningsThis specification classifies CPVC plastic-to-metal transition
fittings intended for use up to and including 1800F [820C] as CPVC-I800F on the basis of
resistance to failure by thermo-cycling.
Solvent Cements and Adhesives This specification classifies solvent cements and adhesives
meeting the requirements contained herein as CPVC Solvent Cement or CPVC Adhesive.
Dimensions and Tolerances:
Wall MinimumsTable 2 of IS 15778- 2007 show wall thickness minimums. Calculated SDR 11
tubing wall thicknesses that fall below 0.068 in. [1.73 mm] shall be arbitrarily increased to that
value. Calculated SDR 11 fitting wall thicknesses that fall below 0.102 in. [2.59 mm] for the fitting
socket bottom, or 0.I28 in. [3.25 mm] for the fitting body, shall be arbitrarily increased to these
values.
CPVC Solvent Cements:
Note 6CPVC solvent cements may exist which meet the requirements of the specification
when used in accordance with the manufacturer's recommendations, without a primer or
cleaner. It is recommended that those CPVC solvent cements which may be used without a
primer or cleaner be dear or yellow in color. Otherwise, it is recommended that CPVC solvent
cement requiring the use of 3 primer or cleaner be orange in color. Color identification is
recommended to facilitate cement recognition to prevent the misuse of the cement and to the
minimize the unintentional use of other cements that may fail at elevated service temperatures.
GeneralCPVC solvent cements, for use in CPVC 41, plastic-to-plastic, socket-type joints shall
meet the requirements set forth in Specification F 493.
Hydrostatic Burst Strength2-in. [50-mm] CPVC solvent cement joints shall exceed the
minimum hydrostatic burst strength requirements given in Table 6 after a maximum drying
interval of 2 h when tested in accordance with 10.1.3, Failure to pass the burst requirement at
either temperature is cause for rejection.
Hydrostatic Sustained Pressure Strength-in. [I5-mm] CPVC solvent cement joints shall meet
the requirements of 6.2 when tested in accordance with 9.3.
Safe Handling of Solvent CementRefer to Practice F402.
CPVC Adhesives:
CPVC adhesives (other than CPVC solvent cement), shall qualify for use in CPVC socket-type
joints by a rigorous simulated use testing program as further defined in 7.2.2 and 7.2.3. CPVC
adhesives shall be tested in the largest size joint and in the exact type of joint for which they are
intended; that is, 2-in. [50-mm] plastic-to-metal or 2-in. [50-mm] plastic-to-plastic.
Workmanship, Finish, and Appearance
The pipe shall be homogeneous throughout and essentially uniform in color, opacity, density,

229

and other properties. The inside and outside surfaces shall be semi-matte or glossy in
appearance (depending on the type of plastic) and free of chalking, sticky or tacky material. The
surfaces shall be free of excessive bloom, that is slight bloom is acceptable. The pipe walls shall
be free of cracks, holes, blisters, voids, foreign inclusion, or other defects which are visible to the
naked eye and which may affect the wall integrity. Holes deliberately placed in perforated pipe
are acceptable. Bloom or chalking may develop in pipe exposed to direct rays of the sun
(ultraviolet radiant energy) for extended periods and consequently these requirements do not
apply to pipe after extended exposure to direct rays of the sun
5.2 TESTING
Before any pipes are painted or covered, they shall be tested to a hydrostatic pressure of
7kg/sqcm. Or 1.5 times the working pressure of the pumping main whichever is greater.
Pressure shall be maintained for at least eight hours without an appreciable drop in pressure. In
addition to the sectional testing of water supply pipes, the contractor shall test the whole
installation to the entire satisfaction of the Engineer in charge. He shall rectify any leakages,
failure of fittings or valves at his cost.
5.3

MODE OF MEASUREMENT
Pipes above ground shall be measured along the centre line of the pipes and fittings. The quoted
rate for respective item shall be per Rmt and shall include the following:
Cost of respective pipes and specials.
Laying, fixing and jointing with standard pipe clamps available for different sizes inside the wall
chase and fixed on MS angle iron brackets and GI U clamps for pipes in ducts as shown on the
drawing.
Cutting holes and chases in walls, floors, etc. and making good the same.
All supporting arrangements, brackets, etc.
Testing and making good the defects, if any. pipes below ground shall be measured.

5.4 SPACING FOR PIPES SUPPORTS

Pipe work shall be properly supported with clamps, hangers, saddles, anchors and brackets as
required to avoid strain on equipment connections and designed by the Contractor and approved
by the client / consultants. Pipe work layouts shall take into consideration any expansion and
contraction in pipes and include expansion joints where necessary.
Pipe supports shall be steel, adjustable for height and primer coated with rust preventive paint.
Where pipes and pipe supports are of dissimilar materials De-Zincified Resistance (DZR)
fittings shall be used.
5.5 ACCESSORIES
Pipe line accessories such as unions, pressure or temperature test plugs, flow sensors, gauges,
flexible connectors, etc., shall be employed as appropriate to assure a well-functioning, easy-tomaintain system.

230

Expansion joints or expansion loops shall be installed on long, straight runs to compensate for
thermal expansion of the pipe whenever the calculated expansion is 1/8 inch or more. Spacing
and location shall be based on the maximum probable temperature fluctuation and the thermal
co-efficient of the pipe material.
Pipeline identification labels shall be ANSI-approved with color code as recommended by OSHA,
of a size proportional to the pipe diameter, and shall clearly identified pipe contents (i.e., Water
is not acceptable, as it could be portable water, recycled water, etc.,) and the direction of flow.
Labels shall be easily readable. Labels shall be installed at intervals of 15 feet maximum on
straight runs, near each sectional valve, near major branch take-offs, near each sectional valve,
near major branch take-offs, near connection points to equipment, and at each side of
penetration through a wall.
5.6 SUPPORTS
For parallel pipe runs, trapeze type supports shall be spaced to suit the smallest pipe in the
group. Spare room for possible future pipe lines should be reserved. Hanger spacing shall also
be coordinated with supporting steel overhead. Hangers shall be of sufficient strong to support
the pipes and contents plus 85 Kgs. Metallic pipes must not be in direct contact with hangers
and supporting structures. Spacing of pipe supports shall not exceed the following dimensions:
Pipe Size

Spacing between Supports

Up to l2mm

1.5 meter

15 to25mm

2.5meter

32 to 150 mm
150 mm and over

2.5 meter
3.0 meter

Vertical risers shall be parallel to walls and column lines and shall be straight and plumb. Risers
passing from floor to floor shall be supported at each floor by approved clamps or collars
attached to pipes and with 15mm thick rubber pads or other equal and approved resilient
material. Where pipes pass through terrace floors, suitable flashings shall be provided to prevent
water leakage. Risers shall have approved clean-out holes at low points and air vents at high
points. Supports shall also be provided at all change in directions & at all pipe junctions.
5.7 Laying, joining, curing
Where pipes have to be cut or rethreaded, ends shall be carefully filed out so that no obstruction
to bore is offered. For internal work all pipes and fittings shall be fixed truly vertical and
horizontal, either by means of standard pattern holder bat clamps keeping the pipes (12mm)
clear of the wall everywhere or concealed as directed.
For external work, GI pipes and fittings shall be laid in trenches. The width of the trench shall be
the minimum width required for working. The top level of pipes laid underground shall not be less
than 60 cms from the finished ground level. The work of excavation and refilling shall be done as
specified elsewhere, or concealed as directed.
Follow manufacturers' instructions for all related products.
231

Cut pipe square.

As joints are sealed at the base of the fitting socket. An angled cut may

result in joint failure.

Acceptable tools include miter saw, mechanical cut off saw or wheel cutter. Wheel type
cutters must employ a blade designed for plastics.

Remove all burrs from inside and outside of pipe with a knife-edge, file, or de-burring tool.
Chamfer (bevel) the end of the pipe 10 -15

Remove surface dirt, grease, or moisture with a clean dry cloth.

With light pressure, pipe should go one half to one third of the way into the fitting socket.
Pipe and fittings that are too tight or too loose should not be used.

Use an applicator that is one half the pipe diameters. Too large an applicator will force
excessive cement into the inside of small diameter fittings. Too small an applicator will not
apply sufficient cement to large diameter systems.

Recommended initial set times Apply a full even layer of cement to the outside of a pipe and
medium layer of cement to inside of a fitting. Assemble pipe and fitting socket until it contacts
socket bottom. Give pipe a quarter turn. Hold pipe and fitting together until the pipe does not
back out. See table for recommended cure times. Remove excessive cement from the exterior.
A properly made joint will show a continuous bead of cement around the perimeter.
5.8 Testing Pressure System
Prior to testing, safety precautions should be instituted to protect personnel and property in case
of test failure. Conduct pressure testing with water. DO NOT USE AIR OR OTHER GASES for
pressure testing.
The piping system should be adequately anchored to limit movement. Water under pressure
exerts thrust forces in piping systems. Thrust blocking should be provided at changes of
direction change in size and at dead ends.
The piping systems should be slowly filled with water, taking care to prevent surge and air
entrapment. The flow velocity should not exceed 1 foot per second.
The piping system can be pressurized to 125% of its designed working pressure. However care
must be taken to ensure the pressure does not exceed the working pressure of the lowest rated
component in the system (valves, unions, flanges, threaded parts etc). The pressure test should
not exceed one hour. Any leaking joints or pipe must be cut out and replaced and the line
recharged and retested using the same procedure. All trapped air must be slowly released.
Automatic air vents must be provided at highest elevation of the piping system such that any air
entrapped can be easily removed from the system.
5.9 COLOUR CODE FOR WATER SUPPLY PIPES
Color code for water supply pipes shall be as per standard requirement. Details are as mentioned
below.

232

COLOUR CODE FOR GENERAL SERVICES

Sl
no

DESCPRITION

GROUN
D

FIRST
COLOUR

SECOND

COLOUR

BAND

COLOUR
BAND

WATER

1.0

Cooling

Sea
green

2.0

Boiler feed

Sea
green

3.0

Condensate

Sea
green

Light brown

4.0

Drinking

Sea
green

French blue

5.0

Treated

Sea
green

Light orange

6.0

Cold water from storage

tank.

Sea
green

French blue

French blue

Signal red

Canary
yellow

End of Section

233

6.0 SOIL, WASTE, RAIN WATER PIPES & SEWER APPURTENANCES

6.1 SCOPE OF WORK
Work under this section consists of furnishing all labor, materials, equipment and appliances
necessary and required to completely install soil, waste, vent pipes and rain water as required by
the drawings, specified herein after and given in the bill of quantities.
Without restricting to the generality of the foregoing, the soil waste and vent piping system shall
include the following: Vertical and Horizontal Soil & Waste PVC pipes and fittings, joints,
clamps and connections to fixtures.
Connection of all pipes to sewer lines as shown on the drawings.
Floor and urinal traps cleanout plugs and inlet fittings.
Testing of all pipelines.
6.2 GENERAL REQUIREMENTS
Materials shall be of the approved make and quality specified. They shall conform to the
respective Bureau of Indian Standards Specifications and supported by Manufacturing test
certificate.
Pipes and fittings shall be fixed truly aligned to vertical, horizontal or on slopes as required for
proper functioning of the system.
Pipes shall be fixed in a manner as to provide easy accessibility for repair and maintenance and
shall not cause obstruction in shafts, passages etc.
Pipes shall be fixed securely to walls and ceilings by suitable clamps at intervals specified.
Access door for fittings and cleanouts shall be so located that they are easily accessible for
repair and maintenance.

