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SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.5607A-H-CCH400

Chimney

SECTION:
SHEET i OF iii

BHUBANESHWAR POWER PRIVATE LIMITED


(JV COMPANY OF TATA STEEL, RAWMET & JASPER)

2 X 80MW CAPTIVE POWER PLANT AT ANANTPUR, NEAR


CUTTACK, ORISSA

SPECIFICATION NO.TCE.5607A-H-CCH-400

Specification For Chimney

73/1, ST. MARKS ROAD


BANGALORE - 560 001
INDIA
December -2009

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.

TCE-5607A-H-CCH400

TITLE

SECTION:
CONTENTS

CONTENTS

SHEET ii OF iii

CONTENTS
SECTION

SUBSECTION

SPECIFICATION NO.

ISSUE

A1

TCE.5607A-H-CCH-400

P0

SCOPE OF ENQUIRY

1-3

A2

TCE.5607A-H-CCH-400

P0

DEFINITION OF TERMS AND


SPECIFICATION DOCUMENTS

1-6

A3

TCE.5607A-H-CCH-400

P0

TIME SCHEDULE AND WORK


PROGRAMME

1-9

A4

TCE.5607A-H-CCH-400

P0

RC CHIMNEY - SPECIFIC
TECHNICAL REQUIREMENTS
(DATA SHEET A)

1-4

TCE.5607A-H-CCH-400

P0

PROJECT INFORMATION

1-4

C1

TCE.5607A-H-CCH-400

P0

GENERAL NOTES

1-1

C2

TCE.5607A-H-CCH-400

P0

SCHEDULE OF QUANTITIES &


PRICES FOR RC CHIMNEY

1-6

C3

TCE.5607A-H-CCH-400

LIST OF BID DRAWINGS

1-1

D1

TCE.5607A-H-CCH-400

P0

EARTHWORK
EXCAVATION
FILLING

IN GRADING
AND
BACK

1-11

D2

TCE.5607A-H-CCH-400

P0

SPECIFICATION FOR TIMBER


SHORING

1-2

D3

TCE.5607A-H-CCH-400

P0

DEWATERING

1-1

D4

TCE.5607A-H-CCH-400

P0

RAIN WATER DRAINAGE

1-1

D5

TCE.5607A-H-CCH-400

P0

CONCRETE & ALLIED WORKS

1-26

D6

TCE.5607A-H-CCH-400

P0

REINFORCED CONCRETE
CHIMNEY-CIVIL

1-30

D7

TCE.5607A-H-CCH-400

P0

REINFORCED CONCRETE
CHIMNEY-ELECTRICAL AND
INSTRUMENTATION

1-15

B
C

TITLE

NO. OF
SHEETS

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.

TCE-5607A-H-CCH400

SECTION
D

CONTENTS

SHEET iii OF iii

SUBSECTION
D8

SPECIFICATION NO.

ISSUE

TCE.5607A-H-CCH-400

P0

SUPPLY AND FABRICATION


OF STRUCTURAL STEEL

1-7

D9

TCE.5607A-H-CCH-400

P0

ERECTION OF STRUCTURAL
STEEL

1-7

D10

TCE.5607A-H-CCH-400

P0

PAINTING OF STRUCTURAL
STEEL

1-8

TCE.5607A-H-CCH-400

P0

GENERAL CONDITIONS OF
CONTRACT

1-36

F1

TCE.5607A-H-CCH-400

P0

SCHEDULE OF DEVIATIONS
FROM TECHNICAL
SPECIFICATIONS

1-1

F2

TCE.5607A-H-CCH-400

P0

SCHEDULE OF DEVIATIONS
FROM GENERAL
CONDITIONS

1-1

F3

TCE.5607A-H-CCH-400

P0

SCHEDULE OF PRICE
IMPLICATION ON ACCOUNT
OF DEVIATIONS.

1-1

F4

TCE.5607A-H-CCH-400

P0

SCHEDULE OF CEMENT
REQUIREMENT

1-1

F5

TCE.5607A-H-CCH-400

P0

SCHEDULE OF
REINFORCEMENT
REQUIREMENT

1-2

F6

TCE.5607A-H-CCH-400

P0

SCHEDULE OF
CONTRACTORS TECHNICAL
STAFF TO BE DEPLOYED ON
THIS CONTRACT

1-1

F7

TCE.5607A-H-CCH-400

P0

SCHEDULE OF EQUIPMENT

1-1

F8

TCE.5607A-H-CCH-400

P0

SCHEDULE OF RATES FOR


LABOUR

1-1

F9

TCE.5607A-H-CCH-400

P0

SCHEDULE OF BIDDERS
EXPERIENCE

1-1

TITLE

SECTION:
CONTENTS

TITLE

NO. OF
SHEETS

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC NO.

SCOPE OF ENQUIRY

TCE-5607A-H-CCH-400

1.0

SCOPE

1.1

Scope of Work covered under this specification comprises of


a)

SECTION: A1

SHEET 1 OF 3

Analysis, Design, preparation of Construction drawings and Construction


of one number 150M high multiflue Reinforced Concrete Chimney with all
accessories as per specification.

The scope also includes soil investigation, supply of all materials and labour
along with necessary tools and tackles etc. It also includes collection of
materials from the Owners stockyard either at site or from other places,
transporting the same to the site, unloading, storing them in the Contractors
own covered storage area. Storing shall be done in a neat & systematic manner
and also providing necessary fencing and security to ensure proper utilization of
such material exclusively for the project.
1.2

It is not the intent to completely specify herein all details of design, manufacture
and construction. Nevertheless, the structure/equipment shall conform in all
respects to high standards of engineering, design and workmanship, complying
with the technical specifications and shall be capable of performing in continuous
commercial operation, up to VENDORs guarantee, in a manner acceptable to
OWNER, who will interpret the meaning of drawings and specifications and shall
have the power to reject any work or materials which, in his judgement, are not
in full accordance therewith.

1.3

The scope of work includes, but is not limited to the following. The VENDOR
shall furnish everything necessary and as required by OWNER although not
listed herein, for the successful operation of the equipment supplied by him as
specified above:

i)

Design of Chimney including all appurtenant civil works

ii)

Supply at site of all required materials

iii)

Construction of Reinforced Cement Concrete raft supporting the wind shield


as well as duct supports staircases etc including excavation, dewatering,
backfilling, etc complete.

iv)

Construction of R.C.C wind shield using jump form slip including provision of
openings of various sizes in the windshield at various levels.

v)

Construction of internal RCC corbels at various levels to support structural


steel beams.

vi)

Construction of RCC roof slab for wind shield including acid resistant tile
protection of the roof and drainage arrangement of roof.

vii)

Providing structural steel platform at various levels such as roof supporting


platform, flue support platform, with openings for flues, flooring of RCC slab,
hand rail etc including their bearing supports on the wind shield.

ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC NO.

TCE-5607A-H-CCH-400

SECTION: A1

SCOPE OF ENQUIRY

SHEET 2 OF 3

viii)

Providing brick flues supported on platforms.

ix)

Structural steel flue gas ducting of rectangular configuration from terminal


points of supply for steam generator vendor, of structural steel up to circular
brick flue including structural steel stiffening arrangement for the ducting.

x)

Providing restraint and support arrangement for ducts on the windshield.

xi)

Providing RCC ash hoppers connected at the lowest level of duct.

xii)

Providing supporting arrangement for duct supports outside wind shield.

xiii)

Providing insulation on the outside of brick flues and ducts including


protective aluminium sheet.

xiv)

Providing structural steel work for supporting ducting, both inside and outside
of windshield.

xv)

Provision of structural steel stair case inside wind shield from ground floor
level to top platform with interconnection to various platforms and cage ladder
from top platform to roof of chimney.

xvi)

Painting of RCC windshield and structural steel works.

xvii)

Aviation warning lightning, general lighting inside the chimney and obstruction
lighting and all connected electrical works including embedding conduits,
junction boxes, pull boxes, cabling etc.

xviii)

Earthing and lighting protection system including all connected works from
top of chimney to terminal point outside chimney at ground level.

xix)

Provision of inserts/pipe sleeves for mounting instruments for monitoring air


quality, including conduiting junction, pull boxes, cabling etc.

xx)

Provision of discrete strakes of galvanised structural steel, if required.

2.0

TIME OF COMPLETION

2.1

Time of Completion of Works shall be as follows


Chimney
Work covered under this tender shall be completed within 19 (nineteen) calendar
months from the date of issue of Letter of Intent or Work Order whichever is
earlier.

ISSUE
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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC NO.

TCE-5607A-H-CCH-400

SCOPE OF ENQUIRY

SECTION: A1

SHEET 3 OF 3

PERIOD OF
COMPLETION IN
MONTHS FROM THE
DATE OF LOI

SL.
NO.

DESCRIPTION

1.

Completion of shell and raft design and submitting the


same for approval of Consultant / Owner

1 Months

2.

All foundation works below ground level including


backfilling etc.

3 Months

Completion of remaining design and submitting the


same for approval of Consultant / Owner.

4 Months

4.

(a)

Construction of Shell

8 Months

(b)

Construction of all internal platforms

12 Months

(c)

Completion of lining, insulation, hopper, duct &


duct connections complete in all respects, for
first Unit

16 Months

(d)

5.

Completion of lining, insulation hopper, duct &


duct connections complete in all respects for
second Unit
All other accessories such as staircase, MS ladders,
lighting including aviation obstruction lights and
lightening system, portholes including access platform
/ staircase, doors, pulley brackets, wire mesh screen,
louvers, caps, hand railing, duct work & its
connections, painting etc and finishing works

18 Months

19 Months

2.2

Bidder shall submit a construction bar chart including all activities keeping in
mind the period of completion time.

3.0

SOIL CHARACTERISTICS
A detailed report on geotechnical investigation and foundation recommendation
for the plant site is available for reference. The BIDDER should contact TCE,
Bangalore or BBPL and apprise himself of the details of the report before
submitting his bid. The BIDDER, before submission of his bid, may conduct soil
investigation test as required by him to ascertain the actual soil condition at site.
No claim for extra payment will be entertained if the actual soil conditions are at
variance with the data given in the investigation report or with the borelog data
enclosed as a bid drawing and the recommended net safe bearing capacity as
indicated in Data SheetA, Section-A4. However, in case the BIDDER by his
investigation, arrives at a higher bearing capacity or more favourable values of
soil parameters, he shall adopt the bearing capacity and parameters as specified
and as given in the borelogs enclosed with this specification.
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.

TCE-5607A-H-CCH-400

TITLE

SECTION: A2
SHEET 1 OF 6

DEFINITION OF TERMS AND SPECIFICATION


DOCUMENTS

1.0

DEFINITION OF TERMS

1.1

Owner shall mean M/s Bhubaneswar Power Private Limited.


Engineer shall mean the authorised engineer of the Owner.

1.2

Consultant shall mean TCE Consulting Engineers limited who are


appointed by Owner for the project and shall include their duly
authorised representatives.

1.3

Bidder shall mean the firm / party who quotes against an enquiry.

1.4

Vendor/Contractor/ Fabricator shall mean the successful Bidder


whose Bid has been accepted by the Owner and on whom the
contract or Purchase Order is placed by the Owner and shall include
his heirs, legal representatives, successors and permitted assigns.

1.5

`Sub-Vendor/ Sub-Contractor/ Sub- Purchaser shall mean the person


named in the `Contract undertaking a part of the work or any person to
whom a part of the `Contract has been sublet with the consent in
writing of the Owner and shall include his heirs, legal representatives,
successors and permitted assigns.

1.6

`Manufacturer refers to a person or firm who is the producer and


furnisher of material or designer and fabricator of equipment to either
the Owner or the Vendor/Contractor or both under the `contract

1.7

`Others shall mean other successful bidders whose bids have been
accepted by the owner and to whom the orders have been placed by
the owner and shall include their heirs. legal representatives,
successors and permitted assigns.

1.8

`Inspector shall mean the authorised representatives appointed by the


`Owner or the Engineers/Consultant for purpose of inspection of
materials/ equipment/works.

1.9

`Project shall mean the project specified in the project information


section -B of the `specification.

1.10

`Site shall mean the actual place of the proposed ` project as detailed
in the `specification or other place where work has to be executed
under the contract.

1.11

`Month shall mean calendar month.

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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.

TCE-5607A-H-CCH-400

TITLE

SECTION: A2
SHEET 2 OF 6

DEFINITION OF TERMS AND SPECIFICATION


DOCUMENTS

1.12

`Specification shall mean collectively all the terms and stipulations


contained in those portions of the `contract known as General
Conditions, the Specifications and such Amendments, Revisions,
Deletions or Additions, as may be made in the Agreement and all
written Agreements made or to be made pertaining to the method and
manner of performing the work or to the quantities and qualities of the
materials to be furnished under this `contract.

1.13

`Bid shall mean the proposal/document that the bidder submits in the
requested and specified form in the `specification.

1.14

`Plant or Equipment and work or `works shall mean respectively


the goods to be supplied and services to be provided by the Vendor/
Contractor/Fabricator under the purchase order or contract

1.15

`Contract or `purchase order shall mean the order and associated


specifications executed by the Owner and the Vendor including other
documents agreed between the parties or implied to form a part of the
`contract

1.16

`Contract price shall mean, if there is a formal agreement, the prices


referred to in the agreement or if there is no formal agreement, the
price agreed to be the value of the `contract

1.17

`Date of Contract shall mean the calendar date on which the Owner
and Vendor/Contractor/Fabricator have signed the `contract. Effective
Date of contract shall mean the calendar date on which the Owner
have issued to the Vendor the `Letter of Intent or three months prior to
the `Date of contract or six months prior to the date of issue of the
import licence whichever is later or as otherwise mutually agreed to
between the Owner and the Vendor.

1.18

`Contract period shall mean the period during which the `contract shall
be executed as agreed between Vendor/Contractor/ Fabricator and
Owner in the Contract

1.19

Guarantee period shall mean the period during which the plant or
`Equipment shall give the same performance guaranteed by the
Vendor in the schedule or guarantee as in the `Specification.

1.20 `Approved and `Approval where used in the Specification shall mean,
respectively, approved by / approval of the Owner/Purchaser or the
Engineer/Consultant.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.

TCE-5607A-H-CCH-400

TITLE

SECTION: A2
SHEET 3 OF 6

DEFINITION OF TERMS AND SPECIFICATION


DOCUMENTS

When the words Approved Approval


subject to Approval,
satisfactory Equal to proper Requested As directed Where
directed `When Directed, Determined by Accepted Permitted or
words and phrases of like import are used the approval, judgement,
direction etc, is understood to be a function of the Owner or the
Engineer/ Consultant
1.21

Engineers Instructions shall mean any drawings and /or instructions


oral and/or in writing details. Direction and explanations issued by the
Engineer/Consultant or the Owner from time to time during the contract
period

1.22

Writing shall include any manuscript. Typewritten or printed statement.


Under or over signature and /or seal as the case may be.

1.23

Notice in Writing or Written Notice shall mean a notice in written,


typed or printed characters sent (unless delivered personally or by
email or other wise proved to have been received) by registered post to
the last known private or business address or registered office of the
addressee and shall be deemed to have been received when in the
ordinary course of post it would have been delivered.

1.24

`Contractors works or Manufacturers works shall mean and include


the land and other places which are used by the
Vendor/Contractor/Fabricator or Sub-Vendor.
Sub Contractor, Sub
Fabricator for the manufacture of equipment or performing the works

1.25

Virtual Completion shall mean that all work is completed as directed


and the site is cleared to the satisfaction of the Owner or the Engineer/
Consultant

1.26

Commercial Use shall mean that use of the Equipment or work which
the contract contemplates or that for which Equipment or work is
commercially capable

1.27

Minor Modification shall mean the modification work which need a


maximum of 8 man-hours per item of work.

1.28

Major Modification shall mean the modification work needing more


than 8 man-hours per item of work.

1.29

Words importing persons shall include Firms, Companies Corporations


and other Bodies whether incorporated or not.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.

TCE-5607A-H-CCH-400

TITLE

SECTION: A2
SHEET 4 OF 6

DEFINITION OF TERMS AND SPECIFICATION


DOCUMENTS

1.30

Words importing the singular only shall also include the plural and vice
versa where the context requires

1.31

Drawings shall mean all:


a) Drawings furnished by the Owner or the Engineer/Consultant as a
basis for proposals.
b) Supplementary drawings furnished by the Owner or the Engineer/
Consultant to clarify and to define in greater detail the intent of the
Contract.
c) Drawings submitted by the Vendor with his proposal provided such
drawings are acceptable to the Owner or the Engineer/Consultant.
d) Drawings furnished by the Owner or the Engineer/ Consultant to the
Vendor during the progress of the work:
e) Engineering data and drawings submitted by the Vendor during the
progress of the work provided such drawings are acceptable to the
Engineer/Consultant.

2.0

SPECIFICATION DOCUMENT

2.1

The specification document consists of six sections as listed below


and all of these are to be considered together for correct understanding
and interpretation of the specification.

2.2

SECTION A

2.2.1 Section-A covers the scope of enquiry, definition of terms and


specification documents and instructions to bidders. It also includes Data
Sheet-A, which gives specific technical requirements if any

2.3

SECTION-B
Section -B furnishes relevant `Project information for the reference and
use of the Bidder

2.4

SECTION-C

2.4.1 Section -C contains General notes, schedule of Quantities & rates and
list of bid drawings.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TITLE

TCE-5607A-H-CCH-400

2.5

SECTION: A2
SHEET 5 OF 6

DEFINITION OF TERMS AND SPECIFICATION


DOCUMENTS

SECTION-D

2.5.1 Section-D comprises technical specifications for works..


2.6

SECTION-E
Section-E covers General Conditions of contract and Special
Conditions of Contract.

2.7

SECTION-F
Section-F covers Schedule of technical and general deviations if any,
Schedule of equipment and schedule of rates for labour.

2.8

The Bidder shall be deemed to have carefully examined the


Specification in its complete form and to have fully informed and
satisfied himself as to the details, nature, character and quantities of
the work to be carried out, site conditions and other pertinent matters
and details.

2.9

In case of any conflict relating to the definition of the terms and


conditions of contract, specifications, designs, drawings and
instructions mentioned herein after and as to the quality of
workmanship or materials used on the works, the decision of the
Owner/Consultant shall be final, conclusive and binding on all parties to
the Contract.

2.10

In case of conflict between clauses of different sections of this


specifications, the following section(s) shall govern in the order
indicated below.
1.)
2.)
3.)
4.)
5.)

2.11

Section C
Section A
Section D
Section C5
Other sections.

It is the intent of the Owner to incorporate these specification


documents in the final Contract or Purchase order for the services.
Bidders are required to review these documents and clearly state in
their proposals their acceptance of the same. Exceptions, if any, shall
be clearly stipulated in the appropriate bidding schedule. The final
`Contract between the Owner and the Contractor shall be subjected to
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.

TCE-5607A-H-CCH-400

TITLE

SECTION: A2
SHEET 6 OF 6

DEFINITION OF TERMS AND SPECIFICATION


DOCUMENTS

such changes, if any mutually agreed upon between the Owner and the
Contractor and included in the main text of the `Contract or Purchase
Order
2.12

The Bidder shall specify all the deviations with respect to this
specification in the appropriate schedule.(Given in Section F)

2.13

The Bidder shall furnish the data called for in the Schedules in the
standard Pro forma to facilitate correct evaluation of his Bid in a most
expeditious manner. The Bidder shall submit the 'Bid' in the above
manner, failing which it is likely that his 'Bid' may not be considered.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE. 5607A-H-CCH-400

TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 1 OF 9

1.0

INFORMATION FURNISHED

1.1

This specification is intended as a general description of quality envisaged for


material, workmanship and of the finished work. It is not intended to cover
minute details. The work shall be executed in accordance with the best modern
practice and to the complete satisfaction of Owner Special techniques approved
by Engineer shall be used if and where found necessary.

1.2

The information given in this specification is in good faith and meant to serve as a
guide to the Bidder. It is, therefore, imperative that Bidder shall obtain and
examine for himself all the data, information and particulars required for the
satisfactory execution of the work under this enquiry. The submission of a bid by
Bidder implies that he has fully read the specifications, bid drawing, and general
conditions of contract. Bidder shall make himself aware of the scope and the
specifications for the work to be performed and local conditions and other
features which have a bearing on the cost and execution of the work. Extra
charges for any reason whatsoever will not be entertained by Owner.

1.3

General Notes (given in Section-C) shall also be noted before quoting rates
against various items in Section -C.

1.4

In case of any conflict among clauses of different technical specifications given


under Section-D, the decision of the Owner/Engineer shall be final and binding on
the Contractor.

2.0

INSPECTION OF SITE BY BIDDER

2.1

Bidder shall inspect the site, examine and obtain all information required and
satisfy himself regarding matters such as access to site, communication,
transport, right of way, the type and number of equipment and facilities required
for the satisfactory completion of work, the quantity of various items of the work,
the availability of local labour, availability and rates of material, local working
conditions, uncertainties of weather, obstructions and hindrances that may arise,
etc., which may affect the work or cost thereof, before submission of his Bid.
Ignorance of site conditions shall not be accepted by the Owner as basis for any
claim for compensation. The submission of a bid by the Bidder will be construed
as evidence that such an examination was made and any later claims/ disputes in
regard to rates quoted shall not be entertained or considered by the Owner.

2.2

The rates quoted by Bidder shall be based on his own knowledge and judgement
of the conditions and hazards involved and shall not be based on any
representations of the Engineer.

3.0

VALIDITY OF BID
The Bid shall remain valid for acceptance for three (3) months from the due date
of receipt of the Bids and during this period no bidder shall be allowed to
withdraw the bid.

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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TITLE

TCE. 5607A-H-CCH-400

4.0

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 2 OF 9

ACKNOWLEDGEMENT
On receipt of bidding document, bidder shall acknowledge the receipt and
confirm his intention to bid for the work. Any addendum issued by Owner/
Consultant shall become part of bidding document and bidder shall submit
Original addendum duly signed and stamped as a token of his acceptance.

5.0

MATERIAL SUPPLY AND FACILITIES BY THE OWNER

5.1

The Owner will provide the following facilities to the Contractor free of cost.
(a)

Provision of one permanent benchmark and base line for laying out.

(b)

Construction water at one point.

The owner will provide construction power at one point on chargeable basis.

6.0

PRICES AND RATES

6.1

Prices and rates quoted shall include cost of all materials , labour, supervision,
setting out, machinery and equipment, transport charges, wastage of material, all
consumables such as, but not limited to petrol, oil, diesel, lubricants, drill bits,
pipes, ropes, etc., construction facilities such as scaffolding, cribbing, tarpaulins,
wind break, etc., taxes, duties, royalties, octroi and any other levies payable on
all transactions, all leads and lifts, etc., overheads/profits of Contractor for due
performance of the work under this contract. The rates shall also include cost for
mobilization/demobilization of equipment.

6.2

Prices and rates quoted shall be deemed to include everything necessary to


satisfactorily complete the work as determined by the Engineer though they may
not have been specifically referred to in these documents.

6.3

Prices and rates quoted shall be firm for the entire duration of the contract and
any agreed extensions thereafter.

6.4

The rates quoted by bidder shall remain unaltered for the use of any type of.
cement such as pozzolana, ordinary Portland, sulphate resisting, etc.

6.5

No price escalation on any account shall be allowed during the entire period of
Contract.

7.0

LIST OF WORKS
Bidder shall submit along with their bids complete particulars of similar jobs
executed by him.

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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE. 5607A-H-CCH-400

TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 3 OF 9

8.0

BID DOCUMENTS

8.1

Under Section-C3, list of the bid drawings enclosed is indicated. The drawings
are intended to give the Bidder general idea of the type and extent of work
involved. As such, they are indicative and for bid purpose only. Engineering
design and construction drawings will be prepared by the contract. Work shall
proceed only after approval of construction drawing by the Consultant/ Owner.

8.2

No alteration or mutilation, other than filling in particulars wherever called for,


shall be made in the bid documents. Any changes/modifications made by the
Bidder on the bid documents itself shall not be taken into consideration.

8.3

In case of conflict regarding interpretation of the intent or meaning of the


specification or drawing, the Engineer shall interpret such intent or meaning,
which will be final and binding on the Contractor.

9.0

SECURITY DEPOSIT
Successful Bidder shall be required to provide a security deposit of 2.5% of the
total contract price and shall furnish immediately after placement of LOI, either in
the form of unconditional Bank Guarantee (in the format given by owner) from a
Nationalized bank or Demand Draft drawn in favour of M/s Bhubaneswar Power
Private Limited payable at ________or as advised by owner. This Bank
Guarantee shall be valid till completion of the defect liability period.

10.0

MOBILIZATION ADVANCE
Interest free mobilization advance of 5% (Five percent) of the contract value
will be paid to the successful bidder on submission of an unconditional
Bank Guarantee for equivalent amount in the standard format given by the
owner from a Nationalized bank. Mobilization advance will be paid only on
completion of mobilization at site and after the submission of Security deposit.
Mobilization advance shall be recovered from the running account bills of the
Contractor on pro-rata basis till the mobilization advance is fully recovered.

11.0

RETENTION MONEY
10% of the gross value of each RA bill shall be retained as retention money. The
retention money will be released only after satisfactory completion of all the
works and against a bank guarantee (from a Nationalized bank) of equivalent
amount. This bank guarantee towards retention money shall be valid till
completion of defects liability period.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE. 5607A-H-CCH-400

TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 4 OF 9

12.0

TIME OF COMPLETION AND WORK SCHEDULE

12.1

Time is the essence of this contract. The Contractor shall, within two weeks of
receipt of the Letter of Intent submit to the Owner for his approval, a detailed
work schedule showing how he proposes to carry out the work. It shall
specifically mention time period as well as dates of commencement and
completion of each activity. Contractor must strictly adhere to the approved
schedule. The Owner reserves the right to revise the schedule at his discretion in
order to keep up to the completion date and to suit the project requirement and
such alterations shall not entitle the Contractor to any extra payment.

12.2

The whole works must be proceeded with, within such sections and at such times
and in such order and manner as described in these specifications and as
directed by the Engineer. No extra payment or relaxation in the rates will be
permitted on account of this.

12.3

Contractor shall make all necessary arrangement at site to mobilize and maintain,
machinery, equipment, labour, material and operators to guarantee such
minimum / peak rate of progress of the work as is required by the agreed
schedule for the timely completion of the work,

12.4

Bidder shall furnish along with the bid a list of machinery and other equipment he
proposes to employ in the work.

12.5

The Contractor shall make his own arrangements for providing accommodation
for all their staff and storage space for equipment and consumables such as but
not limited to petrol, diesel, lubricants, oxygen, acetylene, welding rods, etc.,
together with sufficient quantity of spare parts for efficient and uninterrupted
execution of the work.

12.6

The Contractor shall furnish the engineer monthly report describing the summary
of the progress / milestones achieved on each of the major fronts during the
month accompanied with Photographs. Apart from it weekly work charts shall be
submitted.

12.7

Extension of contract period will not be granted by the owner except only under
force majeure conditions equal to the time, force majeure conditions were in
existence. Monsoon or inclement weather shall not be considered as a reason
for extension of time.

12.8

Idle time charges for any reason whatsoever shall not be entertained by the
owner
If the Contractor fails to maintain the stipulated time of completion specified
herein above, he shall be liable to pay penalty as set out in `General Conditions
of Contract' under Section-E. It shall be clearly understood that failure to meet
interim completion dates shall also attract penalty.

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TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
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TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 5 OF 9

13.0

NIGHT WORK

13.1

The time of completion as defined in clause herein above, shall be deemed to


exclude working during night shifts. However, Engineer may consider granting
permission for working during night shifts, if he considers it essential in order to
complete the work in the stipulated time, on specific request by the Contractor.
Where night work is in progress, the Contractor, at his cost, to safeguard the
workmen and the public shall provide sufficient lights, shall take suitable
precautions to prevent accidents. Accident-prone areas shall be barricaded and
provided with red lights as caution to prevent accidental falls. Contractor shall
take all necessary precaution to ensure the quality of work.

14.0

EQUIPMENT

14.1

Contractor shall provide and maintain at the site necessary number and type of
machinery and equipment including survey instruments in good working condition
for proper setting out and timely completion of the various works covered under
this specification. All arrangements for transporting the equipment, men and
machinery, to and from the site shall be done by the Contractor at his own
expense. No claim shall be entertained for mobilizing additional equipment and/or
personnel to complete the work within the stipulated time.

14.2

The Contractor shall ensure a continuous supply of coarse and fine aggregates
and other materials conforming to the specification for the duration of the contract
period.

14.3

Contractor shall provide all fuels and lubricants required for the operation and
maintenance of construction machinery and equipment as well as his transport
vehicles.

14.4

Contractor shall ensure that work shall proceed uninterrupted even in the event of
power failures. As such, adequate number of diesel operated machinery (such as
concrete mixers, vibrators, welding sets, etc.) shall be provided by the Contractor
as an alternative arrangement in case electrically operated machinery are
proposed to be brought to site.

15.0

WORK EXECUTION AND SUPERVISION

15.1

Contractor shall have at the site adequate number of qualified engineers and
supervisors with experience in execution of similar type of works and also
sufficient number of foremen and operators for machinery and equipment, for
satisfactory progress and timely completion of the works.

15.2

In the event of occurrence of any accident at/near the site of work or in


connection with execution of the work, a report shall be made immediately to the
Engineer, giving full details of the accident. He shall also report such accidents to
all the competent authorities.

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TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE. 5607A-H-CCH-400

TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 6 OF 9

15.3

The Engineer reserves the right to order in writing from time to time during
progress of the work, removal and re-execution of any work which is not, in the
opinion of the Engineer, in accordance with the specification.

15.4

During inclement weather, rains, Contractor shall suspend grouting/ concreting


for such time as the Engineer may direct and shall protect from damage all works
already in progress or completed just then. All such temporary protective
measures shall be at Contractor's cost and any damage to works shall be made
good by the Contractor at his own expense.

15.5

Should the works be suspended by reason of strike/riots by Contractor's own


employees or any other cause whatsoever, save and except the force majeure
condition, Contractor shall take all precautions necessary for the protection of
work and make good, at his expense, any damage arising from any of these
causes.

15.6

Owner reserves the right to split up the work mentioned in the scope of enquiry
among more than one Contractor at the stage of initial award of contract or during
progress of work due to unsatisfactory progress of work at site by the Contractor.
Bidders quoted rates shall remain unaltered even if the work is split up. Owner
will not entertain any claim from the Contractor as a result of such splitting up.

17.0

SURVEYING AND LAYOUT

17.1

Only a base line and one permanent benchmark would be furnished to the
Contractor on site. Surveying and laying out of all works shall be done by the
Contractor at his cost. Contractor shall maintain without disturbance during the
course of execution of the work the reference line and the benchmark. The
Contractor shall also check the accuracy of positioning of the footings and anchor
bolts for the structural to be erected by him. Any discrepancy shall immediately
be reported to the Owner.

18.0

CONTRACTOR'S RESPONSIBILITIES

18.1

The Contractor will be required to provide at his own cost all facilities for his
office, warehouse, tool room, change room or any other building/structure
required to execute his work.

18.2

Each Contractor shall establish his own office / shed at specified place inside the
plant. The office/shed shall have proper ventilation lighting and sanitary facilities.
The Contractor shall obtain clearance from the Owner before construction of the
office/shed.

18.3

All royalties shall be paid by the Contractor as also all tolls, local and other taxes,
etc. at no extra cost to Owner.