6.3 POLYVINYL CHLORIDE (UPVC) PIPES AND FITTINGS

M AT ERIAL
PVC (SWR) class pipes of Type B for use in soil and waste water and conforming to IS 13592:
1992, shall be used. The pipes shall be supplied in nominal lengths of 2, 3, and 4 or 6 meters,
tolerance on specified lengths shall be +10mm and 0mm. Any physical test requirements shall
be as per IS13592-1992.

PVC (SWR) class pipes of Type A for use in rain water and conforming to IS 13592: 1992, shall
be used. The pipes shall be supplied in nominal lengths of 2, 3, and 4 or 6 meters, tolerance on
specified lengths shall be +10mm and 0mm. Any physical test requirements shall be as per
IS13592-1992.
HANDLING
Because of their light weight, there may be a tendency for the PVC pipes to be thrown much
more. Reasonable care should be taken in handling and storage to prevent damage to the
pipes. Contractor should hold the fullest responsibility in this case. On no account the pipes
should be dragged on the ground. Pipes should be given adequate supports at all times.
234

LAY ING
The PVC pipes shall be laid under the floors below slab or on walls either buried or exposed as
the case may be, as shown in the drawings. The minimum thickness of fittings shall be of 3.2
mm. the fittings shall be of injection mould type with solvent cement joint or rubber ring joint. The
pipes and fittings shall be capable of withstanding suns rays. PVC pipes laid below slab or
suspended in ceiling shall be supported by angle brackets / supports as detailed in the drawings.
After laying and testing the pipe , the bores shall be packed and grouted with CM1:4 with water
proofing compound & finish surface water tight.
JO INT ING
The jointing of pipes to fittings shall be done as per the manufacturers instructions /
recommendations.
The PVC pipes and fittings shall be joined with Solvent Cement and jointing shall be carried out
as follows:
1. Cut the spigot end of the pipe square.
2. All burrs from the internal and external surfaces should be removed.
3. The spigot should be marked with a pencil line and a distance equivalent to the socket
depth. Clean the surface within the marked area.
4. Apply uniform coat of solvent cement on the external surface to the pipe and a lighter
coat on the internal surface of the fitting.
5. Insert the pipe end into the socket of the fitting and push it in upto the mark.
Remove the excess solvent cement and hold the joint firmly in position for 30seconds to dry.
Gluing should be avoided in a rainy or foggy weather.
The other method of jointing shall be by rubber rings. The material of rubber ring should conform
to IS 5382-1969.The ring is housed in groove formed in a plastic or metallic housing. The rubber
is compressed and makes a seal between the pipe and housing. Lubricating paste should be
applied before compressing the rubber. Where natural rubber rings are used, mineral oil or
petrol or grease should be used.
T EST ING
PVC pipes and fittings shall be tested in accordance with IS 13592 - 1992. The openings of the
pipes shall be sealed for the section to be tested. The water pressure of 0.5Mpa (50.98 m of
h2o or 5.98 kg/cm2) shall be maintained for a maximum of one hour. The Engineer-in-Charge
shall examine carefully all the joints for leakage.
M O DE O F M EASUREM ENT
PVC Pipes shall be measured along the centerline of the pipeline including the specials in
running meter (Rm.) between:
a)

Chambers: Shall be recorded from the inside of one chamber to inside of another

chamber.
b)

Gully trap and Chamber: Shall be recorded between socket pipe near gully trap and

inside of chamber.

235

The quoted rate shall include the following:

i)

The cost of pipes, specials and other jointing materials.

ii)

Laying, jointing and curing.

iii)

Testing and making good the defects, if any.

PVC PRESSURE PIPES AND FIT T ING S

The PVC pressure pipes and fittings shall be used for conveying waste water from wash basins,
kitchen sinks, floor drain connecting to washing machines, etc.
The pipes shall be class 3, 6 Kg/cm2. PVC pipes and fittings shall be jointed with solvent
cement. The pipes shall conform to IS 4985. Fittings shall be of injection moulded PVC
conforming to IS 7834.
LAYING AND FIXING
Pipes shall be cut to size and chamfered well. Burrs if any shall be removed. Pipes and fittings
shall be jointed using solvent cement. The pipes and fittings shall be jointed accurately without
any stress to achieve leak proof joints.
TESTING
The method which is commonly in use is filling the pipe with water, taking care to evacuate any
entrapped air and slowly raising the system to the test pressure at 3Kg/cm2. The pressure
testing may be followed as follows. The field test pressure to be imposed should be not less
than the greatest of the following:

One and half times of maximum sustained operating pressure.

One and half times the maximum pipe line static pressure.

Sum of the maximum sustained operating pressure and the maximum surge pressure.

Sum of the maximum pipe line static pressure and the maximum surge pressure, subject to
a maximum equal to the works test pressure for any pipe fittings incorporated.

The field test pressure should wherever possible be not less than 2/3rd working pressure
and should be applied and maintained for at least four hours. If the visual inspection
satisfies that there is no leakage the test can be passed.

6.4 SEWER APPURTENANCES

MANHOLE, INSPECTION CHAMBERS, STORM WATER GULLIES ETC.
MANHOLE:
Where depth of sewer exceeds 1.5m, circular conical manholes shall be provided. Various types
and sizes of the manholes are specified for different depths typical drawing of various types of
manholes shall be supplied to the successful bidder. In the absence of such drawings the
standard drawings of the CPWD or local body, if available, shall be followed. Manholes and
inspection chambers which are provided on roads or where heavy vehicular traffic is expected
are provided with heavy duty Pre cast concrete (heavy Duty) air tight frame and cover. For those
236

built on foot paths, carriage drives and cycle tracks, medium duty covers are provided. For
locations within premises or areas not subjected to wheel traffic loads they shall be provided
Medium duty cover.
The manhole are categorized into 4 types
Type

Base
dia
in
m

Top
dia
in
m

Depth
manhole

of

MH
type-01

1.2

0.6

Upto 2.5

MH
type-02

1.2

0.6

2.5 to 4.5

MH
type-03

1.5

0.6

4.5 to 6.5

MH
type-04

1.5

0.6

More than 6.5

in m

INSPECTION CHAMBERS:
Where depth of sewer is less than 1.5m rectangular chambers shall be used having size as
specified. Usual sizes are 600 x 450 or 600 x 600 or 600 x 900 or 1200 x 1200. These shall be
constructed in the sewer line at such places and dimensions as indicated on the drawing sizes
specified shall be clear internal dimensions of the chamber.
STORM WATER GULLIES
Storm water gullies shall be constructed for admitting storm water from the open land area. It is
constructed of specified size and is provided and pre-cast RCC or CI grating on top of admitting
storm water run off into it. A typical drawing shall be provided to the successful bidder giving all
details of construction to the successful bidder.
LOCATION AND SIZES
The size indicated in the drawings shall be the internal size of chamber. Unless otherwise
specified, manholes and inspection chambers are provided at all changes of direction of drains
and where branch drain meets the main drain. Chambers shall be of such size as to allow
necessary examination and clearance of drains. The minimum internal sizes shall be taken as
per detail drawings, standards specified and local byelaws if any. In the absence of local
byelaws, the requirements stipulated in IS 4111 (Part I) Code of Practice for Ancillary Structures
on Sewage System shall be followed. The work shall be done strictly as per standard drawings
and the following specifications:
BED CONCRETE
Bed concrete shall be in 1:4:8 cement concrete 150 mm thick for inspection chambers, 230 mm
for depths upto 2.1 m and 300 mm for greater depths in case of manholes or as per prevailing.
BRICK MASONRY/BLOCK MASONRY
Brick / Block work shall be with best quality table moulded bricks/blocks in 1:6 cement mortar as
237

per specification. Bricks shall be soaked in water prior to using the sand bricks/blocks used shall
be true to size & shape & any under burnt or over burnt bricks not be used for construction.
PLASTER
Inside walls of chambers/manholes shall be plastered with 15mm thick cement plaster 1:3
mixed with waterproofing material and finished smooth with a floating coat of neat cement.
External walls shall be plastered in CM 1:3 and sponge finished.
BENCHING
Channels and benching shall be done in cement concrete 1:3:6 rendered smooth with neat
cement. The following sizes of channels for the bench shall be adopted:
Size of Drain

Depth of Centre

Depth at sides i.e, atwalls

100 mm (4")

150 mm (6")

250 mm (10")

150 mm (6")

200 mm (8")

300 mm (12")

CHAMBER/MANHHOLE COVERS
Covers shall be of heavy / medium duty cast iron with lifting hooks as per IS 1726 - 1974 and as per
the details given in the drawings and fixed on CI frame embedded in concrete. These covers shall
depend upon the location of usage Covers placed on the frames shall be air tight. The height of frame
and cover shall be as per bill of quantities. Pre cast RCC frame and cover to withstand fire truck
load.
STEPS
CI steps duly painted shall be provided wherever the depth of the manhole/chamber
is more than 1.2M. Steps shall be arranged in a staggered manner as per drawings.
DROP CONNECTIONS
In case the difference in invert levels between the main drain and the branch line requires a
drop more than 600 mm, a drop connection should be provided with a cast iron or stoneware
four way junction, fixed at right angles to the drop pipe at the level where the branch pipe
enters the manhole. Access for cleaning the bend should be provided at finished ground level.
GULLY TRAP CHAMBERS
Stoneware gully traps of specified size shall be provided as per IS 651. It shall be fixed on 15
cm. thick and 70 cm square 1:4:8 cement concrete bedding and the gully outlet shall be
jointed similarly to the jointing of HDPE pipes. A brick masonry chamber 300 x 300 mm
(internally) shall be constructed in 1/2 brick masonry with 1:6 cement mortar and the spaces
between the trap and the wall shall be filled up with 1:3:6 concrete and the upper portion of the

238

chamber shall be finished with neat cement. The corners and bottom of the chamber shall
be rounded off so as to slope towards the grating and the bottom of the chamber shall not be
less then 230 mm. In addition to 150mm x 150mm CI grating, the chamber shall have a CI
frame cover (300mm x 300 mm). It shall then be placed on top of the brick masonry.
PVC FLOOR TRAPS
The PVC floor trap shall be of P Trap with top boss connection for multi-inlet type. The floor
trap shall be deep seal type with an effective seal of minimum 40mm. The waste from sanitary
fixtures shall be directly discharged to the floor trap. Jointing of the waste pipe to the floor trap
shall be done as per manufacturer's instructions. The height riser fitting shall be made use of,
wherever the floor drain is located in deep-sunk floors or is suspended from the ceiling..
The floor trap shall be provided with 100 x 100mm square cast CP or stainless steel grating
with rim of approved design. Minimum thickness of the grating shall be 4 to 5mm.
URINAL TRAP
The urinal trap shall be shall be of P Trap with top boss connection for multi-inlet type. The traps
shall be deep seal type with an effective seal of minimum 75mm. The outlet from urinals after the
trap shall be directly discharged to the floor trap. The floor trap shall be provided with 150 x 150mm
SS or cost bronze chrome plated frame with screw type cover for airtight fitting. Frame and cover
shall be of a make and model approved by the Employer/OE&PMC/Architects/Consultants.
MODE OF MEASUREMENT
INSPECTION CHAMBERS
Inspection chambers shall be measured in numbers and the rate quoted shall also be per
number only. The quoted rate shall include the cost of all the following items:

Bed concrete.
Brick work.
Plastering shall be of both internal and external faces.
Concrete benching channeling.
Inspection chamber cover and frame including PCC bed for fixing the
frame.
Providing holes and embedding pipes for all connections.
Excavation, refilling, necessary dewatering and disposing off extra material
to a place as directed by the Engineer.
Curing,
Testing.

MANHOLE
Manholes shall be measured in numbers. The depth of a manhole shall be reckoned from
the invert of the channel to the top of manhole cover. Quoted rates shall cover the range of +/240 mm on the depth specified and also the cost of all the following items:

Bed concrete.