18.4

All materials supplied by the Contractor shall be of the best quality and shall
conform to this specification. Approval in writing shall be obtained from Owner
before any alternative or equivalent material is proposed to be used by the
Contractor.
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TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE. 5607A-H-CCH-400

TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 7 OF 9

18.5

Contractor shall furnish manufacturer's test certificates for the materials supplied
by him. Where such certificates are not available, the specimen of the material
shall be got tested at a recognized testing laboratory (approved by Owner) at
Contractor's cost.

18.6

Contractor shall obtain all necessary permits and licenses before commencement
of work at no extra cost to Owner.

18.7

Contractor shall take all necessary insurance coverage as per the statutory
requirement at no extra cost to Owner.

19.0

DEMOBILISATION
On completion of work, the Contractor shall promptly demobilize from the site and
leave the place in a manner as directed by the Owner/Engineer, including
cleaning of the area. Contractor shall start demobilization only after the
successful completion of the contract with the permission of Owner.

20.0

OTHER WORKS
During the course of contractors works, other works either by the Owner or by
other Contractors or by both simultaneously will be in progress within the project
area. Contractor shall make his best effort to work in harmony with others in the
best overall interest of the project and towards its speedy completion.

21.0

SECURITY & SAFETY RULES OF OWNER

21.1

All persons employed or allowed at the site shall at all times conform to all
regulations laid down by the Owner.

21.2

Contractor shall strictly abide by the rules and regulations of security and safety
enforced by the Owner. Contractor shall provide proper identity cards, badges,
etc., to his employees whenever directed by the Owner.

21.3

Contractor shall be solely responsible for the security of his personnel and
equipment.

21.4

Contractor, his employees and agents shall not disclose any information or
drawing furnished to them by the Owner / Engineer. All drawings, reports or any
other information prepared by the Owner / Engineer / Contractor, either
individually or jointly for the execution of the contract shall not be disclosed
without prior written approval of the Owner. No photographs of the work or plant
within the project site shall be taken without prior written approval of the Owner.

21.5

Contractor shall adopt all safety measures/provide necessary protection to


already constructed foundation/structures irrespective of the sequence of
construction.

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TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
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22.0

TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 8 OF 9

PAYMENT
The mode of submission of bills and payment shall be as indicated in the General
Conditions of Contract under Section-E.

23.0

DRAWINGS AND DETAILS

23.1

The Contractor shall prepare fabrication drawings for structural steel works based
on his design drawings approved for construction by the Consultant / Owner.

24.0

SUBMISSION OF BID

24.1

Procedure for Submission


The completed bids shall be submitted on or before the last date and in the
manner described in the notice inviting tender

24.4

Bid shall be sealed and cover shall be superscribed


BHUBANESWAR POWER PRIVATE LIMITED- Proposed 2X80MW
Captive Power Plant

24.5

Each page of the bid document including the bid drawings shall be signed and
dated in ink by the Bidder as a token of having examined the same. English
language and metric units shall only be used.
Any corrections in the rates entered in the Schedule of Quantities shall also be
signed and dated by the Bidder in ink, before submitting the bid. Non-compliance
with these conditions will make the bid liable for rejection.

24.6

The bid prices and rates must be filled only in the Schedule of Quantities. Bidder
shall also fill in the schedule of deviations from technical specifications and
general conditions of contract. If these schedules of deviations are not filled up, it
shall be deemed that the bidder abides by the stipulations as in the bid
documents.

24.7

Bid shall be accompanied by a covering letter, in which Bidder may furnish any
information, which he wishes to be considered along with the bid.

24.8

All accompaniments of the bid shall be in duplicate.

24.9

Bidder shall submit along with his bid an attested copy of Income Tax and Sales
Tax Clearance Certificates, audited balance sheet for the last three financial
years and latest solvency certificate from the competent authorities.

24.10

Details of concurrent commitments of bidder along with list of similar works


executed in last five years and list of Manpower and equipment to be deployed
on this project and schedule of execution to be furnished along with the bid.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE. 5607A-H-CCH-400

TITLE

INSTRUCTIONS TO BIDDERS

SECTION:

A3

SHEET 9 OF 9

25.0

OWNER RESERVES RIGHT

25.1

The Owner reserves the right to accept any bid irrespective of whether it is the
lowest or otherwise or reject any or all bids without assigning any reasons
whatsoever. Owner reserves the right to split the work and/ or delete or add
some works from the scope of this contract.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE.5607A-H-CCH-400

SECTION: A4

TITLE

SHEET 1 OF 4

RC CHIMNEY - SPECIFIC TECHNICAL

(A)

PRINCIPAL DESIGN PARAMETERS

1.0

DIMENSIONS OF CHIMNEY

1.1 (a)

Clear inside diameter of brick lining at :


exit level

3000 mm

1.1 (b)

Clear inside diameter of concrete shell at :


top (Minimum)

11000 mm

1.1 (c)

Minimum thickness of shell at the top

250 mm

1.2

Top elevation of concrete shell

EL +150.000M

1.3

Batter of concrete surface


:
:

1.4

Maximum external diameter of shell of :


chimney grade slab level

1.5

Graded level of ground (EL)

(+) 0.000

1.6

Chimney grade slab level (EL)

(+) 0.30 m

1.7

Number of flue duct openings

Two

1.8

Minimum earth filling on top of raft (refer :


1.5 above)

2.0

FLUE GAS DATA

2.1

Maximum volume of flue gas through the :


chimney

151 m3/sec.

2.2

Maximum flue gas temperature at entry :


of chimney

140 0C

2.3

Flue gas pressure at chimney inlet

2.4

Maximum flue gas quantity

2.5

Gas analysis by volume %


N2

69.57(Prelimnary)

CO2

13.33

(-do-)

O2

3.05

(-do-)

Internal
External

1000 mm

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE.5607A-H-CCH-400

TITLE

SHEET 2 OF 4

RC CHIMNEY - SPECIFIC TECHNICAL

SO2

0.09

(-do-)

H2O

13.95

(-do-)

:
:

-0C
- 0C

3.0

DESIGN TEMPERATURES

3.1

Outside ambient temperature :


Maximum
Minimum

3.2

Minimum thermal gradient in shell for :


whole height

4.0

ANALYSIS
(a)
Wind Load Analysis
CD

SECTION: A4

Drag coefficient

200C

0.8

:
:
:
:

50 m/sec.

(For strake portion additional drag


coefficient shall be considered as per
Cl.A.7.1 of IS:4998 (Par-I)).
Vb

Basic Wind Speed

Terrain category
Class of structure
Topography factor k3
(b)

2
C
1.00

For Seismic Analaysis

Seismic Zone =

III

5.0

DESIGN DATA

5.1

Modular Ratio for stress computation

As per IS:4998(Part-1)-1975

5.2

Increase in concrete stress permissible :


due to ageing

Nil

5.3

Density of ash in hopper

1.12 t/m3

5.4

Maximum
coefficient
of
thermal :
conductivity of glass / mineral wool
insulation at 1500C mean temperature

0.06 kCal/m/hr/0C

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TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE.5607A-H-CCH-400

TITLE

RC CHIMNEY - SPECIFIC TECHNICAL

SECTION: A4

SHEET 3 OF 4

5.5

For computation of temperature stress,


the modules of Elasticity of Concrete to
be used shall be obtained as Es/m
where modular ratio m shall be as per
Clause 5.1 above, and Es taken as
210000 N/mm2.

5.6

Coefficient of linear thermal expansion of :


concrete and reinforcement

6.0

GENERAL REQUIREMENTS

6.1

Method of shell construction

Slipform above hopper ring


beam and slip/jump form
below this level.

6.2

Provision of strakes

If required it shall be provided


as per the Stipulation of IS
4998 - (Part I)

6.3

6.4

Provision for separate hoists for :


materials
and
passenger
during
construction
Provisions for instrumentation
:

7.0

DEFLECTION ON WIND SHIELD

7.1

The permissible deflection at top of windshield shall not exceed H/500, where
H is the total height of the windshield above top of foundation.

7.2

The amplitude of cross wind oscillation shall also be restricted to 80% of the
limits laid down as above.

11x10 6/0C

Yes

Provisions
shall
include
embeddment plates, conduits
for all I&C cables and purge
air, junction boxes, etc.
complete as per Specification.
The number of conduits and
size of conduits shall be as
required
during
detail
engineering.
Suitable
opening, pipe sleeve, flange,
access platform for working on
analyser etc. shall be provided
as required for purchasers
analysers.

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TCE CONSULTING ENGINEERS LIMITED

SPEC.NO.
TCE.5607A-H-CCH-400

8.0

TITLE

RC CHIMNEY - SPECIFIC TECHNICAL

SECTION: A4

SHEET 4 OF 4

FLOODING OF CHIMNEY AREA


CONTRACTOR shall be responsible for taking all safety measures necessary
for protecting all materials stored by him against damage by rainwater or
flooding from any other source. If any material is damaged, the
CONTRACTOR shall replace the same at no cost to the OWNER. The
OWNER shall not entertain any claim of the CONTRACTOR on this account.

9.0

The bidder shall assume subsoil water table at ground level for chimney
foundation design.

10.0

TESTS
All materials and workmanship shall be of respective kinds described in the
Contract and in accordance with the Engineer instructions and shall be
subjected from time to time to such tests as the Engineer may direct at the
place of manufacture or fabrication or on site or at all or any of such places.
For other structural components like pre-cast slabs bought out materials like
bitumen, water bar, tarfelt, acid resistant tiles bricks, fire clay bricks and
mortar, aggregates or any other material whose conformity to requirement of
specifications cannot be authenticated by CONTRACTOR by ISI certificate
etc., these materials will be got tested at approved laboratories. The cost of
samples and conducting all such tests as stated above shall be borne by the
CONTRACTOR.

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TCE FORM NO. 329 R4

SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.5607A-H-CCH-400

PROJECT INFORMATION

SECTION: B
SHEET 1 OF 4

BHUBANESHWAR POWER PRIVATE


LIMITED.
TCE Consulting Engineers Limited,
73/1, St. Marks Road,
Bangalore 560 001

1.1

Owner / PURCHASER

1.2

ENGINEER / CONSULTANT

1.3

Project Title

1.4

Location

Ananantpur(village),Athagarh,Tehsil,
Cuttack(Dist.), Orissa

1.5

Elevation above sea level

Undulated. (+)25 m to(+)45m above MSL

1.6

Latitude

200 28 N

1.7

Longitude

850 44 E

1.8

Nearest Railway Station

Ghantikal (4KM)

1.9

Name of Railway

East Coast Railways

1.10

Nearest Airport

Bhubaneshwar (45KM)

1.11

Ambient Air Temperatures

1.12

1.13

Bhubaneshwar Power Pvt. Ltd.-2X80MW


CAPTIVE POWER PLANT(coal based)
near CUTTACK

a)

Maximum
temperature

bulb

47.70 C

b)

Minimum dry bulb temperature

7.80 C

c)

Average dry bulb temperature

330 C

dry

Relative humidity

a)

Maximum

84%

b)

Minimum

47%

c)

Average

77%

Wind Rose Data

November to February- North East/East


March to October- South/ South West.

1.14

Rainfall

Annual average rainfall is 1475.3 mm.


Maximum rainfall occurs between June to
October.
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SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.5607A-H-CCH-400

1.15

Flood level

1.16

Tropicalisation

1.17

Wind Load

1.18

Wind Speed

1.19

SECTION: B
SHEET 2 OF 4

PROJECT INFORMATION

27.61M above MSL


:

a)

All equipment supplied against this


specification shall be given tropical
and
fungicidal
treatment
considering the climatic conditions
prevailing at site as described.

Wind loads shall be considered as


per IS : 875 with basic wind speed
of 50 m / sec with K1 = 1.08, K2
corresponding to terrain category 2
and K3 = 1.0

Max (km/h)

180

Min (km/h)

Annual mean (km/h)

12

Transport

By Road

Barang to Athagarh road, 20KM


from National highway no.42 at
Khuntuni.

By Rail

Broad gauge railway line of East


Coast Railways between Barang to
Ghantical (Khurda Division)

1.20

Seismic Data (As per IS:1893 latest


issue)

As per IS 1893 2002 for zone III,.


Importance factor = 1.75

1.21

Auxiliary Power Supply

Auxiliary electrical equipment to be


supplied against this specification
shall be suitable for operation on the
following supply system.

a)

For motors rated above 200 kW

6600V AC, 3 Phase, 4 Wire, 50


Hz, medium resistance earthed

b)

For motors rated 200 kW and below

c)

DC system for emergency drives, :


emergency lighting, Solenoids, DC

400V AC, 3 Phase,


Hz, solidly earthed

4 Wire, 50

220V DC, 2 Wire, unearthed

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SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.5607A-H-CCH-400

PROJECT INFORMATION

SECTION: B
SHEET 3 OF 4

alarm, control and protections


d)

AC controls and protective devices

110V AC, 1 Phase, 50 Hz, 2 Wire


AC supply. With one point earthed.
The single phase 110V AC supply
shall be derived by VENDOR by
providing 400V / 110V control
transformers of adequate rating with
MCCB / MCB on both the primary
and secondary sides.

e)

Uninterruptible power supply

230V, 1 Phase, 50 Hz, 2 Wire AC


supply from UPS system for I&C
system , SG and TG packages only.

f)

AC Solenoids, space heaters (for :


motors rated 30 kW and above)

230V, 1 Phase, 2 Wire, 50 Hz AC


system. The power supply shall be
derived by VENDOR by providing
400V/240V transformer of adequate
rating with MCCB /MCB on primary/
secondary sides.

g)

Solid state controls


solenoid valves)

(including :

+24 V DC, 2 Wire, unearthed,


supply for I & C system, SG and TG
packages only.

h)

Lighting fixtures

230V, 1 Phase, 2 Wire, 50 Hz


earthed AC system

i)

Lighting fixtures and space heaters :


in panels

230V, 1 Phase, 2 Wire, 50 Hz


earthed AC system. VENDOR shall
provide suitable MCB in the panel to
receive PURCHASERs supply at
the panel.

j)

Construction supply

415V, 3 Phase, 4 Wire, 50 Hz AC


supply with neutral lead solidly
earthed (provided by PURCHASER
at one point only).

k)

The above voltages will vary as


follows:

All devices shall be suitable for continuous operation over the entire range of voltage
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SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE.5607A-H-CCH-400

SECTION: B
SHEET 4 OF 4

PROJECT INFORMATION

and frequency indicated below without any change in their performance.:


= 10%
i)
AC Supply
: Voltage variation
Frequency variation

= 5%

Combined voltage &


Frequency variation = 10%
Ii)

Iii)

DC Supply

UPS
Supply (on standby AC
supply with automatic voltage
regulator)

24V DC: Voltage variation = + 10%


to - 10%.
220V DC: +10% to -15%
Voltage regulation
(steady state)
= 20%
Transient voltage
Regulation

= 10%

Frequency variation = 5%
1.22

Design
temperature
equipment / devices

for

electrical

500 C

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SPEC.NO.
TCE-5607A-H-CCH-400

TCE CONSULTING ENGINEERS LTD.

SECTION: C1

SCHEDULE OF QUANTITIES AND PRICES


GENERAL NOTES

SHEET 1 OF 1

TITLE

1.0

The Schedules in SectionC2 must be read in conjunction with the enclosed


specifications and drawings. The BIDDER is deemed to have examined the
technical, general and special conditions of contract and to have acquainted
himself with the site conditions and the details of the work to be done, and the
manner in which the work is to be executed at site.

2.0

The Lumpsum price should include cost of all materials (except those issued
by the OWNER), labour, tools, plants, equipments all requirements of
temporary work and contingencies whether referred to or not in the
specification, for the satisfactory and proper completion of the job.

3.0

The BIDDER shall quote his rates against items of work listed in SectionC2,
which may be required to be executed or deleted by him as a variation from
the Lumpsum Price quoted, and for works which may not fall under the
Lumpsum Price.

4.0

The rates given will not be considered for tender analysis. The rates quoted
shall be reasonable.

5.0

Rates and prices shall be written in ink and shall be both in figure and in
words.

6.0

Where there is any discrepancy between the rates quoted in figures and
words, the rates quoted in words shall prevail.

7.0

The unit rates quoted shall include for minor details of construction which are
obviously and fairly intended and which may not have been referred to in this
document but are essential for the satisfactory completion of the work.

8.0

Rates against the Lumpsum Price and for item rates shall include cost of
dewatering where necessary and no claim for payment on this account will be
entertained by the OWNER.

9.0

Rates quoted shall include for clearances of site both prior to commencement
of work and after its completion.

10.0

Being a Lumpsum Tender, the payment clauses mentioned in detailed


specifications of SectionD are not applicable for any work / item carried out
under the scope of lumpsum Contract.

11.0

Abbreviations used for the unit of various items are as stated below:
t
kg
rm
mm
m2
m3
No

=
=
=
=
=
=
=

tonne (1000 kg )
kilogram
running meter
millimeter
square meter
cubic meter
Number
ISSUE
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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SECTION: C2

BIDDING SCHEDULE FOR MULTIFLUE CHIMNEY


WITH BRICK FLUE

SHEET 1 OF 6

SPEC.NO.
TCE-5607A-H-CCH-400
TITLE

SL.
NO.
1.1

DESCRIPTION

AMOUNT
Rs.

Lumpsum price for designing, supplying, constructing and commissioning of


one number two flues RCC Chimney 150M High including but not limited to
excavation for foundation raft with de-watering, if required, back filling
including compaction and disposal of surplus soil to stack or fill, concreting
of raft including removal of muck, laying of PCC mudmat, casting of
pedestals for supporting flue ducts and stair case, providing of dowels in raft
to start shell construction, approved quality earth filling over raft, RCC
flooring with integral finish inside the chimney including laying of 100mm
thick PCC 1:4:8 over compacted earth filling, shell (shaft) including air inlet
and outlet openings with Aluminium louvers and SST bird screens,
pockets/openings to seat steel beams for intermediate internal platforms
with RCC slabs, openings for aviation obstruction lights, access to roof slab,
openings for flue ducts, etc., strakes (if required) with MS plates, angles
etc., including cost of all materials, labour, hot dip galvanising, anticorrosive painting, designing and installation on the chimney shell with hot
dip galvanised bolts in sleeves left in the shell for the purpose, intermediate
internal platforms including elastomeric bearing pads below beams & filler
material at top of beams, hand-rails, bottom soot / ash hoppers with cellular
concrete including pipes with flanges in hoppers, fire / acid resistant brick
lining with metal ties including curing, steel bands around brick lining, acid
proof tile flooring on the top platform, insulation around brick lining and
ducts, GI sheet cladding around insulation, access, maintenance and clean
out doors, structural steel stair case, hot dip galvanised MS ladders,
lightning protection system, earthing system, aviation warning beacons,
flood lights, lighting conduits with cable boxes, control panel, main
Distribution Board / lighting Distribution Board, photocells, CI Chimney
Caps, fabrication and fixing of flue ducts including their supports, portholes
with their fitting for installation of gas analysers in MS ducts with access
staircase platforms arrangement, mild and /or steel reinforcement
embedments / inserts, plates anchors / bolts, pipe sleeves, for instruments,
fixtures, wind strakes, etc. painting both internal and external surfaces,
providing and installing of hoists for construction purposes with all
accessories for men & material, necessary staging, shuttering (formwork
including slipform), scaffolding, bracing, centering, including supervision,
supply and cost of all materials, labour, all tools and plants, equipments,
winches, machinery (including diesel operated) and all leads and lifts
vibrating, curing etc. dismantling etc., clearance of site to restore it to
original finish and all other remaining & finishing works, complete to form a
workable complete chimney arrangement as detailed in the scope of work,
as per specifications, as depicted in the bid drawings and as directed by
ENGINEER.

SL.
NO.

DESCRIPTION

PERCENTAGE
OF LUMPSUM
ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SECTION: C2

BIDDING SCHEDULE FOR MULTIFLUE CHIMNEY


WITH BRICK FLUE

SHEET 2 OF 6

SPEC.NO.
TCE-5607A-H-CCH-400
TITLE

PRICE
2.0

Price Break up as a percentage of the total Lumpsum price


quoted under item 1.1.

2.1

a)
b)

2.2

2.3

2.5

On approval of soil investigation report, G.A. drawings and


design & detailed foundation drawings
On approval of design & detailed shell, shell openings
drawings

0.5%
0.5%

FOUNDATION WORK
a)
On completion of Excavation work including disposal

1%

b)

On laying raft including pedestals for duct & stair case


earth filling (inside), earth filling (outside), compaction
etc.

10%

c)

On raising RCC shell to 0.00m level

2%

RCC SHELL
a)
On mobilisation of slipform equipment at site

3%

b)

On erection of slipform equipment in position

2%

c)

On completion of RCC shell

To

45.0m level

9%

To

90.0m level

7%

To 135.0m level

5%

To 150.0m level

2%

2.4
a)

STEEL BEAM PLATFORMS


On fabrication of steel beams

2%

b)

On erection of steel beams

1%

c)

On laying of RCC slabs on


beams

1%

d)

On completion of painting of
steel beams

1%

RCC PLATFORMS
a)
On completion of RCC platforms

12%
ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SECTION: C2

BIDDING SCHEDULE FOR MULTIFLUE CHIMNEY


WITH BRICK FLUE

SHEET 3 OF 6

SPEC.NO.
TCE-5607A-H-CCH-400
TITLE

b)

c)
2.6

2.7

On completion of laying of concrete on top level


platforms (including laying of top slab)

1%

On completion of railing work (external & internal)

1%

LINING & INSULATION (BOTH FLUES)


a)
For complete lining work

6%

b)

6%

For complete Insulation & cladding work (including


provision of MS bands around brick flues)

HOPPERS (BOTH FLUES)


a)
Construction of hoppers

2%

2.8

Providing and fixing of CI caps

1%

2.9

STAIRCASE & LADDERS


a)
Fabrication and galvanising

2.10

2.5%

b)

On completion of erection work

1%

c)

On completion of painting work

1%

Provision of port holes, of completion of ducts connections


including painting (both flues)

1%

2.11

Electrical works including earthing, aviation obstruction lights

3%

2.12

Lightning protection works including earthing

1%

2.13

PAINTING OF CHIMNEY
a)

External surface of chimney

1.5%

b)

Internal surface of shell and platforms

1.5%

c)

Internal provision such as railings and doors etc.

0.5%

2.14

Flooring at 0.00 metre level including laying of 100 mm thick


PCC (1:4:8) over compacted sand filling

0.5%

2.15

Miscellaneous Fabrication, erection and painting works such as


portholes including access platforms, doors, pulley brackets,
wire mesh screens, louvers, etc.

1.5%

2.16

Finishing work, site clearance, etc

1%

ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SECTION: C2

BIDDING SCHEDULE FOR MULTIFLUE CHIMNEY


WITH BRICK FLUE

SHEET 4 OF 6

SPEC.NO.
TCE-5607A-H-CCH-400
TITLE

2.17

Final commissioning and completion of all other works in all


respects

10%

Total

100%

NOTES:
1.

In the event of the tenderer not accepting the break-up of lumpsum price his
bid shall be treated as unresponsive and shall be summarily rejected.

2.

The bidder shall under no circumstances change the pattern of the break up.

3.

Intermediate payments shall be released in stages to the extent as per price


break up given above.

4.

VENDOR shall quote his rates against items of work which may be required
to be executed/deleted by him as a variation from the Lumpsum price quoted
in Bidding Schedule and for essential works which may not fall under the
Lumpsum price which the CONTRACTOR may be asked to execute/delete.

5.

This schedule will not be considered for bid analysis. The rates quoted shall
be reasonable :

Sl. No.

Description

1.

Excavation below ground/grade level in all kinds of


ordinary and hard soils for foundation/footings, trenches,
etc. including desilting, dewatering, if required, shoring,
strutting as necessary, backfilling around foundation with
selected earth and consolidating by watering and
transporting excess excavated soil to stackyards as
directed by the OWNER.

2.

Unit

Rate (Rs.)

m3

Providing and placing reinforced cement concrete with


40 mm down graded coarse aggregate excluding
reinforcement but including dewatering if required,
shuttering, scaffolding, vibrating, finishing, curing, for
all,etc, complete.

For works below ground level as per specification and as


directed by the ENGINEER:
ISSUE
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TCE CONSULTING ENGINEERS LIMITED

SECTION: C2

BIDDING SCHEDULE FOR MULTIFLUE CHIMNEY


WITH BRICK FLUE

SHEET 5 OF 6

SPEC.NO.
TCE-5607A-H-CCH-400
TITLE

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

3.

5.

M25
M30
M35
M40

Providing and placing reinforced cement concrete with


20 mm down graded coarse aggregate excluding
reinforcement but including dewatering if required,
shuttering, scaffolding, vibrating, finishing, curing,etc
complete for all works below ground level as per
specification and as directed by the ENGINEER.
(a) M25
(b) M30
(c) M35

m3
m3
m3

Same as above but providing above ground level


(a) M25
(b) M30
(c) M35
(d) M40

m3
m3
m3
m3

Providing and laying plain cement concrete in blinding


layer/fill under etc. with 40 mm down graded coarse
aggregate including dewatering, shuttering, curing etc.
complete for the following grades :
(a) 1:4:8

6.

8.

m3

Providing, supplying, cleaning, cutting, lapping, bending


as per drawings and placing in position reinforcement
bars at all locations and levels including binding with 2
strands of 18 gauge soft annealed wire/welding as
required etc. complete as shown on construction
drawings :
(a) Mild steel bars conforming to IS:432 Gr-I
(b) High yield strength deformed bars conforming to
IS:1786

7.

m3
m3
m3
m3

Providing, supplying, placing, aligning fixing in position to


correct lines and levels all steel inserts in reinforced
concrete works including fabrication and painting
exposed surfaces as per specification.

t
t

Supply, providing and fix in position, etc. complete 5 x 6


mm GI strip down conductor anchored at every 700 mm
ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SECTION: C2

BIDDING SCHEDULE FOR MULTIFLUE CHIMNEY


WITH BRICK FLUE

SHEET 6 OF 6

SPEC.NO.
TCE-5607A-H-CCH-400
TITLE

including all necessary fixtures as per specification and


as directed by OWNER, including painting with black
bitumen over a coat of etching primer.
9.

Supply, provide and fix in position two stranded tinned


copper down conductors of area 75 sq.mm including
embedding in the concrete shell, etc completed as per
specification and as directed by OWNER.

rm

rm

ISSUE
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TCE FORM NO. 329 R4

SPEC. NO.
TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED

SECTION: C3
SHEET 1 OF 1

TITLE

LIST OF BID DRAWINGS

LIST OF BID DRAWINGS

1.0

TCE-5607A-GA-100-1001-P5

Plot Plan

2.0

TCE-5607A-266-RC-5004-P0

3.0

TCE 5312A-816-GL-3071-P0

4.0

TCE 5312A-815-GL-3070-P0

150Mt High RCC Chimney General


Arrangement
RC Chimney Earthing and Lightning
Protection Layout
RC Chimney Lighting Layout

ISSUE
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SPEC. NO.

TCE-5607A-HCCH-400

1.

SECTION: D1

TCE CONSULTING ENGINEERS LIMITED


TITLE

SHEET 1 OF 11

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SCOPE
This specification covers the general requirements of earthwork in
excavation in different materials, site grading, filling in areas as shown
in drawing, filling back around foundations and in plinths, conveyance
and disposal of surplus soils or stacking them properly as shown on the
drawings and as directed by the Engineer and all operations covered
within the intent and purpose of this specification.

2.

APPLICABLE CODES
The following Indian Standard Codes, unless otherwise specified
herein, shall be applicable. All Codes and Standards referred to shall
be the latest version on the date of offer made by the Bidder unless
otherwise indicated.

1. IS 783-1985

- Code of practice for laying of concrete pipes.

2.

- Method of measurement of building and civil


engineering works.

IS 1200
(Part 1)

Part 1- Earthwork

(Part 27)

Part 27- Earthwork done by mechanical


appliances.

3.

IS 3764-1992

- Excavation work-code of safety.

4.

IS 2720

- Methods of test for soils:

(Part 1)-1973

- Part 1 Preparation of dry soil samples for


various tests.

(Part 2)-1986

- Part 2 Determination of water content.

(Part 4)-

- Part 4 Grain size analysis.

(Part 5)

- Part 5 Determination of liquid and plastic


limit.

(Part 7)

- Part 7 Determination of water content-dry


density relation using light compaction.

Part (9)

- Part 9 Determination of dry density - moisture


content relation by constant weight of soil
method.

(Part 14)

- Part 14 Determination of density index


(relative density) of cohesionless soils.

(Part 28)

- Part 28 Determination of dry density of soils


in place, by the sand replacement method.
ISSUE
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SPEC. NO.

SECTION: D1

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

SHEET 2 OF 11

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

(Part 33)

- Part 33 Determination of the density in place


by the ring and water replacement method.

(Part 34)

- Part 34 Determination of density of soil in


place by rubber balloon method.

(Part 38)

- Part 38 Compaction control test (Hilf


Method).

3.

DRAWINGS

3.1

The Engineer will furnish drawings wherever, in his opinion, such


drawings are required to show areas to be excavated/ filled grade level,
sequence of priorities etc. The Contractor shall follow strictly such
drawings.

4.

GENERAL

4.1

The Contractor shall furnish all tools, plants, instruments, qualified


supervisory personnel, labour, materials any temporary works,
consumables, any and everything necessary, whether or not such
items are specifically stated herein for completion of the job in
accordance with the specification requirements.

4.2

The Contractor shall carry out the survey of the site before excavation
and set properly all lines and establish levels for various works such as
earthwork in excavation for grading, basement, foundations, plinth
filling, roads, drains, cable trenches, pipelines etc. Such survey shall
be carried out by taking accurate cross sections of the area
perpendicular to established reference/ grid lines at 8 m. intervals or
nearer as determined by the Engineer based on ground profile. These
shall be checked by the Engineer and thereafter properly recorded.

4.3

The excavation shall be done to correct lines and levels. This shall
also include, where required, proper shoring to maintain excavations
and also the furnishing, erecting and maintaining of substantial
barricades around excavated areas and warning lamps at night for
ensuring safety.

4.4

The rates quoted shall also include for dumping of excavated materials
in regular heaps, bunds, riprap with regular slopes as directed by the
Engineer, within the lead specified and levelling the same so as to
provide natural drainage. Rock/ soil excavated shall be stacked
properly as directed by the Engineer. As a rule, all softer material shall
be laid along the centre of heaps, the harder and more weather
resisting materials forming the casing on the sides and the top. Rock
shall be stacked separately.
ISSUE
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SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 3 OF 11

5.

CLEARING

5.1

The area to be excavated / filled shall be cleared of fences, trees,


plants, logs, stumps, bush, vegetation, rubbish, slush, etc. and other
objectionable matter. If any roots or stumps of trees are met during
excavation, they shall also be removed. The material so removed shall
be burnt or disposed off as directed by the Engineer. Where earthfill is
intended, the area shall be stripped of all loose/ soft patches, top soil
containing objectionable matter/ materials before fill commences.

6.

PRECIOUS OBJECTS,RELICS,OBJECTS OF ANTIQUITY,ETC.

6.1

All gold, silver, oil, minerals, archaeological and other findings of


importance, trees cut or other materials of any description and all
precious stones, coins, treasures, relics, antiquities and other similar
things which may be found in or upon the site shall be the property of
the Owner and the Contractor shall duly preserve the same to the
satisfaction of the Owner and from time to time deliver the same to
such person or persons as the Owner may from time to time authorise
or appoint to receive the same.

7.