Brick work.
239

Plastering shall be of both internal and external faces

Concrete benching and channeling including drop connections.

Supply and fixing C.I. steps.

Providing holes and embedding pipes for all connections.

Excavation, refilling, necessary dewatering and disposing off extra material to a place as
directed by the Engineer.

Curing.

Cost of frame and CI cover and embedding the frame in a concrete bed.

Testing.

GULLY TRAP CHAMBER

Gully trap chambers shall be measured in numbers and the rate quoted shall also be per
number only. The quoted rate shall include the cost of all the following items:

Bed concrete.

Brick work.

Plastering shall be of both internal and external faces

Gully trap and grating.

Concrete to embed the gully trap.

Chamber cover and frame.

Providing holes and embedding pipes for all connections.

Excavation, refilling, necessary dewatering and disposing off extra.

Cement Concrete Pipes:

The pipes shall be with or without reinforcement as required and of the class NP2 as specified.
These shall confirm to IS 458-1961. The reinforced cement concrete pipes shall be manufactured
by centrifugal (or spun) process. All pipes shall be true to shape, straight, perfect sound and free
from cracks and flaws. The external and internal surface of the pipes shall be smooth and hard. The
pipes shall be free from defects resulting from imperfect grading of the aggregate, mixing or
molding.

Laying of pipes:
Loading, transporting and unloading of concrete pipes shall be done with care. Handling shall be
such as to avoid impact. Gradual unloading by inclined plane or by chain block is recommended. All
pipe sections and connections shall be inspected carefully before being laid. Broken or defective
pipes or connections shall not be used. Pipes shall be lowered into the trenches carefully.
Mechanical appliances may be used. Pipes shall be laid true to line and grade as specified. Laying
of pipe shall proceed upgrade of a slope.

240

If the pipes have spigot and socket joints, the socket end shall face upstream. In the case of pipe
with joints to be made with loose collars. The collar shall be slipped on before the next pipe is laid.
Adequate and proper expansion joints shall be provided where directed.
In case where the foundation conditions are unusual such as in the proximity of trees or holes, under
existing or proposed manholes etc., the pipe shall be encased all round in 15cm thick cement
concrete 1:5:10 (1 cement, 5 fine sand, 10 graded stone aggregated 40mm nominal size) or
compacted sand or gravel.
In cases where the natural foundation is inadequate the pipes shall be laid either in concrete suitably
designed structure as specified. If a concrete cradle bedding is used the depth of concrete below the
th

bottom of the pipe shall be at least 1/4 of the internal dia and shall extend up to the sides of the
pipe at least to a distance of of the outside diameter of pipes 300 mm and in dia.. The pipes laid in
trenches in earth shall be bedded evenly and firmly and as far up the haunches of the pipe as to
safely transmit the load expected from back fill through the pipe to the bed. This shall be done either
by excavating the bottom of the trench to fit the curve of the pipe or by compacting the earth under
around the curve of the pipe to form an even bed. Necessary provision shall be made for joints
wherever required.
When the pipe is laid in the trench in rock, hard clay, or other hard material, the space below the
pipe shall be excavated and replaced with an equalizing bed of concrete, sand or compact earth. In
on place shall pipe be laid directly on such hard material.
When the pipes are laid completely above the ground the foundations shall be made even and
sufficiently compacted to support the pipe line without any material settlement. Alternatively the pipe
line shall be supported on PCC saddle blocks. Similar arrangement shall be made to retain the pipe
line in the proper alignment, such as by shaping the top of the supports to fit the lower part of the
pipe, the distance between the supports shall be no case exceed the length of the pipe. The pipe
shall be supported as far as possible close to the joints. In no case shall the joint come in center of
the span. Care shall be taken to see that superimposed loads greater than the total load equivalent
to the weight of the pipe when running full shall not be permitted.
JOINTS OF PIPES :
Joints are generally of rigid type. When specified flexible type joints may also be provided.
SPIGOT AND SOCKET JOINT (RIGID) :
The spigot of each pipe shall be slipped home well in to the socket of the pipe previously laid and
adjusted in the correct position. The opening of the joints shall be filled with stiff mixture of cement
mortar in the proportion 1:2 (1 cement, 2 fine sand) which shall be rammed with caulking tool.
After a days work any extraneous material shall be removed from the inside of the pipe and the
newly made joint shall be cured.
End of Section

241

7.0 VALVES, STRAINERS AND PRESSURE GAUGES

GENERAL
This section deals with different type of valves like butterfly valves, gate valves, ball valves, check
valves, balancing valves and Strainers and pressure gauges. The Plumbing and Sanitary
Nominated Contractor shall refer to the approved make of materials specified herein and the
drawings.
Valves shall be provided on branch pipe connections to mains and at connection to equipment
where indicated. All valves are to be located for easy access. All valves shall be supported wherever
necessary with MS brackets. Valves shall comply with IS 780 (Class I) for C.I sluice valves and IS
778 for G.M valves.
Pressure gauges shall have outer diameter not less than 115mm with 10mm BSP full thread, brass
body siphon and gauge cock of size10mm. Dial gauges shall have adequate response for the
pressures encountered within the specified (Range 0-15Kg/sq.cm).
VALVES
Gate valves or butterfly valves for shut-off or sectionalizing service, globe or ball valves for flow
modulation.

For on-site control, use gate valves.

Specialty valve shall be employed where

appropriate, such as check valves on a pump discharge, pressure regulating valves for equipment
requiring lower-than-available system pressure, solenoid valves, etc. Flanged or threaded end
valves are preferred. Locate valves in accessible locations, not more than six feet above the floor, if
frequently used, and with a union on the downstream side of threaded end valves.
Provide each valve with brass, aluminium or plastic disc not les than 32mm diameter engraved with
numbers, piping service and normal operating position (i.e. NO, NC) corresponding to valves shown
on the diagram. Fasten disc to valve with 14gauge brass wire or 16gauge jack chain.
GATE VALVE
The primary function of a gate valve is for starting and stopping of flow. It has a disc actuated by a
stem screw and hand wheel, moves up and down at right angles to the path of flow of fluid and
seats against two faces to shut of flow. As the disc of the gate valve presents a flat surface to the
direction of flow, this valve is only for starting and shutting the flow in the pipe.
These valves are of Gun Metal (GM) make. Supplying, fixing and testing correspond to IS 778-1984,
Specifications for Copper Alloy Gate, Globe and Check Valves for Water Works.
All globe and check valves shall have working parts suitable for hot and cold water, as required.
Valves shall be tagged with permanent label under hand wheel indicating type or duty.
All valves should have manufacturers test certificate indicating the date of shop test and other
quality control tests with the material used for the same.
BALL VALVE
The ball valve shall be of high-pressure type and shall be of sizes as specified and/or shown in the
drawings the normal size of a ball valve shall be that, corresponding to the size of the pipe to which it
is fixed. Ball valves shall have body of carbon steel. The ball and the shaft shall be of stainless
steel. The seat shall be of PTFE. The valve shall be complete with socket weld ends and the float

242

of copper sheet. The minimum thickness of copper sheet used for making the float shall be 0.45mm
for a float exceeding 115mm dia. The body of the high pressure ball valve when assembled in
working condition with the float immersed to not more than half of its diameter shall remain closed
against a test pressure of 3.5kg/sqcm.
The ball valve shall generally conform to IS specification No.1703:1977. The weight of ball cock and
the size of the ball cock shall be as per IS specification.
FOOT VALVES
Foot valves are provided with cast iron body with brass disc and strainer of approved quality as
shown in drawings and/or specified herein. The foot valve shall be of spring loaded or flapper type
depending on the requirement. The valves should be tested physically for free operation before
being mounted or assembled to the pipeline.
BUTTERFLY VALVES
Butterfly valves shall be slim seal, short wafer type with standard finish. The valves shall be suitable
for mounting between flanges drilled to ANSI 125. The valve body shall be cast iron. The disc shall
consist of disc pivot and driving stem shall be in one piece centrally located. The disc shall move in
bearings on both ends with O ring to prevent leakage. The seat shall be molded with black nitrile
rubber or nylon and shall line the whole body. The spindle shall be AISI 41 steel. The valve shall be
suitable for a working pressure of 16.5 kg/sq.cm and shall be complete with flow control lever and
notches, factory machined companion flanges and bolts and nuts. These valves conform to BS
5155 with electrosteel nickel coated SG Iron (N) and seat material EPDM3.
CHECK VALVES
Check valves are designed to prevent reversal of flow. These are also called Non-return valves or
reflux valves to avoid reversal of flow. Check valves shall be Dual Plate check valves with CI body,
aluminum bronze plate SS 316 hinge pins and springs and Buna-N seals to ANSI series 125. They
can also conform to IS 778-1984, Specifications for Copper Alloy Gate, Globe and Check Valves for
Water Works.
STRAINERS
Y strainers up to 50mm shall be of gunmetal and above 50mm shall be of cast iron body.
Strainers shall incorporate a removable bronze screen with 3.175 mm (1/8) perforations and a
permanent magnet. Strainers shall be provided with flanges at both inlet and outlet. They shall be
designed to enable blowing out of accumulated dirt and facilitate dirt and facilitate removal and
replacement of the screen without disconnection of the main pipe.
All strainers shall be provided with equal size isolating Slim Seal butterfly valves of approved
brands as shown in drawings so that the strainer may be cleaned without draining the system
FLANGES AND UNIONS
Sufficient number of flanges and unions shall be provided as required to facilitate maintenance work
after the piping is installed.

Mild steel flanges shall be used for pipes. The flanges shall be

connected to the pipeline by screwing or welding depending on the requirement. The flanges shall
conform to the relevant ASTM standard for the particular material used for its manufacture. The

243

flanges shall also conform to IS 5211.

PRESSURE REDUCING VALVE
Pressure relief valves are provided to keep the pressure in the line below a given value within the
reasonable limits in the downstream side of the pipeline when the pressure builds up beyond the
design value. Pressure reducing valves shall be of high-pressured type of specified sizes. The
valves should be suitable for mounting between flanges and threading connections also. The valve
body shall be of bronze / SS as specified. The valve shall be of spring loaded, direct operation,
metallic diaphragm type, as required for the particular usage.
The

pressure

reducing

valves

should

be

manufactured

in

conformance

with

ASA-

150,300,600,800,900 and 1500, or to BS10- table D, E, F, H or DIN- ND-16 & ND-40.

LEVEL SENSORS
Level sensor shall consist of control unit, preamplifier and one full insulated probe-mounted
vertically or two part insulated probe mounted from tanks side wall adjustable switching system
for pump control application, the same to be housed in stove enamel painted cast aluminium
weather proof suitable for black panel / wall mounting etc.,
The enclosure of probes shall be manufactured with SS316 material. The least count of the
central unit with amplifier should be +/- 0.10mm for response value of 30 seconds. Level sensors
shall be provided with controls housed in control panel of the pumps.
RELIEF VENTS
Drainage systems are frequently found to develop extremely high and objectionable pneumatic
effects in several specific portions of such piping. Special air pressure relief vents are
recommended to control, within tolerable limits.
The air pressure relief vent, at least one-half the diameter of the building drain, should be
provided at the top of vertical offset so as to supply such additional air to the drain as may be
required by the sudden increase in liquid velocity in the vertical offset Where a building trap or
other sharp change in flow direction is provided in the building drain downstream from the vertical
offset, an air pressure relief vent should be provided at the base of, and within 3 ft (0.900m) of,
the vertical offset. Lower relief vent should be branch connected to the upper relief vent at a
sufficient height.
The recommended provision for soil and waste stacks more than ten stories in height is to
provide a yoke relief vent at each tenth story of the drainage stack, counting downward from the
top story. The lower end of the yoke relief vent should connect to the drainage stack by means of
a Y located below the horizontal branch drain serving fixtures in that story, and the upper end
should connect to the vent stack by means of a T or inverted Y located at least 3 ft (0.900m)
above the floor level as shown in the drawing.
INSTALLATION OF VALVES
Valves should be installed in true tolerance of +/-5mm with respect to the center line of the pipe.
Where threaded joints are encountered the threads should be initially sealed with UPVC tape to
avoid leakage due to improper tightening and leakage from threading.