CLASSIFICATION

7.1

All materials to be excavated shall be classified by the Engineer, into


one of the following classes and shall be paid for at the rate tendered
for that particular class of material. No distinction shall be made
whether the material is dry, moist or wet. The decision of the Engineer
regarding the classification of the material shall be final and binding on
the Contractor and not be a subject matter of any appeal or arbitration.

7.2

Any earthwork will be classified under any of the following categories:


(a) Ordinary and Hard Soils
These shall include all kinds of soils containing kankar, sand, silt,
murrum and/or shingle, gravel, clay, loam, peat, ash, shale, etc., which
can generally be excavated by spade, pick axes and shovel, and which
is not classified under "Soft and Decomposed Rock" and "Hard Rock"
defined below. This shall also include embedded rock boulders not
longer than 1 metre in any one direction and not more than 200 mm in
any one of the other two directions.
(b) Soft and Decomposed Rock
This shall include rock, boulders, slag, chalk, slate, hard micaschist,
laetrile and all other materials which in the opinion of Engineer is rock,
but does not need blasting and could be removed with picks, hammer,
crow bars, wedges, and pneumatic breaking equipment. The mere fact
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TCE CONSULTING ENGINEERS LIMITED

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TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 4 OF 11

that the Contractor resorts to blasting for reasons of his own, shall not
qualify for classification under 'Hard Rock'.
This shall also include excavation in macadam and tarred roads and
pavements. This shall also include rock boulders not longer than
1 metre in any direction and not more than 500 mm in any one of the
other two directions. Masonry to be dismantled will also be measured
under this item.
(c) Hard Rock
This shall include all rock occurring in large continuous masses which
cannot be removed except by blasting for loosening it. Harder varieties
of rock with or without veins and secondary minerals which, in the
opinion of the Engineer require blasting shall be considered as hard
rock. Boulders of rock occurring in such sizes and not classified under
(a) and (b) above shall also be classified as hard rock. Concrete work
both reinforced and unreinforced to be dismantled will be measured
under this item, unless a separate provision is made in the Schedule of
Quantities.
8.

EXCAVATION

8.1

All excavation work shall be carried out by mechanical equipment


unless, in the opinion of the Engineer, the work involved and time
schedule permit manual work.

8.2

Excavation for permanent work shall be taken out to such widths,


lengths, depths and profiles as are shown on the drawings or such
other lines and grades as may be specified by the Engineer. Rough
excavation shall be carried out to a depth 150 mm above the final level.
The balance shall be excavated with special care. Soft pockets shall
be removed even below the final level and extra excavation filled up as
directed by the Engineer. The final excavation if so instructed by the
Engineer, should be carried out just prior to laying the mud-mat.

8.3

The Contractor may, for facility of work or similar other reasons


excavate, and also backfill later, if so approved by the Engineer, at his
own cost outside the lines shown on the drawings or directed by the
Engineer. Should any excavation be taken below the specified
elevations, the Contractor shall fill it up, with concrete of the same
class as in the foundation resting thereon, upto the required elevation.
No extra shall be claimed by the Contractor on this account.

8.4

All excavation shall be done to the minimum dimensions as required for


safety and working facility. Prior approval of the Engineer shall be
obtained by the Contractor in each individual case, for the method he
proposes to adopt for the excavation, including dimensions, side
ISSUE
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SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 5 OF 11

slopes, dewatering, disposal, etc. This approval, however, shall not in


any way relieve the Contractor of his responsibility for any consequent
loss or damage. The excavation must be carried out in the most
expeditious and efficient manner. Side slopes shall be as steep as will
stand safely for the actual soil conditions encountered.
Every
precaution shall be taken to prevent slips. Should slips occur, the
slipped material shall be removed and the slope dressed to a modified
stable slope. Removal of the slipped earth will not be paid for if the
slips are due to the negligenc e of the Contractor.
8.5

Excavation shall be carried out with such tools, tackles and equipment
as described hereinbefore. Blasting or other methods may be resorted
to in the case of hard rock; however not without the specific permission
of the Engineer.

8.6

The Engineer may also direct that in some extreme case, the rock may
be excavated by heating and sudden quenching for splitting the rock.
Fire-wood shall be used for burning and payment shall be made for
such work as called for in the schedule of quantities.

9.

STRIPPING LOOSE ROCK

9.1

All loose boulders, semi detached rocks (along with earthy stuff which
might move therewith) not directly in the excavation but so close to the
area to be excavated as to be liable, in the opinion of the Engineer, to
fall or otherwise endanger the workmen, equipment, or the work, etc.,
shall be stripped off and removed away from the area of the
excavation. The method used shall be such as not to shatter, or render
unstable or unsafe the portion which was originally sound and safe.

9.2

Any material not requiring removal as contemplated in the work, but


which, in the opinion of the Engineer, is likely to become loose or
unstable later, shall also be promptly and satisfactorily removed as
directed by the Engineer. The cost of such stripping will be paid for at
the unit rates accepted for the class of materials in question.

10.

FILL, BACK FILLING AND SITE GRADING

10.1

General
All fill material will be subject to the Engineer's approval. If any
material is rejected by the Engineer, the Contractor shall remove the
same forthwith from the site at no extra cost to the Owner. Surplus fill
material shall be deposited/ disposed off as directed by the Engineer
after the fill work is completed.

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SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 6 OF 11

No earthfill shall commence until surface water discharges and streams


have been properly intercepted or otherwise dealt with as directed by
the Engineer.
10.2

Material
To the extent available, selected surplus soils from excavated materials
shall be used as backfill. Fill material shall be free from clods, salts,
sulphates, organic or other foreign material. All clods of earth shall be
broken or removed. Where excavated material is mostly rock, the
boulders shall be broken into pieces not larger than 150 mm size,
mixed with properly graded fine material consisting of murrum or earth
to fill up the voids and the mixture used for filling.

10.3

If any selected fill material is required to be borrowed, the Contractor


shall make arrangements for bringing such material from outside
borrow pits. The material and source shall be subject to prior approval
of the Engineer. The approved borrow pit area shall be cleared of all
bushed, roots of trees, plants, rubbish etc. top soil containing salts/
sulphate and other foreign material shall be removed. The materials so
removed shall be burnt or disposed off as directed by the Engineer.
The Contractor shall make necessary access roads to borrow areas
and maintain the same, if such access road does not exist, at his cost.

10.4

Filling in pits and trenches around foundations of structures,walls


etc.
As soon as the work in foundations has been accepted and measured,
the spaces around the foundations, structures, pits, trenches etc. shall
be cleared of all debris, and filled with earth in layers not exceeding 15
cm., each layer being watered, rammed and properly consolidated,
before the succeeding one is laid. Each layer shall be consolidated to
the satisfaction of the Engineer. Earth shall be rammed with approved
mechanical compaction machines. Usually no manual compaction
shall be allowed unless the Engineer is satisfied that in some cases
manual compaction by tampers cannot be avoided. The final backfill
surface shall be trimmed and levelled to proper profile as directed by
the Engineer or indicated on the drawings.

10.5

Plinth filling
Plinth filling shall be carried out with approved material as described
hereinbefore in layers not exceeding 15 cm, watered and compacted
with mechanical compaction machines. The Engineer may however
permit manual compaction by hand tampers in case he is satisfied that
mechanical compaction is not possible. When filling reaches the
finished level, the surface shall be flooded with water, unless otherwise
directed, for at least 24 hours allowed to dry and then the surface again
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SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 7 OF 11

compacted as specified above to avoid settlements at a later stage.


The finished level of the filling shall be trimmed to the level/ slope
specified.
Where specified in the schedule of works, compaction of the plinth fill
shall be carried out by means of 12 tonne rollers smooth wheeled,
sheep-foot or wobbly wheeled rollers. In case of compaction of
granular material such as sands and gravel, vibratory rollers shall be
used. A smaller weight roller may be used only if permitted by the
Engineer. As rolling proceeds water sprinkling shall be done to assist
consolidation. Water shall not be sprinkled in case of sandy fill.
The thickness of each unconsolidated fill layer can in this case be upto
a maximum of 300 mm. The Engineer will determine the thickness of
the layers in which fill has to be consolidated depending on the fill
material and equipment used.
Rolling shall commence from the outer edge and progress towards the
centre and continue until compaction is to the satisfaction of the
Engineer, but in no case less than 10 passes of the roller will be
accepted for each layer.
The compacted surface shall be properly shaped, trimmed and
consolidated to an even and uniform gradient. All soft spots shall be
excavated and filled and consolidated.
At some locations/ areas it may not be possible to use rollers because
of space restrictions etc. The Contractor shall then be permitted to use
pneumatic tampers, rammers etc. and he shall ensure proper
compaction.
10.6

Sand filling in plinth and other places


At places backfilling shall be carried out with local sand if directed by
the Engineer. The sand used shall be clean, medium grained and free
from impurities. The filled-in-sand shall be kept flooded with water for
24 hours to ensure maximum consolidation. Any temporary work
required to contain sand under flooded condition shall be to the
Contractor's account. The surface of the consolidated sand shall be
dressed to required level or slope. Construction of floors or other
structures on sand fill shall not be started until the Engineer has
inspected and approved the fill.

10.7

Filling in trenches
Filling in trenches for pipes and drains shall be commenced as soon as
the joints of pipes and drains have been tested and passed. The
backfilling material shall be properly consolidated by watering and
ramming, taking due care that no damage is caused to the pipes.
ISSUE
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TCE FORM NO. 329 R4

SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 8 OF 11

Where the trenches are excavated in soil, the filling from the bottom of
the trench to the level of the centreline of the pipe shall be done by
hand compaction with selected approved earth in layers not exceeding
8 cm; backfilling above the level of the centreline of the pipe shall be
done with selected earth by hand compaction or other approved means
in layers not exceeding 15 cm.
In case of excavation of trenches in rock, the filling upto a level 30 cm.
above the top of the pipe shall be done with fine materials, such as
earth, murrum etc. The filling up of the level of the centreline of the
pipe shall be done by hand compaction in layers not exceeding 8 cm.
where as the filling above the centreline of the pipe shall be done by
hand compaction or approved means in layers not exceeding 15 cm.
The filling from a level 30 cm. above the top of the pipe to the top of the
trench shall be done by hand or other approved mechanical methods
with broken rock filling of size not exceeding 15 cm mixed with fine
material as available to fill up the voids.
Filling of the trenches shall be carried simultaneously on both sides of
the pipe to avoid unequal pressure on the pipe.
11.

GENERAL SITE GRADING

11.1

Site grading shall be carried out as indicated in the drawings and as


directed by the Engineer. Excavation shall be carried out as specified
in the specification. Filling and compaction shall be carried out as
specified under Clause 10.0 and elsewhere unless otherwise indicated
below.

11.2

If no compaction is called for, the fill may be deposited to the full height
in one operation and levelled. If the fill has to be compacted, it shall be
placed in layers not exceeding 225 mm and levelled uniformly and
compacted as indicated in Clause 10.0 before the next layer is
deposited.

11.3

To ensure that the fill has been compacted as specified, field and
laboratory tests shall be carried out by the Contractor at his cost.

11.4

Field compaction test shall be carried out at different stages of filling


and also after the fill to the entire height has been completed. This
shall hold good for embankments as well.

11.5

The Contractor shall protect the earthfill from being washed away by
rain damaged in any other way. Should any slip occur, the Contractor
shall remove the affected material and make good the slip at his cost.

11.6

The fill shall be carried out to such dimensions and levels as indicated
on the drawings after the stipulated compaction. The fill will be

ISSUE
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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 9 OF 11

considered as incomplete if the desired compaction has not been


obtained.
11.7

If specifically permitted by the Engineer, compaction can be obtained


by allowing loaded trucks conveying fill or other material to ply over the
fill area. Even if such a method is permitted, it will be for the Contractor
to demonstrate that the desired/ specified compaction has been
obtained. In order that the fill may be reasonably uniform throughout,
the material should be dumped in place in approximately uniform
layers. Traffic over the fill shall then be so routed to compact the area
uniformly throughout.

11.8

If so specified, the rock as obtained from excavation may be used for


filling and levelling to indicated grades without further breaking. In such
an event, filling shall be done in layers not exceeding 50 cms
approximately. After rock filling to the approximate level, indicated
above has been carried out, the void in the rocks shall be filled with
finer materials such as earth, broken stone, etc. and the area flooded
so that the finer materials fill up the voids. Care shall be taken to
ensure that the finer fill material does not get washed out. Over the
layer so filled, a 100 mm thick mixed layer of broken material and earth
shall be laid and consolidation carried out by a 12 tonne roller. No less
than twelve passes of the roller shall be accepted before subsequent
similar operations are taken up.

12.

FILL DENSITY

12.1

The compaction, only where so called for, in the schedule of quantities/


items shall comply with the specified (Standard Proctor/ Modified
Proctor) density at moisture content differing not more than 4 percent
from the optimum moisture content. The Contractor shall demonstrate
adequately at his cost, by field and laboratory tests that the specified
density has been obtained.

13.

LEAD

13.1

Lead for deposition/ disposal of excavated material, shall be as


specified in the respective item of work.
For the purpose of
measurement of lead, the area to be excavated or filled or area on
which excavated material is to be deposited/ disposed off shall be
divided into suitable blocks and for each of the blocks, the distance
between centrelines shall be taken as the lead which shall be
measured by the shortest straight line route on the plan and not the
actual route taken by the Contractor. No extra compensation is
admissible on the grounds that the lead including that for borrowed
material had to be transported over marshy or 'katcha' land/ route.
ISSUE
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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 10 OF 11

14.

MEASUREMENT AND PAYMENT

14.1

All excavation shall be measured nett. Dimensions for purpose of


payment shall be reckoned on the horizontal area of the excavation at
the base for foundations of the walls, columns, footings, tanks, rafts or
other foundations/ structures to be built, multiplied by the mean depth
from the surface of the ground in accordance with the drawings.
Excavation in side slopes will not be paid for. The Contractor may
make such allowance in his rates to provide for excavation in side
slopes keeping in mind the nature of the soil and safety or excavation.
Reasonable working space, beyond concrete dimensions and
shuttering where considered necessary in the opinion of the Engineer
will be allowed in excavation and considered for payment. However, if
concreting is proposed against the excavated sides, no such overexcavation will be permitted. In such cases over-excavation shall be
made good by the Contractor with concrete of the same class as in the
foundations at his cost.

14.2

Unless otherwise specified, the unit rates quoted for excavation in


different types of material shall also account for a basic lead of 100
metres for disposal as specified or directed. Only leads beyond the
basic lead of 100 metres will be considered as extra lead and paid for
at the rates quoted in the schedules.

14.3

Backfilling as per specification the sides of foundations of columns,


footings, structures, walls, tanks, rafts, trenches etc. with excavated
material will not be paid for separately. It shall be clearly understood
that the rate quoted for excavation including backfilling shall include
stacking of excavated material as directed, excavation/ packing of
selected stacked material, conveying it to the place of final backfill,
compaction etc. as specified. As a rule material to be backfield shall
be stacked temporarily within the basic lead of 100 metres unless
otherwise directed by the Engineer. If the Engineer directs/ permits a
lead of over 100 metres for such material, the conveyance of the
material for the extra distance over the basic lead of 100 metres for
backfilling will be paid for.

14.4

Payment for fill inside trenches, plinth or similar filling with selected
excavated material will be made for only compaction as specified/
directed. Cost of all other operations shall be deemed to have been
covered in the rate quoted for excavation. Payment for this work will
be made based on measurement of plinth/ trench dimensions filled.
The plinth ground levels shall be surveyed before hand for this
purpose. If no compaction is specified/ desired such filling will not be
separately paid for. In such a event the fill shall be levelled/ finished to
the profile as directed at no extra cost.
ISSUE
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TCE FORM NO. 329 R4

SPEC. NO.

TCE CONSULTING ENGINEERS LIMITED

TCE-5607A-HCCH-400

TITLE

EARTHWORK IN GRADING,
EXCAVATON AND BACK FILLING

SECTION: D1
SHEET 11 OF 11

14.5

Backfilling, plinth filling etc. with borrowed earth will be paid for at rates
quoted. The quoted rate shall include all operations such as clearing,
excavation, lead and transport, fill, compaction etc. as specified.
Actual quantity of consolidated filling or actual quantity or excavation in
the borrow pits (less such top soil which has been excavated and not
used for filling) whichever is less shall be measured and paid for in
cubic metres. The lead, lift etc. shall be as indicated in the schedule of
quantities.

14.6

Actual quantity of consolidated sand filling shall be measured and paid


in cubic metres.

ISSUE
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TCE FORM NO. 329 R4

SPEC. NO.
TCE. 5607A-H-CCH400

1.0

TITLE

TCE CONSULTING ENGINEERS LIMITED

SECTION : D2

SPECIFICATION FOR
TIMBER SHORING

SHEET 1 OF 2

SCOPE
This specification covers the general requirements of timber shoring for
excavation of trenches, pits, open excavations etc.

2.0

Close timbering shall be done by completely covering the sides of the trenches
and pits generally with short, upright members called 'polling boards'. These shall
be of minimum 25 cm x 4 cm sections or as directed by Engineer. The boards
shall generally be placed in position vertically side by side without any gap on
each side of the excavation and shall be secured by horizontal walings of strong
wood at maximum 1.2 metres spacings, strutted with ballies or as directed by
Engineer. The length of the ballie struts shall depend on the width of the trench or
pit. If the soil is very soft and loose, the boards shall be placed horizontally
against each side of the excavation and supported by vertical walings, which in
turn shall be suitably strutted. The lowest boards supporting the sides shall be
taken into the ground and no portion of the vertical side of the trench or pit shall
remain exposed, so as to render the earth liable to slip out.

2.1

Timber shoring shall be 'close' or 'open' type, depending on the nature of soil and
the depth of pit or trench. The type of timbering shall be as approved by
Engineer. It shall be the responsibility of Contractor to take all necessary steps to
prevent the sides of excavations, trenches, pits, etc., from collapsing.

2.2

Timber shoring may be required to keep the sides of excavations vertical to


ensure safety of adjoining structures or to limit the slope of excavations, or due to
space restrictions or for other reasons. Such shoring shall be carried out, except
in an emergency, only under instructions from Engineer.

2.3

The withdrawal of the timber shall be done very carefully to prevent the collapse
of the pit or trench. It shall be started at one end and proceeded with
systematically to the other end. Concrete or masonry shall not be damaged
during the removal of the timber. No claim shall be entertained for any timber
which cannot be withdrawn and is lost or buried.

2.4

In the case of open timbering, the entire surface of the side of trench or pit in not
required to be covered. The vertical boards of minimum 25 cm x 4 cm sections
shall be spaced sufficiently apart to leave unsupported strips of maximum 50 cm
average width. The detailed arrangement, sizes of the timber and the spacings
shall be subject to the approval of Engineer. In all other respects, specification for
close timbering shall apply to open timbering.

2.5

In case of large pits and open excavations, where shoring is required for securing
safety of adjoining structures or for any other reasons and where the planking for
sides of excavations/pits cannot be strutted against, suitable inclined struts
supported on the excavated bed shall be provided. Load from such struts shall be
suitably distributed on the bed to ensure no yielding of the strut. If, however,
Engineer directs any timbering to be left-in, keeping in mind the type of
construction or any other factor, Contractor shall be paid for at the scheduled
item-rate for such left-in timbering.

ISSUE
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TCE FORM NO. 329 R4

SPEC. NO.
TCE. 5607A-H-CCH400

3.0

TCE CONSULTING ENGINEERS LIMITED

SECTION : D2

SPECIFICATION FOR
TIMBER SHORING

SHEET 2 OF 2

TITLE

MEASUREMENT
The actual effective area of shored faces as approved by Engineer shall be
measured in sq.m. The area of planking embedded in the bed/sides of excavation
will not be considered, nor the area supporting inclined struts in case of large
pits/open excavation. All planks, boards, walings, verticals, struts, props and all
other materials required for shoring and subsequent safe dismantling and
removal shall be included in the quoted unit rates. Unless separately provided for
in the Schedule of Prices, the cost of shoring/struting shall be included in the item
rate for excavation.

ISSUE
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TCE FORM NO. 329 R4

SPEC.NO.
TCE-5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED

SECTION: D3
SHEET 1 OF 1

DEWATERING

1.0

SCOPE
This specification covers
excavations in general.

the

general

requirements

of

dewatering

2.1.

All excavations shall be kept free of water. Grading in the vicinity of


excavation shall be properly closed to prevent surface water running into
excavated areas. Contractor shall remove by pumping or other means
approved by Engineer any water inclusive of rain water and subsoil water
accumulated in excavation and keep all excavations dewatered until the
foundation work is completed and backfilled. Sumps made for dewatering
must be kept clear of the excavations / trenches required for further work.
Method of pumping shall be approved by Engineer; but in any case, the
pumping arrangement shall be such that there shall be no movement of
subsoil or blowing in due to differential head of water during pumping.
Pumping arrangements shall be adequate to ensure no delays in
construction.

2.2.

When there is a continuous inflow of water and quantum of water to be


handled is considered in the opinion of Engineer, as large, well point system
- Single stage or multi stage, shall be adopted. Contractor shall submit to
Engineer his scheme of well point system including the stages, the spacing,
number and diameter of well points, headers etc., and the numbers, capacity
and location of pumps of approvals. Unless separately provided for in the
Schedule of prices, the cost of dewatering shall be included in the item rate
for excavation.

ISSUE
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TCE FORM NO. 329 R4

SPEC.NO.
TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED

SECTION: D4

TITLE

SHEET 1 OF 1

RAIN WATER DRAINAGE

1.

SCOPE
This section covers the drainage of rain water in excavated areas.

2.

Grading in the vicinity of excavation shall be such as to exclude rain /


surface water draining into excavated areas. Excavation shall be kept clean
of rain and such water as the Contractor may be using for his work by
suitably pumping out the same at no extra cost to the owner. The scheme
for pumping and discharge of such water shall be approved by the Engineer.

ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC. NO

SECTION : D5
SHEET 1 OF 26

TCE.- 5607A-H-CCH-400

TITLE

CONCRETE AND ALLIED WORKS

1.0

SCOPE

1.1

This Specification covers the general requirements for concrete using on-site
production facilities including requirements in regard to the quality, handling,
storage of ingredients, proportioning, batching, mixing, transporting, placing,
curing, protecting, repairing, finishing and testing of concrete; formwork;
requirements in regard to the quality, storage, bending and fixing of
reinforcement; grouting as well as mode of measurement and payment for
completed works.

1.2

Section D6,D7 covers the specific requirements for Chimney Section D6, D7
and this specification are complementary and are to be read together.

1.3

It shall be very clearly understood that the specifications given herein are brief
and do not cover minute details. However, all works shall have to be carried
out in accordance with the relevant standards and codes of practices or in
their absence in accordance with the best accepted current engineering
practices or as directed by ENGINEER from time to time. The decision of
ENGINEER as regards the specification to be adopted and their interpretation
and the mode of execution of work shall be final and binding on
CONTRACTOR and no claim whatsoever will be entertained on this account.

2.0

APPLICABLE CODES AND SPECIFICATIONS

2.1

The following specifications, standards and codes, including all official


amendments/revisions and other specifications & codes referred to therein,
should be considered a part of this specification. In all cases the latest
issue/edition/revision shall apply. In case of discrepancy between this
specification and those referred to herein below or other specifications
forming a part of this bid document, this specification shall govern.

2.2

MATERIALS
1)

IS:269

Specification for 33 grade ordinary portland


cement.

2)

IS:455

Specification for portland slag cement.

3)

IS:1489
(Parts 1 & 2)

Specification for portland-pozzolana cement

4)

IS:8112

Specification for 43 grade ordinary portland


cement.

5)

IS:12330

Specification for sulphate resisting Portland


Cement.

6)

IS:383

Specification for coarse and fine aggregates


from natural sources for concrete.
ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC. NO

SECTION : D5
SHEET 2 OF 26

TCE.- 5607A-H-CCH-400

TITLE

CONCRETE AND ALLIED WORKS

2.3

7)

IS:432
(Parts
1 & 2)

Specification for mild steel and medium tensile


steel bars and hard-drawn steel wires for
concrete reinforcement.

8)

IS:1786

Specification for high strength deformed steel


bars and wires for concrete reinforcement.

9)

IS:1566
(Parts II)

Specification for hard-drawn steel wire fabric for


concrete reinforcement.

10)

IS:9103

Specification for admixtures for concrete.

11)

IS:2645

Specification for integral cement waterproofing


compounds.

12)

IS:4900

Specification for plywood for concrete shuttering


work.

13)

IS:12269

Specification for 53 grade ordinary portland


cement.

Methods of physical tests for


hydraulic cement.

2)

IS:4031
(Parts 1
to 15)
IS:4032

Method of chemical analysis of hydraulic


cement.

3)

IS:650

Specification for standard sand for testing of


cement.

4)

IS:2430

Methods for sampling of aggregates for


concrete.

5)

IS:2386
(Parts
1 to 8)

Methods of test for aggregates


for concrete.

6)

IS:3025

Methods of sampling and test (physical and


chemical) water used in industry.

7)

IS:6925

Methods of test for determination of water


soluble chlorides in concrete admixtures.

MATERIAL TESTING
1)

2.4

MATERIAL STORAGE
1)

2.5

IS:4082

Recommendations on stacking and storing of


construction materials at site.

CONCRETE MIX DESIGN


ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC. NO

SECTION : D5
SHEET 3 OF 26

TCE.- 5607A-H-CCH-400

TITLE

CONCRETE AND ALLIED WORKS

2.6

2.7

1)

IS:10262

2)

SP:23 (S&T)

Recommended guidelines for concrete mix


design.
Handbook on Concrete Mixes.

CONCRETE TESTING
1)

IS:1199

Method of sampling and analysis of concrete.

2)

IS:516 -

3)

IS:9013

Method of making, curing and determining


compressive strength of accelerated cured
concrete test specimens.

4)

IS:8142

Method of test for determining setting time of


concrete by penetration resistance.

5)

IS:9284

Method of test for abrasion resistance of


concrete.

6)

IS:2770

Methods of testing bond in reinforced concrete.

Method of test for strength of concrete.

EQUIPMENT
1)

IS:1791

Specification for batch type concrete mixers.

2)

IS:2438

Specification for roller pan mixer.

3)

IS:4925

Specification for concrete batching and mixing


plant.

4)

IS:5892

Specification for concrete transit mixer and


agitator.

5)

IS:7242

Specification for concrete spreaders.

6)

IS:2505

General Requirements for concrete vibrators :


Immersion type.

7)

IS:2506

General Requirements for screed board


concrete vibrators.

8)

IS:2514

Specification for concrete vibrating tables.

9)

IS:3366

Specification for pan vibrators.

10)

IS:4656

Specification for form vibrators for concrete.

11)

IS:11993

Code of practice for use of screed board


concrete vibrators.
ISSUE
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FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC. NO

SECTION : D5
SHEET 4 OF 26

TCE.- 5607A-H-CCH-400

TITLE

CONCRETE AND ALLIED WORKS

2.8

12)

IS:7251

Specification for concrete finishers.

13)

IS:2722

14)

IS:2750

Specification for portable swing weigh batchers


for concrete (single and double bucket type).
Specifications for steel scaffoldings.

CODES OF PRACTICE
1)

IS:456

Code of practice for plain and reinforced


concrete.

2)

IS:457

Code of practice for general construction of


plain and reinforced concrete for dams and
other massive structures.

3)

IS:3370
(Parts
1 to 4)

Code of practice for concrete structures for


storage of liquids.

4)

IS:3935

Code of practice for composite construction.

5)

IS:2204

Code of practice for construction of reinforced


concrete shell roof.

6)

IS:2210

Criteria for the design of reinforced concrete


shell structures and folded plates.

7)

IS:2502

Code of practice for bending and fixing of bars


for concrete reinforcement.

8)

IS:5525

Recommendation for detailing of reinforcement


in reinforced concrete works.

9)

IS:2751

Code of practice for welding of mild steel plain


and deformed bars used for reinforced concrete
construction.

10)

IS:9417

Specification for welding cold worked bars for


reinforced concrete construction.

11)

IS:3558

Code of practice for use of immersion vibrators


for consolidating concrete.

12)

IS:3414

Code of practice for design and installation of


joints in buildings.

13)

IS:4326

14)

IS:4014
(Parts
1 & 2)

Code of practice for earthquake resistant design


and construction of buildings.
Code of practice for steel tubular scaffolding.

ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC. NO

SECTION : D5
SHEET 5 OF 26

TCE.- 5607A-H-CCH-400

TITLE

CONCRETE AND ALLIED WORKS

2.9

2.10

15)

IS:2571

Code of practice for laying in-situ cement


concrete flooring.

16)

IS:7861

Code of practice for extreme weather


concerning.

Part -1

Recommended practice for hot weather


concreting

Part-2

Recommended practice for cold weather


concreting

CONSTRUCTION SAFETY
1)

IS:3696
(Parts 1
& 2)

Safety code for scaffolds and ladders.

2)

IS:7969

Safety code for handling and storage of building


materials.

3)

IS:8989

Safety code for erection of concrete framed


structures.

MEASUREMENT
1)

IS:1200 (Part 1 to 12) -

Method of measurement of building and


engineering works.

3.0

GENERAL

3.1

ENGINEER shall have the right at all times to inspect all operations including
the sources of materials, procurement, layout and storage of materials, the
concrete batching and mixing equipment, and the quality control system.
Such an inspection shall be arranged and ENGINEERs approval obtained,
prior to starting of concrete work.
This shall, however, not relieve
CONTRACTOR of any of his responsibilities. All materials which do not
conform to this specification shall be rejected.
Materials should be selected so that they can satisfy the design requirements
of strength, serviceability, safety, durability and finish with due regards to the
functional requirements and the environmental conditions to which the
structure will be subjected. Materials complying with codes/standards shall
generally be used. Other materials may be used after approval of the
ENGINEER and after establishing their performance suitability based on
previous data, experience or tests.

3.2

4.0

MATERIALS

4.1

CEMENT
ISSUE
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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC. NO
TCE.- 5607A-H-CCH-400

SECTION : D5
SHEET 6 OF 26

TITLE

CONCRETE AND ALLIED WORKS


4.1.1

Unless otherwise specified or called for by ENGINEER/OWNER, cement shall


be ordinary portland cement conforming to IS:269, IS:8112 or IS:12269.

4.1.2

Where portland pozzolana or slag cements are used, it shall be ensured that
consistency of quality is maintained, there will be no adverse interactions
between the materials and the finish specified is not marred.

4.1.3

Only one type of cement shall be used in any one mix. The source of supply,
type or brand of cement within the same structure or portion thereof shall not
be changed without approval from ENGINEER.

4.1.4

Cement which is not used within 90 days from its date of manufacture shall
be tested at a laboratory approved by ENGINEER and until the results of
such tests are found satisfactory, it shall not be used in any work.

4.2

AGGREGATES (GENERAL)

4.2.1

Aggregates shall consist of naturally occurring stones (crushed or


uncrushed), gravel and sand. They shall be chemically inert, strong, hard,
clean, durable against weathering, of limited porosity, free from
dust/silt/organic impurities/deleterious materials and conform to IS:383.
Aggregates such as slag, crushed over burnt bricks, bloated clay ash,
sintered fly ash and tiles shall not be used.

4.2.2

Aggregates for special purposes shall be as specified elsewhere.

4.2.3

Aggregates shall be washed and screened before use where necessary or if


directed by the ENGINEER.

4.2.4

Aggregates containing reactive materials shall be used only after tests


conclusively prove that there will be no adverse affect on strength, durability
and finish, including long term effects, on the concrete.

4.2.5

The fineness modulus of sand shall neither be less than 2.2 nor more than
3.2.