244

Proper care has to be taken in welded installation so that the centerline of valve should not
deviate from the pipe causing uneven load on the pipe and further stress during its operation. The
welding should be done only after proper inspection of the joint by the Employer / OE&PMC /
Architects / Consultants in the tacked position of the joint.
Before putting the line in operative mode the valves should be checked for free and easy
operation of the hand wheel. Any burrs or foreign materials should be removed by flushing before
final operation so that no choking in the valves should occur which might damage the valve seat

8.0SANITARY FIXTURES & FITTINGS

GENERAL
All fixtures shall be fixed in a neat workman like manner true to line and as recommended
by the manufacturer or shown in the drawings.

Care shall be taken to fix all fixtures,

brackets and accessories by proper bolts and nuts (expansion bolts).

Care shall be taken in fixing all approved chromium plated (CP) fixtures and ac cessories
so as not to leave any tool marks or damages on the finish. The Plumbing and Sanitary
Nominated Contractors shall be responsible for any of the rectification works. All such
fixtures shall be tightened with fixed spanners. Use of Stiltson' type pipe wrenches with
toothed jaws shall not be allowed.
All fixtures shall be thoroughly tested after connecting the drainage and water supply
system. All fixtures shall be thoroughly finished and any leakage in piping valves and waste
fittings corrected to the complete satisfaction of the Employer / OE&PMC / Architects /
Consultants.
Upon completion of the work, all labels, stickers, plaster, etc. shall be removed from the
fixtures and all fixtures shall be cleaned with soap and water so as to present a neat and
clean toilet.
All the CP & sanitary fixtures are measured in No,s or set comprising of list of items
mentioned with the specifications. The make, color, range, finish of the fittings shall be as
per the detailed BOQ specifications.
INDIAN TYPE WATER CLOSET- (Orissa type)
The closet shall be of white / color made of vitreous China and shall be of the best quality
manufactured by an approved firm. Each closet shall be provided with the following
accessories: The make and model to be as specified in the BOQ.
Indian water closet orissa type with P traps connector.
Concealed flushing valve of 3 or 6ltrs capacity with all internal parts (Dual flush).
CP wall flanges, Bib tap
EUROPEAN TYPE WATER CLOSET- Wall hung type
The closet shall be of white / color made of vitreous China and shall be of the best quality
manufactured by an approved firm. Each closet shall be provided with the following
accessories: The make and model to be as specified in the BOQ.
245

European water closet wall hung type with WC connector, seat cover with buffer flaps.
PVC / Vitreous china flushing Cistern of 3 or 6ltrs capacity with all internal parts of cistern Exposed type (Single flush or dual flush).
Cast-iron chair or cantilever bracket for wall hung type with C.P bolt & nut.
CP wall flanges.
Angle valve.
CP / copper / SS connecting pipe to cistern with end nuts.
Concealed Cistern-low level/high level cistern.
WASH BASINS
They shall be of white / color and of vitreous China with best quality manufactured by
an approved firm and size as specified. Under cut Oval/circular washbasins shall be
supported by a pair of CI brackets of approved design. The make and model to be as
specified in the BOQ.
Each wash basin shall be provided with the following.
Single lever mixer/Pillar Cock/ Pillar cock with sensor unit or Batter operated.
15mm CP brass angular stop cock.
CP / copper / SS inlet connecting pipes with end nuts.
32mm CP waste coupling.
CP wall flanges
32mm CP Bottle Trap with extension pipe(casted type)
40mm dia PVC connecting pipe upto floor trap .
Pedestals- Half / full for rectangular WB ( if required).
URINAL
Urinal shall be back inlet type, white colored and of vitreous China with best quality
manufactured by an approved firm. The urinal shall be fixed with hangers and bracket s.
The urinal shall be provided with auto flush system with sensor, solenoid valve / pneumatic
push cock / angle valve etc., complete. Make and model shall be as specified in the BOQ.
The complete set shall comprise of the following.
Urinal with auto flush system along with battery / electrically operated solenoid valve.
Fixing brackets,
32mm CP Bottle Trap, dome type grating, spreader etc., If the specified model is not
having in-built units as indicated above the same shall be part of the scope of work.
CP wall flanges (if required).
TOILET PAPER HOLDER
Toilet paper holder shall be of CP / sanitary ware. The make and model shall be as
specified in the BOQ.
ELECTRIC HAND DRIER
The electric hand drier shall be twin blower type integrated with timer range 0 to 3 minutes.
The drier shall be fully automatic. The make and model shall be as specified in the BOQ.

246

These shall work on 15A, 220V socket.

FLOOR TRAPS FRAME AND GRATING
The floor trap frame and grating shall be of approved material as specified in t he BOQ.
The trap shall be fitted with anti- cockroach grating. A minimum of 70mm depth of water
seal shall be provided in the trap.
GRAB BARS
The grab bars shall be of stainless steel of approved quality. The size and location shall be
as specified in the BOQ.
Ablution Tap
These shall be of CP / sanitary ware. The make and model shall be as specified in the
BOQ. These shall be fixed by means of stainless steel counter sunk screws to wooden /
plastic cleats firmly embedded in the wall.
15 mm CP Ablution taps with 1.0m long flexible tube with end nuts & Hook.
1 No 15mm CP brass angular stop cock with wall flange
Hook with CP brass counter sunk screws.
WATER HEATER:
These shall be of best approved make and type and capacity as per schedule of quantities.
They shall be mounted on the wall/left with necessary bolts of approved make. They shall
have 15 mm PVC inlet pipe, 15 mm PVC/copper pipe outlet, 15 mm non -return valve.
These shall be measured per number and the quoted rate shall include.
Cost of water heater with all the built -in electrical accessories like pilot lamp, thermostat,
standard length of cable and 3 pin 15A plug.
PVC inlet lead outlet pipe and non-return valve.
Fixing accessories like bolts, nuts, etc.
BIB TAP
15mm CP brass bib tap having regular body with adjustable wall flange. These shall be
fixed by means of stainless steel counter sunk screws to wooden / plastic cleats firmly
embedded in the wall.
15mm CP brass bib tap with wall flange

247

TECHNICAL SPECIFICATIONS FOR

ELECTRICAL WORKS

248

SPECIFICATION FOR ERECTION, TESTING & COMMISSIONING OF LT PANEL

1.0

Scope:
Receiving, Inspection, Unloading, Storage, Installation, Testing and commissioning of the LT
panels shall be in accordance with the specified code of practice manufacturers instructions.
The panels shall be aligned property and bolted to the flooring by at-least four bolts for each
division of transport. The cable shall be terminated into the panel through glands fixed to bottom /
top plate. The panels shall be bonded to the earth by connecting leads to the panel earth bus.

2.0

Handling / Unloading:
Panels and all its accessories shall be handled / unloaded carefully in its upright position as
indicated in the packing case. Lifting lugs and jacking pads shall be used for lifting of panels.
While using jacking pads utmost care shall be taken in proper application of jacks. Where panels
is dragged or pulled on sleeper or rollers of the traction eyes provided at the bottom frame shall
be used with suitable wire ropes and shackles. Unloading from the lorry shall be carried out using
a mobile crane or tripod with chain pulley block for rolling over to platform.

3.0

Storage:
Equipments shall be stored under shelter in a well-ventilated, dry place and covered by suitable
polythene or tarpaulin covers for protection against moisture.

4.0

Erection:
Panels shall be installed over a trench. The panels shall be aligned properly and bolted to the
flooring by at least four bolts. The cables shall be terminated into the panel through bottom plate.
The panel shall be bounded to the earth by connecting earthing leads to the panel earth bus.

5.0

Tests:
The following preliminary checks and pre-commissioning tests shall be carried out before
commissioning the panels in the presence of Buyer / Architects / Consultants representatives.
5.1.0

5.2.0

Preliminary checks:
5.1.1

Check nameplate details according to specifications.

5.1.2

Check for physical damage.

5.1.3

Check tightness of all bolts, clamps and connecting terminals.

5.1.4

Check oil level air pressure and leakage (wherever applicable).

5.1.5

Check earth connections.

5.1.6

Check the cleanliness of insulators and bushings, arc chambers.

5.1.7

Check that all moving parts are properly cleaned and lubricated.

5.1.8

Check it spare heaters provided.

Pre-commissioning checks:
5.2.1

Check alignment of breaker trucks for free movement. Check correct operation of
shutters.

5.2.2

Slow-closing / opening operation.

5.2.3

Check control wiring for correctness of connections, continuity and IR values.

5.2.4

Manual operation of breakers.

5.2.5

Power closing / opening operation manually and electrically.

249

5.2.6

Breakers closing and tripping time.

5.2.7

Trip free and anti-pumping operation.

5.2.8

I.R. values, resistance and minimum pick up voltage of coils.

5.2.9

Contact resistance.

5.2.10 Simultaneous closing of all three phases.

5.2.11 Pole discrepancy tests.
5.2.12 Single and three-phase auto-reclose operation.
5.2.13 Check electrical and mechanical interlocks provided.
5.2.14 Check on spring charging motor correct operation of limit switches and time of
charging.
5.2.15 Check on CTs
5.2.16 All functional checks with the relays, meters, alarm scheme, interlocks as per
scheme with the primary injection kits.
5.2.17 High voltage tests on control and power circuits (2.5 kV).

250

TECHNICAL SPECIFICATION FOR LOW TENSION PANELS

1.0

GENERAL:
This specification covers design, manufacture, testing and supply at site of the following 415
V,
50 Hz, switchboards.
The panels shall be dust, vermin and corrosion proof construction, sheet steel, clad totally
enclosed, compartmentalised cubicle design with front access and rear access.

2.0

PANEL DESIGN REQUIREMENTS:

2.1

The switchgear shall be formed using distinct vertical sections each comprising following
compartments:

A completely metal enclosed horizontal busbar compartment running horizontally

at top / bottom.

Individual feeder modules organised in multitier mode.

Completely enclosed vertical busbars serving all feeder modules in the vertical
panel.

Cable termination compartment.

Perforated sheet/insulating material enclosed horizontal auxiliary bus way for
control, interlock, indication and metering wiring running horizontally.

3.0

2.2

Metal sheets shall be provided between two adjacent vertical panels running to the full width of
the wider panel and upto full useful height of the switchgear.

2.3

The front of the board shall comprise of individually enclosed Air Break Circuit Breakers,
Starters, Fuse switch and Switch Fuse modules.

2.4

All auxiliary devices for control, indication, measurement and protection such as control and
selector switches, indicating lamps, ammeters, voltmeters, energy meter, protective relays shall be
mounted on the front side of the respective compartment only.

2.5

The design shall be such that unless required for maintenance / inspection purpose, all power on /
off or start / stop and relay reset operations shall be performed without opening the panel door.

CONSTRUCTION:
3.1

The complete board shall be of co-ordinated design so that shipping groups of the
board are easily assembled together at site into a continuos lineup. Necessary
standard connecting materials shall be supplied.

3.2

Name plates of elegant and durable design and quality shall be fixed to the individual
compartments, feeder modules, bus risers, busbars, cable alleys etc.,

3.3

The boards covered by this enquiry shall be designed, manufactured and tested in
accordance with the latest revisions of the related applicable Indian Standards.

3.4

The framework of the boards shall be constructed of preformed steel channels,

angles and side sheets bolted together and suitably reinforced to form a rigid, self
supporting, compact assembly to function properly under both normal and short circuit
conditions.

3.5

The bus compartments shall comprise of one main horizontal TPN bus unit with
vertical risers for connection to the individual modules.

3.6

The board shall be of totally metal-enclosed ventilated multiple unit construction. End
units shall include provisions for future main bus extensions and installation of
additional units on either side with the framework suitably drilled to receive the
251

additional modules and the busbars fitted with fishplates and associated hardware
enabling future extension without involving major fabrication works on the panel in
service.
3.7

Metallic barriers shall be provided between vertical sections and also between
adjacent modules to ensure prevention of accidental contact with live parts during
routine inspection / maintenance of functional units or cable terminations of one or
more functional units when working on those of adjacent units. These barriers shall
have insulating inserts as necessary for taking the interconnections etc.,

3.8

Doors and covers shall be of sheet steel of thickness not less than 1.6 mm cold rolled
and the edges shall be reinforced against distortion by rolling / bending / or by addition
of welded reinforcement members. The doors shall have concealed type of hinges.

3.9

Cut outs shall be true in shape and free from sharp edges.

3.10

The panel shall be provided with integral metal base channel 75 mm in height for
facilitating grouting on the floor.

3.11

The hard wares shall be cadmium plated & passivated; these shall be of the captive
type to obviate loss of these bolts / screws etc., when the doors / covers are opened
for servicing / inspection.

3.12

Cold Rolled Sheet Steel of 2 mm thickness shall be used for all members except for
doors, covers and partitions where it may be of 1.6mm.

3.13

All components including the busbars shall be capable of being removed from front.
The cable alleys shall also be at the front of the board.

3.14

All the doors for the feeder modules in the front shall have individual sheet steel
hinged doors with concealed hinges; these doors shall be capable of being physically
lifted off the main base shell and fixed back in position while the panel is in service
without necessitating removal of any screws or welding etc., and with the adjacent
modules in service with their doors closed.

3.15

The bus bar chamber shall have screwed covers at the front, on the sides and for the
top.

3.16

The covers for the cable chambers ad other compartments shall have covers screwed
on with captive screws so that these do not fall of when the panel is in use while the
operating / maintenance personnel have occasion to open & replace these covers.

3.17

The panels shall be suitable for cable entry at top or bottom as specified in drawings /
data sheet. Drilled gland plates with glands shall be provided for the switchboards to
suit entry of the cables as furnished in the drawings. Cable clamping arrangements
shall be provided in the cable alley.

3.18

The switchboards shall have uniform height. The height of the operating handle for
the feeder module, indicating lamps, instrument fuses etc., in the topmost tier which
may need adjustment shall all be not more than 1800mm from the finished operating
level on the floor so that these are easily accessible for the operating / maintenance
personnel without having to take recourse to ladders / steps etc.,

3.19

The minimum operating height of the switch handles shall not be less than 400mm
from the finished floor level including the safety rubber mat.

3.20

All live parts shall be suitably shrouded with non deteriorating Insulating barriers so as
to prevent any accidental contact with these by the operating / maintenance personnel
while the panel is in service and the modules are opened for inspection / servicing
etc.,

252

3.21

4.0

The switchgear panel shall be provided with space heaters if specified in drawings to
prevent moisture condensation and maintain cubicle temperature 5 Deg. C above the
ambient temperature. The space heater shall be located at the bottom of the
switchboard and shall be supplied from 110 V AC control supply. The space heater
shall be provided with a manually operated rotary switch shall be controlled through a
thermostat. A separate space heater shall be provided for each vertical panel.

BUSBARS:
4.1

The busbars shall be of Hard drawn high conductivity electrolytic grade (63401 WP) Aluminium
confirming to IS:5082. The busbars shall be of uniform cross section along its entire length. No
tapering of the busbar cross section is allowed. Current density shall not exceed 0.8 A/Sq.mm. In
case of copper bus bars current density shall not exceed 1.2 A/sq.mm. The copper bus bar shall
be tin plated.

4.2

Horizontal and vertical busbars shall be provided with PVC sleeves of high quality.

4.3

The joints in the busbars shall be of the bolted type and it shall be ensured that the following
precaution are observed:

The contact pressure must be ample and this shall be maintained during the time
the panel is in service.

The surfaces of the conductors must be clean.

With flat conductors, the overlap should be equal to or greater than the width of

the bars or ten times the bar thickness whichever is greater.

The joints shall be treated by the application of joint compound to render the joint
moisture-proof.
For the joints use of bolts of cadmium plated high tension MS bolts and nuts.

4.4

The efficiency of the joints shall be preserved by smearing the surfaces with oxide inhibiting
grease just prior to making the joint.

4.5

The switchboard shall be provided with power busbars for the 3 phases and neutral. The Busbars
fed by the incomer shall run continuously throughout the length of the switchboard.

4.6

The power busbars shall have a short circuit rating as specified in drawings/ data sheet.

4.7

The busbars shall be phase identified by colour, at regular intervals. Colour code shall be RED,
YELLOW and BLUE for phase buses and BLACK for the neutral. Busbars shall be rated for 40
Deg. C temperature rise over an ambient of 45 Deg. C as measured by thermometer. The cross
section of the busbars shall be uniform throughout.

4.8

Busbars shall be supported on tough, non-hygroscope, resin bonded self

extinguishing fire retardant insulators of SMC/DMC with ribbed construction to prevent
tracking due to dust accumulation and to have larger creepage paths. All the phases
are individually supported. If a common support is provided for all the three phases,
anti tracking barriers shall be incorporated. Busbars and supports shall withstand the
maximum stresses that are likely to be induced by the short circuit currents specified.

4.9

The clearance between the individual bare phase power busbars and between the
phase and earth busbars in air shall be not less than 25 mm and 16 mm respectively.

4.10

All busbars joints shall be of the bolted type. Ring washers shall be used for joints to
prevent loosening of the nuts and over heating. Lock nuts shall be incorporated for the
bolts besides the main nuts. The bolts and nuts used in the current carrying paths
shall all be of steel cadmium plated and the hard ware shall have adequate cove r of
the protective cadmium coating to obviate corrosion while the boards is in service.

253

5.0

4.11

The busbars chambers at the top shall be totally segregated from the rest of
compartments and rendered totally inaccessible under normal circumstances. No
equipment /instrument shall be mounted on the busbar chamber.

4.12

Power shall be distributed to each module or compartment by a set of vertical

busbars. The vertical busbars shall run behind/by the side of the modules.

4.13

All busbars, links, etc., shall be PVC sleeved and adequately shrouded to prevent
accidental contact. The sleeve used shall be of the heat shrinks type.

4.14

The busbars shall run horizontally in a separate enclosure but may run in an
enclosure located within the power busbar compartment.

4.15

Necessary tee off connectors shall be used for distributing auxiliary supply to each
vertical panel. Rubber grommets shall be used for all wire entries to make the entries
dust and vermin proof.

EARTHING CONNECTIONS:
The panel shall be connected to an earth busbar running throughout the length of the switchboard. The
minimum earth bus size shall be 50 x 6mm Aluminium. All doors and movable parts shall be connected to
the earth bus with flexible copper connections. Provision shall be made to connect the earthing busbar to
the plant earthing grid at two ends. All non-current carrying metallic parts of the mounted equipment shall
be earthed. Earthing bolts shall be provided to ground cable armours.

6.0

7.0

PAINTING:
6.1

All sheet steel surfaces shall be chemically cleaned, degreased and pickled in acid to produce a
smooth, clean surface free of scale, grease and rust. After cleaning the surface shall be given a
phosphate coating followed by a coat of high quality primer and backing in the oven.

6.2

The assembly shall be finished with two coats of enamel powder coated paint as
specified in drawings in light Grey as per IS:5 shade 631.

MARKING OF WIRES, CABLES AND MODULES:

7.1

All wirings & cables at the terminations at the switchboard shall have distinct marking
by means of ferrules with letters/ numerals printed corresponding to the wiring
diagram to be furnished by the successful tenderer.

7.2

All labels shall comprise white letters on a black back-ground; the size of the lettering
shall be 6 mm.

7.3

The switchboard shall carry the following district markings / name plates.

The manufacturers name/brand name.

The module nos. with the load designation and rating of the module in kW/Amps.
Danger boards as per the IE Rules and the statutory regulations of the Range
Electrical Inspector.
8.0

NAME PLATE:
8.1

A nameplate with the switchgear designation shall be fixed at the top of the central
panel.

8.2

A separate nameplate giving feeder details shall be provided for each compartment. A
separate nameplate giving details of bus section shall be provided for switch-gears
having more than one bus section.

254

8.3

Nameplate shall be provided for each equipment (amps, push buttons, switches,
relays, auxiliary contactors, etc.,) mounted on the switchboard. Special warning plates
one each front of a shipping section shall be provided on removable covers of doors
giving access to cable terminals and busbars. Special warning labels shall be
provided inside the switchboard also, wherever considered necessary. Identification
tags shall be provided inside the panels matching with those shown on the circuits
diagram.

8.4

Engraved nameplates shall preferably be of 3-ply (Black-white black) lamicoid sheets

or anodised aluminium. Engraving shall be done with square/V groove cutters.
Nameplates shall be fastened by screws and not by adhesives.

8.5

The nameplates for feeder compartments shall be in two parts. One part shall have
necessary details pertaining to the switchboard. The other parts shall be removable
and shall contain all details regarding the drives/equipments controlled by the
particular module.

8.6

The following documents shall be submitted within four (4) weeks from the date of
order:

Connection diagram for all units (like in-comer, outgoing feeders, breaker wiring
diagrams, etc).

Schematic diagram for the complete switchboard.

Terminal connection diagram of the main terminal boards.
Catalogues, Operation & Maintenance / Instruction manuals for major
components.

Sketches of the overall dimensions of the board - Plan, elevation and section
views clearly showing the bus size.

Brand names of all components incorporated like, relays, contractors, pilot device,
pilot lamps, current transformers, HRC fuse fittings / links, terminal blocks, wiring,
cable sockets, meters, selector switches for instruments, instrument fuse fittings /
links etc.,

Certificates of tests giving the results of tests conducted as per the appropriate
Standards on similar switchboard and interior components.

Shipping dimensions of the board and its weight - gross & net (without packing).
9.0

TESTS:
Switchgear assembly shall be subjected to the routine tests as per latest revision of IS: 8623.

255

SPECIFICATION FOR CABLE TRAYS

SCOPE:
This specification covers the design, supply, fabrication, fixing, aligning, and painting of cable
trays and other steel frame works at site as required.
The cable trays shall be designed and fabricated out of various sections such as MS angles,
flats, and channels etc. and got approved by Consultants.
Before fabrication the MS sections shall be properly straightened, aligned, cleaned properly to
remove rust if any.
All materials used for fabrication of cable of cable trays shall conform to IS 226 and fabrication
shall be as per IS: 800.
After fabrication the cable trays, and accessories shall be free from sharp edges, corners, burrs
and unevenness, and a coat of cold phosphating chemical shall be applied followed by a coat of
red oxide primer.
The cable trays shall be welded to the mounting supports, which in turn are either welded to
plate inserts or grouted to structural members.
Plate inserts for cable tray mounting supports shall be provided by Civil Contractor.
Cable trays shall be either run in cable trenches or run overhead and supported from available
structure.
Minimum clearance between the top most tray tier and structural member shall be 300 mm.
The type and size of tray to be used shall be as required.
Each continuous length of cable tray shall be earthed at minimum two places.
The cable trays, accessories, covers etc. shall be painted with two coats of red oxide primer
followed by two finishing synthetic enamel paint of approved shade. Where any cuts or holes are
made or welding is done on finished steel work, the same shall be sealed against oxidation by
red oxide primer followed by finished paint.