4.2.6

The maximum size of coarse aggregate shall be as stated on the drawings,


but in no case greater than 1/4 of the minimum thickness of the member.

4.2.7

Plums 160 mm and above of a reasonable size may be used where directed.
Plums shall not constitute more than 20% by volume of the concrete.

4.3

WATER

4.3.1

Water used for both mixing and curing shall conform to IS:456. Potable
waters are generally satisfactory. Water containing any excess of acid, alkali,
sugar or salt shall not be used.

4.4

REINFORCEMENT
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TITLE

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4.4.1

Reinforcement bars shall conform to IS:432 or IS:1786 and welded wire fabric
to IS:1566 as shown or specified on the drawing.

4.4.2

All reinforcement shall be clean, free from pitting, oil, grease, paint, loose mill
scales, rust, dirt, dust, or any other substance that will destroy or reduce
bond.

4.4.3

If permitted by ENGINEER, welding of reinforcement shall be done in


accordance with IS:2751 or IS:9417 as applicable.

4.5

ADMIXTURES

4.5.1

Accelerating, retarding, water-reducing and air entraining admixtures shall


conform to IS:9103 and integral water proofing admixture to IS:2645.

4.5.2

Admixtures may be used in concrete as per manufacturers instructions only


with the approval of ENGINEER based upon evidence that with the passage
of time neither the compressive strength nor its durability is reduced. An
admixtures suitability and effectiveness shall be verified by trial mixes with
the other materials used in the works. If two or more admixtures are to be
used simultaneously in the same concrete mix, their interaction shall be
checked and trial mixes done to ensure their compatibility. There should also
be no increase in risk of corrosion of the reinforcement or other embedments.

4.5.3

Calcium chloride shall not be used for accelerating set of the cement for any
concrete containing reinforcement or embedded steel parts. When calcium
chloride is permitted such as in mass concrete works, it shall be dissolved in
water and added to the mixing water by an amount not exceeding 1.5 percent
of the weight of the cement in each batch of concrete. The designed concrete
mix shall be corrected accordingly.

4.6

WASTAGE

4.6.1

Wastage allowance for cement and steel shall be as specified under


Instruction to Bidders.

5.0

SAMPLES AND TESTS

5.1

All materials used for the works shall be tested before use.

5.2

Manufacturers test certificate shall be furnished for each batch of


cement/steel and when directed by ENGINEER samples shall also be got
tested by the
CONTRACTOR in a laboratory approved by ENGINEER at no extra cost to
OWNER. However, where material is supplied by OWNER, all testing
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charges shall be borne by OWNER, but transportation of material samples to
the laboratory shall have to be done by CONTRACTOR at no extra cost.
5.3

Sampling and testing shall be as per IS:2386 under the supervision of


ENGINEER. The cost of all tests, sampling, etc. shall be borne by
CONTRACTOR.

5.4

Water to be used shall be tested to comply with requirements of IS:456.

5.5

CONTRACTOR shall furnish manufacturers test certificates and technical


literature for the admixture proposed to used. If directed, the admixture shall
be got tested at an approved laboratory at no extra cost.

6.0

STORING OF MATERIALS

6.1

All material shall be stored in a manner so as to prevent its deterioration and


contamination which would preclude its use in the works. Requirements of
IS:4082 shall be complied with.

6.2

CONTRACTOR will have to make his own arrangements for the storage of
adequate quantity of cement even if cement is supplied by OWNER. If such
cement is not stored properly and has deteriorated, the material shall be
rejected. Cost of such rejected cement, where cement is supplied by
OWNER, shall be recovered at issue rate or open market rate which ever is
higher. Cement bags shall be stored in dry weatherproof shed with a raised
floor, well away from the outer walls and insulated from the floor to avoid
moisture from ground. Not more than 15 bags shall be stacked in any tier.
Storage arrangement shall be approved by ENGINEER. Storage under
tarpaulins shall not be permitted. Each consignment of cement shall be
stored separately and consumed in its order of receipt.

6.3

Each size of coarse and fine aggregates shall be stacked separately and
shall be protected from leaves and contamination with foreign material. The
stacks shall be on hard, clean, free draining bases, draining away from the
concrete mixing area.
CONTRACTOR shall make his own arrangements for storing water at site in
tanks to prevent contamination.

6.4

6.5

The reinforcement shall be stacked on top of timber sleepers to avoid contact


with ground/ water. Each type and size shall be stacked separately.

7.0

CONCRETE

7.1

GENERAL

7.1.1

Concrete grade shall be as designated on drawings. In concrete grade M15,


M20, etc. the number represents the specified characteristic compressive
strength of 150 mm cube at 28 days, expressed in N/sq.mm as per IS:456 .
Concrete in the works shall be DESIGN MIX CONCRETE OR NOMINAL
MIX CONCRETE. All concrete works of grade M5, M7.5 and M10 shall be
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NOMINAL MIX CONCRETE whereas all other grades, M15 and above, shall
be DESIGN MIX CONCRETE.
7.2

DESIGN MIX CONCRETE

7.2.1

Mix Design & Testing

7.2.1.1 For Design Mix Concrete, the mix shall be designed according to IS:10262
and SP:23 to provide the grade of concrete having the required workability
and characteristic strength not less than appropriate values given in IS:456.
The design mix shall in addition be such that it is cohesive and does not
segregate and should result in a dense and durable concrete and also
capable of giving the finish as specified. For liquid retaining structures, the
mix shall also result in water tight concrete. The CONTRACTOR shall
exercise great care while designing the concrete mix and executing the works
to achieve the desired result.
7.2.1.2 Unless otherwise specifically mentioned in Data Sheet-A or respective
Section-D, the minimum cement content for Design Mix Concrete shall be as
per Table-5 of IS:456 or as given below, whichever is higher.
Grade of Concrete

Minimum Cement Content in


Kg/cu.m of Concrete
----------------------------------------M20
300
M25
300
M30
320
M35
340
The minimum cement content stipulated above shall be adopted irrespective
of whether the CONTRACTOR achieves the desired strength with less
quantity of cement. The CONTRACTORs quoted rates for concrete shall
provide for the above eventuality and nothing extra shall become payable to
the CONTRACTOR in this account. Even in the case where the quantity of
cement required is higher than that specified above to achieve desired
strength based on an approved mix design, nothing extra shall become
payable to the CONTRACTOR.
7.2.1.3 It shall be CONTRACTORs sole responsibility to carry out the mix designs at
his own cost. He shall furnish to ENGINEER at least 30 days before
concreting operations, a statement of proportions proposed to be used for the
various concrete mixes and the strength results obtained. The strength
requirements of the concrete mixes ascertained on 150 mm cubes as per
IS:516 shall comply with the requirements of IS:456.

Grade of
Concrete

-------

Minimum
Compressive
Strength
N/Sq.mm
at 7 days
-----------

Specified Characteristic
compressive strength
N/sq.mm
at 28 days
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M15
M20
M25
M30
M35
M40

10.0
13.5
17.0
20.0
23.5
27.0

15.0
20.0
25.0
30.0
35.0
40.0

7.2.1.4 A range of slumps which shall generally be used for various types of
construction unless otherwise instructed by the ENGINEER is given below :
Structure/Member
------------------------------------

Reinforced foundation walls


and footings

7.2.2

Slump in millimeters
--------------------------------Maximum
Minimum
------------------------75
25

Plain footings, caissons and


substructure walls

75

25

T.G. and massive compressor


foundations

50

25

Slabs, Beams and reinforced


walls

100

25

Pumps & miscellaneous


Equipment Foundations

75

25

Building columns
Pavements
Heavy mass construction

100
50
50

25
25
25

Batching & Mixing of Concrete

7.2.2.1 Proportions of aggregates and cements, as decided by the concrete mix


design, shall be by weight. These proportions shall be maintained during
subsequent concrete batching by means of weigh batchers capable of
controlling the weights within one percent of the desired value.
7.2.2.2 Amount of water added shall be such as to produce dense concrete of
required consistency, specified strength and satisfactory workability and shall
be so adjusted to account for moisture content in the aggregates. Watercement ratio specified for use by ENGINEER shall be maintained. Each time
the work stops, the mixer shall be cleaned out, and while recommencing, the
first batch shall have 10% additional cement to allow for sticking in the drum.
7.2.2.3 Arrangement should be made by CONTRACTOR to have the cubes tested in
an approved laboratory or in field at his own expense, with prior consent of
ENGINEER. Sampling and testing of strength and workability of concrete
shall be as per IS:1199, IS:516 and IS:456.
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7.3

NOMINAL MIX CONCRETE

7.3.1

Mix Design & Testing

7.3.1.1 Mix Design and preliminary tests are not necessary for Nominal Mix
Concrete. However works tests shall be carried out as per IS:456.
Proportions for Nominal Mix Concrete and w/c ratio may be adopted as per
Table 3 of IS:456. However, it will be CONTRACTORs sole responsibility to
adopt appropriate nominal mix proportions to yield the specified strength.
7.3.2

Batching & Mixing of Concrete

7.3.2.1 Based on the adopted nominal mixes, aggregates shall be measured by


volume. However cement shall be by weight only.
8.0

FORMWORK

8.1

Formwork shall be all inclusive and shall consist of but not limited to shores,
bracings, sides of footings, walls, beams and columns, bottom of slabs, etc.
including ties, anchors, hangers, inserts, falsework, wedges, etc.

8.2

The design and engineering of the formwork as well as its construction shall
be the responsibility of CONTRACTOR.
However, if so desired by
ENGINEER the drawings and calculations for the design of the formwork
shall be submitted to ENGINEER approval.

8.3

Formwork shall be designed to fulfill the following requirements :


a)

Sufficiently rigid and tight to prevent loss of grout or mortar from the
concrete at all stages and appropriate to the methods of placing and
compacting.

b)

Made of suitable materials.

c)

Capable of providing concrete of the correct shape and surface finish


within the specified tolerance limits.

d)

Capable of withstanding without deflection the worst combination of


self weight, reinforcement and concrete weight, all loads and dynamic
effects arising from construction and compacting activities, wind and
weather forces.

e)

Capable of easily striking without shock, disturbance or damage to the


concrete.

f)

Soffit forms capable of imparting a camber if required.

g)

Soffit forms and supports capable of being left in position if required.

h)

Capable of being cleaned and/or coated if necessary immediately


prior to casting the concrete; design temporary openings where
necessary for these purposes and to facilitate the preparation of
construction joints.
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8.4

The formwork may be of timber, plywood, steel, plastic or concrete depending


upon the type of finish specified. Sliding forms and slip form may be used with
the approval of ENGINEER. Timber for formwork shall be well seasoned, free
from sap, shakes, loose knots, worm holes, warps and other surface defects.
Joints between formwork and formwork and between formwork and structures
shall be sufficiently tight to prevent loss of slurry from concrete, using seals if
necessary.

8.5

The faces of formwork coming in contact with concrete shall be cleaned and
two coats of approved mould oil applied before fixing reinforcement. All
rubbish, particularly chippings, shavings, sawdust, wire pieces, dust etc. shall
be removed from the interior of the forms before the concrete is placed.
Where directed, cleaning of forms shall be done by blasting with a jet of
compressed air at no extra cost.

8.6

Forms intended for reuse shall be treated with care. Forms that have
deteriorated shall not be used. Before reuse, all forms shall be thoroughly
scraped, cleaned, nails removed, holes suitably plugged, joints repaired and
warped lumber replaced to the satisfaction of ENGINEER. CONTRACTOR
shall equip himself with enough shuttering to allow for wastage so as to
complete the job in time.

8.7

Permanent formwork shall be checked for its durability and compatibility with
adjoining concrete before it is used in the structure. It shall be properly
anchored to the concrete.

8.8

Wire ties passing through beams, columns and walls shall not be allowed. In
their place bolts passing through sleeves shall be used. Formwork spacers
left in situ shall not impair the desired appearance or durability of the structure
by causing spalling, rust staining or allowing the passage of moisture.

8.9

For liquid retaining structures sleeves shall not be provided for through bolts
nor shall through bolts be removed if provided. The bolts, in the latter case,
shall be cut at 25 mm depth from the surface and the hole made good by
cement mortar of the same proportion as the concrete just after striking the
formwork.

8.10

Where specified or shown on drawings all corners and angles exposed in the
finished structure shall have chamfers or fillets of 20 mm x 20 mm size.

8.11

Forms for substructure may be omitted when, in the opinion of ENGINEER,


the open excavation is firm enough (in hard non-porous soils) to act as a
form. Such excavations shall be slightly larger, as directed by ENGINEER,
than that required as per drawing to compensate for irregularities in
excavation.

8.12

CONTRACTOR shall provide adequate props of adjustable steel pipes


carried down to a firm bearing without overloading any of the structures.

8.13

The shuttering for beams and slabs shall be so erected that the side
shuttering of beams can be removed without disturbing the bottom shuttering.
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If the shuttering for a column is erected for the full height of the column, one
side shall be built up in sections as placing of concrete proceeds or windows
left for placing concrete from the side to limit the drop of concrete to 1.0 m or
as directed by ENGINEER. CONTRACTOR shall temporarily and securely fix
items to be cast (embedments/inserts) in a manner that will not hinder the
striking of forms or permit loss of grout.
8.14

Formwork showing excessive distortion, during any stage of construction,


shall be removed. Placed concrete affected by faulty formwork, shall be
entirely removed and formwork corrected prior to placement of new concrete
at CONTRACTORs cost.

8.15

The striking time for formwork shall be determined based on the following
requirements :
a)

Development of adequate concrete strength;

b)

Permissible deflection at time of striking form work;

c)

Curing procedure employed - its efficiency and effectiveness;

d)

Subsequent surface treatment to be done;

e)

Prevention of thermal cracking at re-entrant angles;

f)

Ambient temperatures; and

g)

Aggressiveness of the environment (unless immediate adequate steps


are taken to prevent damage to the concrete).

8.16

Under normal circumstances (generally where temperatures are above 20


Deg. C) forms may be struck after expiry of the time period given in IS:456
unless directed otherwise by ENGINEER. For Portland Pozzolona/slag
cement the stripping time shall be suitably modified as directed by the
ENGINEER. It is the CONTRACTORs responsibility to ensure that forms are
not struck until the concrete has developed sufficient strength to support
itself, does not undergo excessive deformation and resist surface damage
and any stresses arising during the construction period.

9.0

REINFORCEMENT WORKMANSHIP

9.1

Reinforcing bars supplied bent or in coils shall be straightened cold without


damage at no extra cost. No bending shall be done when ambient
temperature is below 5 Deg.C. Local warming may be permitted if steel is
kept below 100 Deg.C.
All bars shall be accurately bent gradually and according to the sizes and
shapes shown on the drawings/ schedules or as directed by ENGINEER.

9.2

9.3

Re-bending or straightening incorrectly bent bars shall not be done without


approval of ENGINEER.
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9.4

Reinforcement shall be accurately fixed and maintained firmly in the correct


position by the use of blocks, spacers, chairs, binding wire, etc. to prevent
displacement during placing and compaction of concrete. The tied inplace
reinforcement shall be approved by ENGINEER prior to concrete
placement.Spacers shall be of such materials and designs as will be durable,
not lead to corrosion of the reinforcement and not cause spalling of the
concrete cover.

9.5

Binding wire shall be 16 gauge soft annealed wire. Ends of the binding wire
shall be bent away from the concrete surface and in no case encroach into
the concrete cover.

9.6

Substitution of reinforcement, laps/splices not shown on drawing shall be


subject to ENGINEERs approval.

10.0

TOLERANCES

10.1

Tolerance for formed and concrete dimensions shall be as per IS:456 unless
specified otherwise.

10.2

Tolerance specified for horizontal or vertical building lines or footings shall not
be construed to permit encroachment beyond the legal boundaries.

11.0

PREPARATION PRIOR TO CONCRETE PLACEMENT

11.1

Before concrete is actually placed in position, the inside of the formwork shall
be cleaned and mould oil applied, inserts and reinforcement shall be correctly
positioned and securely held, necessary openings, pockets, etc. provided.