256

SPECIFICATIONS FOR DISTRIBUTION SYSTEM,

CONDUITS, WIRING & ACCESSORIES
1.0

GENERAL:
This specification of medium voltage distribution system shall be applicable for wiring 3 phase, 4
wire 415 volts, and 50 Hz. AC and single phase, 2 wire 230 volts, 50 Hz, AC supply.

2.0

RIGID STEEL / PVC CONDUITS & ACCESSORIES:

2.1

MS conduits shall be of welded and screwed sheet steel construction. Conduits shall be
welded and screwed sheet steel construction. Conduits shall be black stove enamelled
inside and outside. The conduits shall conform to the requirements of relevant IS (latest
edition) in all respects. The conduits shall have uniform wall thickness / cross section
throughout. Conduits shall bear the name, trademark of the manufacturer and size of
conduit on each length. The conduits shall be delivered to the site in original bundles.
Conduits of less than 19-mm dia shall not be used. The minimum wall thickness of
conduits shall be as follows:
Rigid MS conduits:

a) 19, 25 & 32 mm

16 gauge

b) 38 mm & above

14 gauge

Rigid PVC conduits

2.2

2 mm

Conduit Accessories:
Conduit accessories such as bends, inspection bends, inspection tees, elbows, reducers,
draw boxes, junction boxes, etc. shall be of approved makes. Boxes shall have internally
tapped spouts, junction boxes/inspection boxes shall be internally tapped covers.
Necessary pull boxes of adequate sizes shall be provided wherever required at no extra
cost.

3.0

2.3

All conduits shall be ample size for easy draw in and draw out of all the wires in the
conduits. In no case the total cross section of wires measured over all be more than forty
percent of the area of the conduit.

2.4

All the conduits shall be adequately protected while stored on site prior to erection and no
damaged conduit shall be used.

2.5

All conduit accessories shall be made out of 16 gauge thick MS enclosures.

PREPARATION OF CONDUIT:

The inside surface and ends of conduits and threads and fittings used shall be clean, smooth, cut
square and free from burrs and other defects. Powdered soap stone, talc or prepared compounds
shall be used as lubricants to facilitate the smooth pulling in of conductors.

257

4.0

5.0

ERECTION OF CONDUIT:
4.1

The conduit shall be properly and tightly screwed between the various lengths and to the
boxes to which it runs and terminates. No part of the conduit shall be under mechanical
stress and the whole conduit system shall be electrically and mechanically continuous
throughout.

4.2

Conduits shall be installed with provision for ventilation self drainage in the event of
ingress of moisture due to condensation or any other reason and prevent sweating.

INSTALLATION OF RECESSED CONDUIT SYSTEM:

5.1

The conduits shall be installed in such a manner that running can be carried out from the
fittings boxes and switch boxes only.

5.2

Conduits which are to be taken in the ceiling slab shall be laid on the prepared shuttering
work of the ceiling slab before concrete is poured, and tied to bars at every 500 mm. The
conduit shall be watertight by using bituminous compound at the screwed ends. The
conduits in ceiling slab shall be straight as far as possible.

5.3

Conduit recess in walls shall be secured rigidly by means of steel hooks/staples at 0.8
mtrs. intervals. Before conduit is concealed in the walls, all chases, grooves shall be
neatly made to proper dimensions to accommodate the required number of conduits.
The outlet boxes, point control boxes, inspection and draw boxes shall be securely fixed
by means of counter sunk steel screws and rawl plugs. They shall be firmly grouted in
position prior to plastering fixed as and when conduit is being laid. The recessing of
conduits in wall shall be so arranged as to allow atleast 12-mm plaster cover on the
same. All grooves, chases, etc. shall be refilled with cement mortar and finished upto the
wall surface before plastering of walls is taken up by the general contractor. The top
edge of the conduit shall be atleast 25 mm below the finished surface of wall. Wherever
conduits terminate into point control boxes, distribution boards, etc. conduits shall be
rigidly connected to the boxes, boards, etc. with checknuts on either side of the entry to
ensure electrical continuity.

5.4

After conduits, junction boxes, outlet boxes, etc. fixed in position their outlets shall be
properly plugged with PVC stoppers or with any other suitable materials so that water,
mortar, vermins or any other foreign material do not enter into the conduit system.

5.5

To facilitate easy drawing of wires in circuit necessary GI pull wires of 16 SWG shall be
inserted into the conduit immediately after shuttering is removed.

5.6

The Electrical Contractor shall be present during the pouring of concrete to

ensure that the conduits and accessories are not displaced or blocked.

5.7

The conduits shall be swabbed out by drawing dry swabs of rag through the conduit to
remove all moisture prior to drawing of wires.

5.8

Where vertical concealed conduits pass through floors or beams and horizontal
concealed conduits required to pass through columns or beams, these shall be taken
through rigid PVC / GI pipes to be inserted in the floors / columns / beams, etc. during
casting for which no extra payment shall be entertained.

5.9

Extension collars of suitable depth shall be used as necessary to leave all boxes
absolutely flush with the finished wall or ceiling surface.
258

5.10 Conduits shall not be buried or plastered etc. unless and until the work has been
inspected by the Owner / Architects.
6.0

7.0

INSTALLATION OF SURFACE CONDUIT SYSTEM:

6.1

Conduits shall run in square and symmetrical lines. Before the conduits are installed, the
extra routes shall be marked at site and approval of the Architect shall be obtained.
Conduits shall be fixed by heavy guage GI base plates, saddles, secured to suitable rawl
plugs, at an interval of not more than 1 Mtr. conduits shall be joined by means of screwed
couplers and screwed accessories only. In long distance straight runs of conduit,
inspection type couplers or running type couplers or pull boxes shall be provided.

6.2

Bends in conduit runs shall be done by bending conduits by pipe bending machine. Bends
which cannot be negotiated by pipe bends shall be accompanied by introducing inspection
0
boxes or inspection bends. Not more than three equivalent 90 C bends shall be used in a
conduit run from outlet to outlet.

6.3

All the conduit openings shall be properly plugged with PVC stoppers/bushes. The conduits
shall be adequately protected against rust by applying two coats of approved synthetic
enamel paint after the installation is completed.

6.4

Wherever conduits terminate conduits shall be rigidly connected to the box / board with
brass hexagonal check nuts with compression washers on either side of the entry to
ensure proper electrical and mechanical continuity.

6.5

The crossing of surface conduits shall not be generally permitted and to avoid such
crossings, adopter boxes shall be used at junctions/crossings.

6.6

All unused conduit entries shall be blanked off in an approved and where conduits
terminate in adopter boxes. All removable box covers shall be firmly secured to provide
complete enclosure.

CONDUITS ABOVE FALSE CEILING:

7.1

8.0

In the false ceiling area, the conduits shall be run above the false ceiling frame work
supported by means of M.S. straps secured and fixed to both conduits and structural
ceiling, keeping the outlet box as near as possible to the fittings / fans for connections. The
conduit boxes for fittings / fans are independently supported by means of separate fixing
arrangements to the box and structural ceiling so that the box is held rigidly.

ENCLOSURE FOR ELECTRICAL ACCESSORIES:

8.1

Enclosure for electrical accessories shall conform to IS: 5133 Part I. The wall thickness
of MS enclosures shall be not less than 1.6 mm. The enclosure boxes shall be provided
with a minimum of four fixing lugs located at the corners for fixing the covers. All fixing lugs
shall have tapped holes to take machined brass screws.

8.2

Sufficient number of knockouts shall be provided for conduit entries. The enclosures shall
be adequately protected against rust of corrosion both inside and outside. The enclosures
shall be provided with 5 mm thick overlapped white PVC or Perspex sheet cover with
rounded corners and beveled edges for mounting switches, sockets etc. Wherever
different phase conductors are brought into the same enclosure, phase barriers shall be
provided.

259

8.3

Minimum size of the box shall be 75 x 75 x 75 mm.

8.4

Draw boxes of ample dimension shall be provided at convenient points on walls/ceilings to

facilitate pulling of long runs of wire. These boxes will be as few as possible and located
where found necessary and approved by Architects at no extra cost.

8.5

Where flush conduits are required to terminate at surface mounted equipment, the conduit
shall terminate at a flush box and the back of the equipment should fully cover the flush
box and brass screws shall be used between the equipment and the box in addition to any
other means of fixing and earthing arrangement.
The alternative arrangement to the above shall be by means of fixing a terminal extension
box to the flush conduit box in which case a break joint ring shall be fitted between boxes.

9.0

WIRING CONDUCTORS:
9.1

All wiring conductors shall be PVC insulated, copper conductors of 1100 V grade, and shall
conform to IS: 694 Part II (Latest Edition).

9.2

Wiring conductors shall be supplied in Red, Blue, Yellow, Black and Green colors for easy
identification of wires. The wires shall be supplied in sealed coils of 100 Mtrs. lengths and
shall bear manufacturers trademark, name, Voltage grade etc.

10.0 INSTALLATION OF WIRING CONDUCTORS / CABLES:

10.1

The wiring conductors shall not be drawn into the conduits until all the works of any
nature that may cause damage to the wires are completed. The installation and
termination of wires shall be carried out with due regard to the followings:
10.1.1

While drawing the wiring conductors, care shall be taken to avoid scratches and
kinks, which cause breakage of conductors. There shall be no sharp bends in
the conduit system.

10.1.2

Stands of the wires shall not be cut for connecting to the terminals or lugs. The
terminals shall have adequate cross section to take all the strands.

10.1.3

Oxide inhibition grease shall be applied at all terminals and connections.

10.1.4

Brass flat washers of large area shall be used for bolted terminals.

10.1.5

Bimetallic connectors should be used wherever aluminum conductors are

tapped from copper mains or vise-versa.

10.2

Wiring for power and lighting circuits shall be carried out in separate and distinct wiring
systems.

10.3

The wiring system envisaged is generally shown on the layout drawings and line
diagrams. However, a brief account of the general wiring system is given below:

260

10.3.1 Sub-mains wiring;

Wiring from meter boards / switch boards to the individual distribution boards,
and shall consist of wires, conduits, and all conduit and fixing accessories as
required and specified. The sizes of conduits and number of wires shall be as
specified in Schedule of Quantities. Wires shall be drawn in conduits as required
without being damaged, with necessary draw boxes if required. The wire lengths
must be adequate for terminating at either end and identifying ferrules shall be
provided at termination. The wiring shall be color coded. The rate shall include all
materials, connections, labour etc. as specified above.

10.3.2 Circuit wiring;

Wiring from DBs to the first point control boxes for lighting, fans 5 Amps
sockets, call bells, etc. The scope of work shall be same as in sub main wiring.

10.3.3 Power wiring;

The wiring from DBs to heating supplies, 16/6 Amps 5 Pin socket outlets, etc.
The scope of work shall be same as in sub-main wiring.
The wiring from DBs to 63A / 32A, 3 phase/1phase Industrial Socket with control
MCB, etc. The scope of work shall be same as in sub-main wiring.

10.4

Each sub-main / circuit main / power wiring circuit shall also have its own earth continuity
wire as specified.

10.5

All the wiring shall be carried out in loop-in-loop system only and phase or line
conductors shall be looped at switch box and neutral conductor can be looped from light,
fan or sockets.

10.6

The maximum number of various size conductors that could be drawn into various sizes
of conduits shall be as per table II of IS: 732 (Latest Edition). The wiring shall be color
coded for easy identification of phases and neutral. The following color codes shall be
adopted.
Phases

Red, Yellow and Blue

Neutral

Black

Earth

Green or Bare wire as specified

10.7

All sub mains and circuit wiring shall be provided with printed PVC identification ferrules
at either end bearing circuit number and designation.

10.8

All the wiring shall be carried out without any jointing of wires

261

11.0 SWITCHES, SOCKETS AND ACCESSORIES:

11.1

General requirements:
General control switches shall be of a 6 Amps rating and shall be of approved make/type
suitable for flush mounting. Switches shall have integral mounting plates or white PVC /
Perspex of minimum 4.5 mm thick.

11.2

All sockets, 6 Amps and 16/6 Amps ratings shall be of flush mounting type with
combined control switches of the same rating as that of the sockets. All sockets outlet
shall be of 6 pin type.

11.3

The switch, plug socket or regulator boxes shall be made of GI / sheet steel of minimum
16 SWG on all sides except in the front. Depth of boxes shall not be less than 75 mm
and suitably increased where fan regulators are mounted in flush pattern. The boxes
shall be provided with suitable earthing studs. Wherever required switches / fittings shall
be fixed on metal strip which in turn are welded to the box.

11.4

Fan regulators shall be flush type and earthed with earth continuity conductor. The fan
regulators shall be of electronic type.

12.0 LAMP HOLDERS, CEILING ROSES, ETC.:

12.1 Accessories for light outlets such as lamp holders, ceiling roses, etc. shall be in conformity
with requirements of relevant IS specification. Only approved make of accessories shall be
supplied.
12.2 Screwed holder shall be used in brackets and pendants, light fittings shall have brass
holders on T.W. round blocks.
12.3 Ceiling roses for recessed system of wiring shall be porcelain make and flush type. For
surface type of wiring this shall be Bakelite.
13.0 INSTALLATION OF SWITCHES, SOCKETS AND ACCESSORIES:
All the switches shall be wired on phases. Connections shall be made only after testing the wires
for continuity, cross, phase etc. with the help of megger. Regulators shall be fixed on adjustable
M.S. flat straps inside the enclosure. The arrangement of switches and sockets shall be neat and
systematic. Covers for enclosures accommodating switches, sockets etc. (point control boxes)
shall be of 4.5 mm thick, fine finished PVC / Perspex material or laminated hylam sheet and fixed
to the enclosure in plumb with counter sunk head, chromium plated M.S. screws and washers.
Outlets shall be terminated into a flush type fan box for fan points. For wall plug sockets, the
conductors may be terminated directly into the switches and sockets. The outlets point control
boxes etc. shall be set out as shown on the drawings. Before fixing these, the contractors shall
obtain clearance from the Owner/Architect with regard to their proper locations. The enclosure
rd
the enclosures of sockets and 3 pin of the sockets shall be connected to the ground through an
earth continuity wires, as specified.
14.0 CAPACITY OF CIRCUITS:
Light points, 5 Amps socket points, fans, and cal bell points may be wired on a common circuit.
Such of those circuits shall not have more than 10 nos. of Light/fan/socket points or a load of
800 W whichever is less. Not more than two numbers of 15 amps socket outlets shall be wired
on the same circuit.

262

15.0 POINT WIRING:

15.1

Point wiring shall commence from the first point control box / local control box for the
points connected to the same circuit. Point wiring for lights, ceiling and exhaust fans, 5
Amps sockets, call bells etc. shall be carried out with 1100 V grade PVC insulated wires.
The point wiring shall be inclusive of conduits of not less than 19 mm size, switches,
wiring along with conduit accessories such as bends, inspections bends, reducers, pull
boxes, junction boxes, switch boxes, fan boxes, covers etc. together with wiring
accessories such as ceiling roses, brass lamp holders, TW blocks, loose wires up to 1
Mtr. long at outlet end connectors point control boxes (enclosure for electrical
accessories) switches, etc. Point wiring shall be provided with earth continuity wire as
rd
specified for earthing 3 pin of sockets, luminaries and fan fixtures. Light control shall be
either single, twin or multiple points controlled by a switch, as specified.
The point wiring for Light / Fans / 5 Amps sockets etc. shall include the supply and
installation of all materials specified above. Any item not specified above. Any item not
specifically included but required for satisfactory completion of the point wiring shall also
be included. No separate extra price will be allowed for any item under point wiring.

A dependant socket point shall mean the combination 5 Amps switch socket outlet/point
mounted on the same switchboard as any other point/points and shall include the 5
Amps switch and socket.

The fan point shall be complete with fan hook box flush mounted in slab, control switch
mounted in switch box and electronic regulator, complete with cover. The measurement
will be numbers of each kind of point and as specified in Schedule of Quantities.

16.0 FIXTURES / FANS:

16.1

LIGHT FITTINGS:
Unless otherwise specified, light fittings shall be generally fixed as directed by Owner /
Architects.

16.2

16.1.1

Fittings such as wall brackets shall be fixed at 2200 mm from FFL.

16.1.2

Bulk head fittings shall be flush with ceiling / wall as required and shall be at a
height as specified or directed.

16.1.3

Pendant fittings shall be suspended to a height of 2400 mm from FFL.

16.1.4

The fluorescent fittings shall be fixed in such a manner that the wiring
conductors shall not terminate in a ceiling rose but in a junction box 300 mm
away from the centre of the fittings along the length of the fitting so that no
exposed wiring is seen from outside.

FANS:
16.2.1

CEILING FANS:
Ceiling fans shall be suspended from the special fan hook boxes. The fan
wiring shall be terminated in porcelain/PVC multi way connector.
263

Each fan shall have a separate switch and speed regulator. The canopy at the
top of the suspension rod shall effectively hide the suspension hook.
The control switch and the electronic regulator for the fan shall be included in
the point wiring.
17.0 TESTING OF ELECTRICAL INSTALLATION:
17.1

17.2

TESTING OF INSTALLATION SHALL BE AS PER IS: 732-1982.

17.1.1

The insulation resistance shall be measured by applying between earth and

whole system of conductors of any selection thereof with all fuses in place and
all switches closed and except in earthed concentric wiring all lamps in position
or both poles of the installation otherwise electrically connected together,
where a direct current pressure of not less than twice the working pressure
provided that it need not exceed 500 Volts for medium voltage circuits. Where
the supply is derived from the three wires (AC or DC) or a poly phase system,
the neutral pole of which is connected to earth either direct or through added
resistance, the working pressure shall be deemed to be that which is
maintained between the outer or phase conductor and neutral.

17.1.2

The insulation resistance measured as above shall not be less than 50 mega
ohms divided by the number or points on the circuits provided that the whole
installation shall be required to have an insulation resistance greater than one
mega ohm.

17.1.3

Control rheostats, heating and power appliances and electric signs may, if
required be disconnected from the circuit during the test but in the event of the
insulation resistance between the case or frame work and all live parts of each
rheostat appliances and all live parts or each rheostat and sign shall be less
than specified in the relevant Indian Standard Specification or where there is
no such specification shall not be less than half a mega ohm.

17.1.4

The insulation resistance shall also be measured between all conductors

connected to one pole or phase conductor of the supply and all the conductors
connected to the middle wire or the neutral or to the other pole or phase
conductors of the supply and its value shall not be less than specified in subclauses 17.1.2.

TESTING OF EARTH CONTINUITY PATH:

The earth continuity conductor including metal conduits and metallic envelopes in all
cases shall be tested for electrical continuity and the electrical resistance of the same
along with the earthing lead but excluding any added resistance or earth leakage circuit
breaker measured from the connection with the earth electrodes to any point in each
continuity conductor in the completed installation shall not exceed one ohm. For checking
the efficiency of earthing, the earth resistance of each earth electrode shall also be
measured. This test shall preferably be done during summer months.

17.3

TESTING OF POLARITY OF NON-LINKED SINGLE POLE SWITCHES:

In a two wire installation, a test shall be made to verify that all non-linked, single pole
switches have been fitted in the same conductor throughout and that such conductor has
been connected to an outer or phase conductor or to the non-earthed conductor of the
supply.

264

17.4

The contractors shall be responsible for providing the necessary instruments and
subsidiary earth for carrying out the tests. The earth coordinating tests shall comply with
the IS specifications as may be applicable. Should the above tests not complete with the
limits laid down, the contractors shall do the necessary rectification of the fault till the
required results are obtained.

265

SPECIFICATION FOR EARTHING

1.0

This specification covers the requirements of supply, installation, testing and commissioning of
earth electrode system, equipment earthing etc.

2.0

STANDARDS:
Earthing installations shall conform to the Indian Electricity Rules 1956, as amended from
time to time and IS 3043 - Code of Practice for Earthing, with latest amendments.

3.0

TYPES OF EARTH ELECTRODES:

a)
b)
c)
d)

Pipe earth electrodes

Plate earth electrode
Strip conductor earth electrode
Coil earthing

Standard GI pipe earth or GI plate earth electrode shall be used except where it is unavoidable to use copper plate
earth electrode due to corrosive soil conditions for direct current systems or for large capacity substations.
Strip or conductor electrode shall be used at places where soil is hard and rocky and in
locations where there are limitations to the use of pipe or plate earth electrode.
Where the soil is highly corrosive, the earth electrode shall be of copper and when the soil
contains sulfur, copper electrode shall be adequately tinned.
4.0

EARTH ELECTRODE ARRANGEMENT :

4.1

4.2

PIPE ELECTRODE:
4.1.1

Electrode shall be made of GI pipe having a clean surface and not covered
with paint, enamel or poorly conducting material. Galvanized pipe shall not be
smaller than 38 mm ID. Earthing with pipe electrode shall be done as per the
details indicated in IS 3043.

4.1.2

The length of pipe electrodes shall not be less than 3.0 m. If rock is
encountered, pipes shall be driven to a depth of not less than 3.0 m with
suitable inclination. Pipe shall be in one piece and deeply driven.

4.1.3

To reduce the depth of burial of an electrode without increasing the

resistance, a number of rods or pipes may have to be connected together in
parallel. The distance between two electrodes in such a case shall not be less
than twice the length of the electrode. The earthing lead shall be connected
by means of a through bolt, nuts and washers and cable socket.

PLATE ELECTRODE:
For plate electrodes, minimum dimensions of the electrode shall be as under.
4.2.1

GI plate electrode: 600 x 600 x 6 mm thick.

4.2.2

Copper plate electrode: 600 x 600 x 3.15 mm thick.

4.2.3

The electrode shall be buried in ground, with its faces vertical and top not less
than 2.5 M from the surface of the ground.

4.2.4

Earthing using plate electrode shall be done as per details, indicated in IS3043.

266

4.2.5

4.3

4.4

5.0

Plate electrodes shall have a galvanized iron water pipe, buried vertically and
adjacent to the electrode. One end of pipe shall be atleast 5 cm above the
surface of the ground and need not be more than 10 cm. The internal
diameter of the pipe shall be at-least 19 mm. The length of pipe under the
earths surface shall be such that it shall be able to reach the center of the
plate. The earthing lead shall be securely bolted to the plate with two bolts,
checknuts and washers.

STRIP OR CONDUCTOR ELECTRODES :

4.3.1

Strip electrode shall not be smaller than 25 x 1.6 mm, if of copper and 25 x 4
mm, if of galvanized iron and steel. If round conductors area used as earth
2
electrodes, their cross sectional area shall not be smaller than 3 mm , if of
2
copper and 6 mm , if of galvanized iron and steel.

4.3.2

Conductor shall be buried in trenches not less than 0.5 m deep.

Coil earthing shall be done using 8 SWG GI wire. The wire shall be wound into spiral
form of 50 mm dia with turns closely made and buried at 1.5 Mtrs. below ground level.
As in the case of pipe electrode, for this earthing also alternate layers or charcoal and
salt shall be filled in the earth pit.

GENERAL:
5.1

All materials used for connecting the earth lead with electrode shall be of GI in case of
GI pipe and GI plate electrodes, and of tinned brass in case of copper plate electrode.
The earthing lead shall be securely connected at the other end to the main board.

5.2

The earthing lead from electrode onwards shall be suitably protected against
mechanical injury by routing the earth wire/strip through a suitable size of GI pipe.

5.3

All medium voltage equipments shall be earthed by two separate and distinct
connections with the earth. In case of high and extra high voltages, the neutral points
shall be earthed by not less than two separate and distinct connections with the earth,
each having its own electrode at the generating station or substation.

5.4

All materials, fittings etc., used in earting shall conform to Indian Standard
specifications wherever they exist.

5.5

The earth electrode shall be kept free from paint, enamel and grease.

5.6

It shall be ensured that similar materials for respective earth electrodes and earth
conductors are used.

5.7

Earth electrode shall not be installed in proximity to a metal fence.

5.8

Copper / GI strip shall be connected to the respective earth electrodes, either by

brazing or welding respectively. The copper / GI strip shall be jointed only either by
brazing or by riveting at the end of over lapping portions. The over lap shall not be
less than 50 mm.

5.9

Earthing clamps used for supporting earth strip shall be made of such materials so as
to avoid bimetallic action between strip and clamps.

5.10

All earth electrodes to be interlinked at the ground location except Lift and Lightning
protection system
Earth electrodes drawing shall be prepared and submit for approval

5.11
5.12

Size of earth wire / strip for various capacities of the panels / SFUs / equipments
shall be as indicated in the relevant IS / IE Rules which is reproduced below:

267

Equipment earthing: Size of earth lead - (Transformers, motors, generators, switch

gears etc.,)
1.1.1.1.1 Size of Earthing Conductor
Rating of 400 V
3.50 Hz. Equip.
in kVA

Bare copper conductor

or strip

Aluminum
single core
PVC cable

up to 5

10 SWG

10 Sq.mm

7/22

5 to 15

10 SWG

16 Sq.mm

6 SWG

15 to 50

8 SWG

16 Sq.mm

1x1/16 (25 x 1.5 mm)

51 to 75

6 SWG

25 Sq.mm

1x1/16 (25 x 1.5 mm)

75 to 100

6 SWG

35 Sq.mm

1x1/8 (25 x 3 mm)

101 to 125

4 SWG

50 Sq.mm

1x1/4 (25 x 6 mm)

126 to 150

70 Sq.mm

1x1/4 (25 x 6 mm)

151 to 200

2 SWG or 1x1/15
(25 x 1.5mm)
1 x 1/15 (25 x 1.5 mm)

70 Sq.mm

201 and above

1 x 1/8 (25 x 3mm)

185 Sq.mm

1 x
(40 x 5 mm)
2x1/4 (50 x 6 mm)

Galvanized
iron conductor/strip

Transformer/DG Set neutral point earthing

50 kVA
and below
75 kVA
100 kVA

8 SWG

Insulated
(PVC) Single
core standard
Aluminum
16 Sq.mm

6 SWG
4 SWG

25 Sq.mm
35 Sq.mm

1 (40 x 6 mm)
1 x (40 x 6 mm)

150 kVA

70 Sq.mm

1 x (40 x 6 mm)

200 kVA

2 SWG or 1 x 1/6
(25 x 1.5 mm)
1 x 1/8 (25 x 3 mm)

95 Sq.mm

1 x (40 x 6 mm)

250 kVA

1 x 1/8 (25 x 3 mm)

150 Sq.mm

1 x (40 x 6 mm)

300 kVA

1 x 1/8 (25 x 3 mm)

225 Sq.mm

1 x (40 x 6 mm)

500 kVA

1 x (25 x 6mm)

300 Sq.mm

2 x 1/4 (40 x 6 mm)

750 kVA

1 1/2 x (40 x 6mm)

2 x 225 Sq.mm
OR
1 x500 Sq.mm

Above 500 kVA only

copper or Al. strip to be
used

800 kVA

40 x 6 mm

1000 kVA

50 x 6 mm

1250 kVA

60 x 6 mm

1600 kVA

80 x 6 mm
(or 50 x 10 mm)

--

--

Transformer
Rating

Electrolytic bare
Copper conductor
/strip

Galvanized
Iron conductor/ strip
11/8 (25 x 3 mm)

268

Transformer/DG Set neutral point earthing

Transformer
Rating

Electrolytic bare
Copper conductor
/strip

2000 kVA

60 x 10mm

2500 kVA

75 x 10mm

Insulated
(PVC) Single
core standard
Aluminum

Galvanized
Iron conductor/ strip

Transformer and DG neutral earth conductors shall be installed with proper sleeves
and insulated supports
6.0

Testing:
The earth resistance of each electrode shall be measured by using a reliable and calibrated
earth megger. The value of the earth resistance shall not exceed the value as given below:

5 ohms.

i)

Residential buildings and non-residential buildings

ii)

Sub-stations and generating stations

1 ohms.

iii)

Lightning protection

10 ohms.

iv)

Special earthing for computer and other electronics Lab 1 ohm.

v)

Hazardous buildings

1 ohm.

269

SPECIFICATION FOR LOW TENSION CABLES

1.0

SCOPE

This specification covers the technical requirements of supply, laying testing and commissioning of
Heavy duty medium voltage cables up to 1100 Volts for power control and lighting application for
efficient and trouble free operation.

The cable shall be properly packed for transportation, supply and delivery at site.

2.0

CODE AND STANDARDS

The materials covered by this specification shall unless otherwise stated as designed. Constructed,
manufactured and tested in accordance with latest revisions of the relevant Indian Standards.

Sl.

3.0

Code

Standards for

IS -1554 (Part I) 1998

PVC insulated cables for working voltages upto and

including 1000 volts.

IS 5831 1984

PVC insulation and sheath of electric cables.

IS 8130 1984

Conductors for insulated electrical cables.

IS 3961 (Part - II)

Recommended current ratings for PVC insulated

and PVC sheathed heavy-duty cables.

IS 7098 (part 2) 1985

XLPE insulation and sheath of electric cables.

RATING

The cable shall be rated for a voltage rating of 650 / 1100 Volts.

4.0

SELECTION OF CABLES

Cables should be selected considering the conditions of maximum connected load, ambient
temperature, grouping factor, and allowance for voltage drops. However it is the responsibility of the
contractor to recheck the sizes before cables are procured. He should submit the cable derating,
voltage drop and length calculation to Architects for approval before procuring cables.

5.0

INSULATION

The conductor is insulated with suitably compounded PVC/XLPE (CROSSLINKED POLYETYLENE)

applied to the conductor by the extrusion.

The PVC/XLPE compound used for insulation shall have reduced flame propagation properly. This

270

shall also have reduces emission of hydrogen-chloride gas fumes etc., when severely overheated.
CORE IDENTIFICATION
The cores of the cables shall be provided with the colour scheme of PVC insulation as per IS for any
easy identification.
6.0
ARMOURING
The armouring of multi core cable consists of either GI round steel wires or GI flat strips and in case of
single core cable armouring shall be of non-magnetic material such as hard drawn aluminum or
aluminum alloy wires or strips.
7.0
OUTER SHEATH
The PVC compound used for outer sheath shall be resistant to termites, fungus and rodent attacks
and shall also have reduced flame propagation properly as specified above.
8.0
IDENTIFICATION
The manufacturers name, voltage grade of cable, year of manufacture, nominal cross-sectional area
of conductor shall be embossed on the outer sheath of the cables throughout the length of the cable at
regular intervals.
9.0
PARKING, MARKING AND TRANSPORT
The cables shall be supplied in strong, non-returnable wooden drums of heavy construction.
Each cable drum is marked with particulars of cable size, voltage class, length, direction of rolling,
position of outer gross weight, ISI certification marking etc.,
10.0

STORING, LAYING, JOINTING AND TERMINATIONS

10.1
STORING
All the cables shall be supplied in drums, on receipt of cables at site; the cables shall
be inspected and stored in drums with flanges of the cable drum in vertical position.
Employer / Architects will inspect the cables before storing. Contractor shall take out
samples from the drums as per their instructions and send them to the manufacturers
to conduct the approval tests. After the receipt of the test analysis, the cable will be
accepted by the Employer.
10.2

LAYING
Cables shall be laid as per the specification given below:
10.2.1 Cables in Outdoor Trenches:
Cables shall be laid in outdoor trenches wherever called for. The depth of the
trenches shall not be less than 75 cms. From the Formed Ground level (FGL)
which has to be ascertained from the Architects. The width of the trenches
shall be allowed between the cables. The trenches shall not be less than 45
cms. A spacing of not less than 15 cms. shall be allowed between the cables.
The trenches shall be cut square with vertical side walls and with uniform
depth. Suitable shoring and propping may be done to avoid caving in of trench
walls. The floor of the trench shall be rammed level. Cable unreeling from
drums shall e done only with the help of cable drum rolling supports. The
cables shall be laid in trenches over the rollers places inside the trench. The
cable drum shall be rolled in the direction of the arrow for rolling. Wherever
cables are bent, the minimum bending radius shall not be less than 12 times
the diameter of the cable. After the cable is laid and straightened, it shall be
covered with 8 cms. thick layer of sand. Cable shall be taken lifted and placed

271

over this and cushion. The cable shall then be covered with an 8 cms. thick
cushions, where cable is laid in rocky situation.
Extra thick cushioning of sand as may be required / decided by the Project
Manager / Architects shall be done without extra charge. Over this, a course
of cable protection tiles or brick shall be provided to cover the cables by 5
cms. On either side. Unless otherwise specified, the cable shall be protected
by concrete tiles / stone slabs of minimum 25mm thick placed on top of the
trench breadth wise for the full length of the cable. Trench shall be back filled
with earth and consolidated. Cables shall be laid in hume pipes / stoneware
pipes at all road crossings and in GI pipes at the wall entries Approved cable
markers made of concrete blocks indicating blocks indicating the voltage
grade and the direction of run of the cables shall be installed at regular
intervals of 25 Mtrs. the depth of concrete blocks shall be at least 300 mm
below ground and 50mm above ground.
10.2.2 Cables in Indoor Trenches:
10.2.2.1Cables shall be laid in indoor trenches whichever specified. Suitable
painted MS base plate clamps, saddles, GI nuts/bolts shall be used
for securing the cables in position at an interval not more than 450
mm. Spacing between the cables shall not be less than 15 mm
centre. Wherever specified trenches shall be filled with fine sand and
covered with steel chequered trench covers or RCC slabs.

10.2.2.2All chases and passages if necessary for the laying of service cables
at the entry or of premises shall have to be cut and made good to the
satisfaction of the project manager / Consultants.

10.2.2.3All cables entries into the buildings / cable trenches ducts, etc., shall
be suitably sealed as required by the project manager/ consultants
without extra cost.

11.0

JOINTING AND END TERMINATION

Cable jointing shall be done as per the recommendations of the cable manufacturer jointing shall be
done by qualified cable jointer under strict supervision. Sample crimping of different size cables shall
be subjected to contact resistance and heating tests in the presence of the Architects.
Each termination shall be carried out using Electroplated Brass single compression glands and copper
cable sockets and approved jointing materials are to be used Hydraulic crimping tool shall be used for
making the end terminations. Cable gland shall be bonded to the earth by using suitable copper / G.I
wire. The cable armouring is to be earthed properly so that the earth continuity is maintained.
272

12.0

TESTING
12.1

Cables shall be tested at factory as per the regulations of IS: 1554 Part-I. The tests
shall incorporate routine tests, type tests and acceptance tests. Copy of such test
certificates shall be furnished to the Owner.

12.2

Cables shall be tested at site after installation and results shall be submitted to
Consultants / Engineers.

12.3

Pressure test for 15 minutes.

12.4

Insulation resistance between conductors and neutral and conductors and

earth.

273