11.2

All arrangements-formwork, equipment and proposed procedure, shall be


approved by ENGINEER. CONTRACTOR shall maintain separate Pour Card
for each pour as per the format enclosed.

12.0

TRANSPORTING, PLACING AND COMPACTING CONCRETE

12.1

Concrete shall be transported from the mixing plant to the formwork with
minimum time lapse by methods that shall maintain the required workability
and will prevent segregation, loss of any ingredients or ingress of foreign
matter or water.

12.2

In all cases concrete shall be deposited as nearly as practicable directly in its


final position. To avoid seggregation, concrete shall not be rehandled or
caused to flow. For locations where direct placement is not possible and in
narrow forms, CONTRACTOR shall provide suitable drops and Elephant
Trunks. Concrete shall not be dropped form a height of more than 1.0 m as
stipulated in clause 8.13.

12.3

Concrete shall not be placed in flowing water. Under water, concrete shall be
placed in position by tremies or by pipeline from the mixer and shall never be
allowed to fall freely through the water.
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12.4

While placing concrete the CONTRACTOR shall proceed as specified below


and also ensure the following :
a)

Continuously
abutments.

b)

Without disturbance to forms or reinforcement.

c)

Without disturbance to pipes, ducts, fixings and the like to be cast in;
ensure that such items are securely fixed. Ensure that concrete
cannot enter open ends of pipes and conduits, etc.

d)
e)

Without dropping in a manner that could cause segregation or shock.


In deep pours only when the concrete and formwork is designed for
this purpose and by using suitable chutes or pipes.

f)

Do not place if the workability is such that full compaction cannot be


achieved.

g)

Without disturbing the unsupported sides of excavations; prevent


contamination of concrete with earth. Provide sheeting if necessary. In
supported excavations, withdraw the linings progressively as concrete
is placed.
If placed directly onto hardcore or any other porous material, dampen
the surface to reduce loss of water from the concrete.

h)

between

construction

joints

and

predetermined

i)

Ensure that there is no damage or displacement to sheet membranes.

j)

Record the time and location of placing structural concrete.

12.5

Concrete shall normally be compacted in its final position within thirty minutes
of leaving the mixer. Concrete shall be compacted during placing with
approved vibrating equipment without causing segregation until it forms a
solid mass free from voids thoroughly worked around reinforcement and
embedded fixtures and into all corners of the formwork. Immersion vibrators
shall be inserted vertically at points not more than 450 mm apart and
withdrawn slowly till air bubbles cease to come to the surface, leaving no
voids. When placing concrete in layers advancing horizontally, care shall be
taken to ensure adequate vibration, blending and melding of the concrete
between successive layers. Vibrators shall not be allowed to come in contact
with reinforcement, formwork and finished surfaces after start of initial set.
Over-vibration shall be avoided.

12.6

Concrete may be conveyed and placed by mechanically operated equipment


after getting the complete procedure approved by ENGINEER. The slump
shall be held to the minimum necessary for conveying concrete by this
method. When concrete is to be pumped, the concrete mix shall be specially
designed to suit pumping. Care shall be taken to avoid stoppages in work
once pumping has started .

12.7

Except when placing with slip forms, each placement of concrete in multiple
lift work, shall be allowed to set for at least 24 hours after the final set of
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concrete before the start of subsequent placement. Placing shall stop when
concrete reaches the top of the opening in walls or bottom surface of slab, in
slab and beam construction, and it shall be resumed before concrete takes
initial set but not until it has had time to settle as determined by ENGINEER.
Concrete shall be protected against damage until final acceptance.
13.0

MASS CONCRETE WORKS

13.1

Sequence of pouring for mass concrete works shall be as approved by


ENGINEER. CONTRACTOR shall exercise great care to prevent shrinkage
cracks and shall monitor the temperature of the placed concrete if directed.

14.0

CURING

14.1

Curing and protection shall start immediately after the compaction of the
concrete to protect it from :
a)

Premature drying out, particularly by solar radiation and wind;

b)

leaching out by rain and flowing water;

c)

rapid cooling during the first few days after placing;

d)

high internal thermal gradients;

e)

low temperature or frost;

f)

vibration and impact which may disrupt the concrete and interfere with
its bond to the reinforcement.

14.2

All concrete, unless directed otherwise by ENGINEER, shall be cured by use


of continuous sprays or ponded water or continuously saturated coverings of
sacking, canvas, hessian or other absorbent material for the period of
complete hydration with a minimum of 7 days. The quality of curing water
shall be the same as that used for mixing.

14.3

Where a curing membrane is directed to be used by the ENGINEER, the


same shall be of a non-wax base and shall not impair the concrete finish in
any manner. The curing compound to be used shall be got approved from the
ENGINEER before use and shall be applied with spraying equipment
capable of a smooth, even textured coat.

14.4

Curing may also be done by covering the surface with an impermeable


material such as polyethylene, which shall be well sealed and fastened.

14.5

Extra precautions shall be exercised in curing concrete during cold and hot
weather.

15.0

CONSTRUCTION JOINTS AND KEYS

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15.1

Construction joints will be as shown on the drawing or as approved by


ENGINEER. Concrete shall be placed without interruption until completion of
work between construction joints. If stopping of concreting becomes
unavoidable anywhere, a properly formed construction joint shall be made
with the approval of ENGINEER.

15.2

Dowels for concrete work, not likely to be taken up in the near future, shall be
coated with cement slurry and encased in lean concrete as indicated on the
drawings or as directed by ENGINEER.

15.3

Before resuming concreting on a surface which has hardened all laitance and
loose stone shall be thoroughly removed by wire brushing/hacking and
surface washed with high pressure water jet and treated with thin layer of
cement slurry for vertical joints and a 15 mm thick layer of cement sand
mortar for horizontal layers, the ratio of cement and sand being the same as
in the concrete mix.

15.4

When concreting is to be resumed on a surface which has not fully hardened,


all laitence shall be removed by wire brushing, the surface wetted, free water
removed and a coat of cement slurry applied. On this a layer of concrete not
exceeding 150 mm thickness shall be placed and well rammed against the
old work. Thereafter work shall proceed in the normal way.

16.0

FOUNDATION BEDDING

16.1

All earth surfaces upon which or against which concrete is to be placed, shall
be well compacted and free from standing water, mud or debris. Soft or
spongy area shall be cleaned out and back filled with either soil-cement
mixture, lean concrete or clean sand compacted as directed by ENGINEER.
The surfaces of absorptive soils shall be moistened.

16.2

Concrete shall not be deposited on large sloping rock surfaces. The rock shall
be cut to form rough steps or benches by picking, barring or wedging. The
rock surface shall be kept wet for 2 to 4 hours before concreting.

17.0

FINISHES

17.1

GENERAL

17.1.1 The formwork for concrete works shall be such as to give the finish as
specified. The CONTRACTOR shall make good as directed any unavoidable
defects consistent with the type of concrete and finish specified; defects due
to bad workmanship (e.g. damaged or misaligned forms, defective or poorly
compacted concrete) will not be accepted. CONTRACTOR shall construct the
formwork using the correct materials and to meet the requirements of the
design and to produce finished concrete to required dimensions, plumbs,
planes and finishes.
17.2

Surface Finish Type F1

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17.2.1 This type of finish shall be for non-exposed concrete surfaces against which
back fill or concrete is to be placed. The main requirement is that of dense,
well compacted concrete. No treatment is required except repair of defective
areas, filling all form tie holes and cleaning up of loose or adhering debris. For
surfaces below grade which will receive waterproofing treatment the concrete
shall be free of surface irregularities which would interfere with proper and
effective application of waterproofing material specified for use.
17.3

Surface Finish Type F2

17.3.1 This type of finish shall be for all concrete work which will be exposed to view
upon completion of the job. The appearance shall be that of a smooth dense,
well-compacted concrete showing the slight marks of well fitted shuttering
joints. The CONTRACTOR shall make good any blemishes.
17.4

Surface Finish Type F3

17.4.1 This type of finish shall be for concrete work which will be exposed to view but
to give an appearance of smooth, dense, well-compacted concrete with no
shutter marks, stain free and with no discolourisation, blemishes, arises, air
holes, etc. Only lined or coated plywood with very tight joints shall be used to
achieve this finish. The panel size shall be uniform and as large as
practicable. Any minor blemishes that might occur shall be made good by
CONTRACTOR.
17.5

INTEGRAL CEMENT FINISH ON CONCRETE FLOOR

17.5.1 In all cases where integral cement finish on a concrete floor has been
specified, the top layer of concrete shall be screeded off to proper level and
tamped with tamper having conical projections so that the aggregate shall be
forced below the surface. The surface shall be finished with a wooden float
and a trowel with pressure. The finish shall be continued till the concrete
reaches its initial set. No cement or cement mortar finish shall be provided on
the surface. Where specified, a floor hardener as approved by the
ENGINEER shall be supplied and used as recommended by the
manufacturer.
18.0

REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE

18.1

Immediately after the shuttering is removed, all the defective areas such as
honey-combed surfaces, rough patches, holes left by form bolts, etc. shall be
brought to the notice of ENGINEER who may permit patching of the defective
areas or reject the concrete work.

18.2

All through holes for shuttering shall be filled for full depth and neatly plugged
flush with surface.

18.3

Rejected concrete shall be removed and replaced by CONTRACTOR at no


additional cost to OWNER.

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TITLE

CONCRETE AND ALLIED WORKS


18.4

For patching of defective areas all loose materials shall be removed and the
surface shall be prepared as directed by the ENGINEER.

18.5

Bonding between hardened and fresh concrete shall be done either by


placing cement mortar or by applying epoxy. The decision of the ENGINEER
as to be the method of repairs to be adopted shall be final and binding on the
CONTRACTOR and no extra claim shall be entertained on this account. The
surface shall be saturated with water for 24 hours before patching is done
with 1:5 cement sand mortar. The use of epoxy for bonding fresh concrete
shall be carried out as directed by ENGINEER.

19.0

VACUUM DEWATERING OF SLABS

19.1

Where specified floor slabs, either on grade or suspended, shall be finished


by vacuum dewatering including all operations such as poker vibration,
surface vibration, vacuum processing, floating and trowelling as per
equipment manufacturers recommendation. The equipment to be used shall
be subject to ENGINEERS approval.

20.0

HOT WEATHER REQUIREMENT

20.1

Concreting during hot weather shall be carried out as per IS:7861 (Part I).

20.2

Adequate provisions shall be made to lower concrete temperatures which


shall not exceed 40 C at the time of placement of fresh concrete.

20.3

Where directed by ENGINEER, CONTRACTOR shall spray non-wax based


curing compound on unformed concrete surface at no extra costs.

21.0

COLD WEATHER REQUIRMENTS

21.1

Concreting during cold weather shall be carried out as per IS:7861 (PART 2).

21.2

The ambient temperature during placement and upto final set shall not fall
below 5 deg.c. Approved anti-freeze/accelerating additive shall be used
where directed.

21.3

For major and large scale concreting works the temperature of concrete at
times of mixing and placing, the thermal conductivity of the formwork and its
insulation and stripping period shall be closely monitored.

22.0

LIQUID RETAINING STRUCTURES

22.1

The CONTRACTOR shall take special care for concrete of liquid retaining
structures, under ground structures and those other specifically called for to
guarantee the finish and water tightness.
The minimum level of surface finish for liquid retaining structures shall be type
F2. All such structures shall be hydro-tested.

22.2

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22.3

The CONTRACTOR shall include in his price hydro-testing of structure, all


arrangements for testing such as temporary bulk heads, pressure gauges,
pumps, pipe lines, etc.

22.4

Any temporary arrangements that may have to be made to ensure stability of


the structures shall also be considered to have been taken into account while
quoting the rates.

22.5

Any leakage that may occur during the hydro-test or subsequently during the
defects liability period or the period for which the structure is guaranteed shall
be effectively stopped either by cement/epoxy pressure grouting, guniting or
such other method as may be approved by the ENGINEER. All such
rectification shall be done by the CONTRACTOR to the entire satisfaction of
the OWNER/ENGINEER at no extra cost to the OWNER.

23.0

TESTING CONCRETE STRUCTURES FOR LEAKAGE

23.1

Hydro-static test for water tightness shall be done at full storage level or soffit
of cover slab, as may be directed by ENGINEER, as described below :

23.2

a)

In case of structures whose external faces are exposed, such as


elevated tanks, the requirements of the test shall be deemed to be
satisfied if the external faces show no sign of leakage or sweating and
remain completely dry during the period of observation of seven days
after allowing a seven day period for absorption after filling with water.

b)

In the case of structures whose external faces are submerged and are
not accessible for inspection, such as underground tanks, the
structures shall be filled with water and after the expiry of seven days
after the filling, the level of the surface of the water shall be recorded.
The level of water shall be recorded again at subsequent intervals of
24 hrs. over period of seven days. Backfilling shall be withheld till the
tanks are tested. The total drop in surface level over a period for
seven days shall be taken as an indication of the water tightness of
the structure. The ENGINEER shall decide on the actual permissible
nature of this drop in the surface level, taking into account whether
the structures are open or closed and the corresponding effect it has
on evaporation losses. Unless specified otherwise, a structure whose
top is covered shall be deemed to be water tight if the total drop in the
surface level over a period of seven days does not exceed 40 mm.

c)

Each compartment/segment of
individually and then all together.

the

structure

shall be tested

For structures such as pipes, tunnels, etc. the hydrostatic test shall be carried
out by filling with water, after curing as specified, and subjecting to the
specified test pressure for specified period. If during this period the loss of
water does not exceed the equivalent of the specified rate, the structure shall
be considered to have successfully passed the test.

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TITLE

CONCRETE AND ALLIED WORKS


24.0

OPTIONAL TEST

24.1

If the ENGINEER feels that the materials i.e. cement, sand, coarse
aggregates, reinforcement and water are not in accordance with the
specifications or if specified concrete strengths are not obtained, he may
order tests to be carried out on these materials in laboratory, to be approved
by the ENGINEER, as per relevant IS Codes. OWNER shall pay only for the
testing of material supplied by the OWNER, otherwise CONTRACTOR shall
have to pay for the tests. Transporting of all material to the laboratory shall
however be done by the CONTRACTOR at no extra cost to OWNER.

24.2

In the event of any work being suspected of faulty material or workmanship


requiring its removal or if the works cubes do not give the stipulated
strengths, ENGINEER reserves the right to order the CONTRACTOR to take
out cores and conduct tests on them or do ultrasonic testing or load testing of
structure, etc. All these tests shall be carried out by CONTRACTOR at no
extra cost to the OWNER. Alternately ENGINEER also reserves the right to
ask the CONTRACTOR to dismantle and re-do such unacceptable work at
the cost of CONTRACTOR.

24.3

If the structure is certified by Engineer as having failed, the cost of the test
and subsequent dismantling/reconstruction shall be borned by
CONTRACTOR.

24.4

The quoted unit rates/prices of concrete shall deemed to provide for all tests
mentioned above.

25.0

GROUTING

25.1

Grout shall be provided as specified on the drawings. The proportion of


Standard Grout shall be such as to produce a flowable mixture consistent with
minimum water content and shrinkage. Surfaces to be grouted shall be
thoroughly roughened and cleaned. All structural steel elements to be
grouted shall be cleaned of oil, grease, dirt, etc. The use of hot, strong
caustic solution for this purpose will be permitted. Prior to grouting, the
hardened concrete shall be saturated with water and just before grouting
water in all pockets shall be removed. Grouting once started shall be done
quickly and continuously. Variation in grout mixes and procedures shall be
permitted if approved by ENGINEER. The grout proportions shall be limited
as follows :
Use

a)

b)

-----Fluid
mix
General
mix

Grout
Thickness
---------------Under 25 mm

25 mm and
over but less
than 50 mm

Mix proportion
-----------------------One part Portland
Cement to one part
sand.
One part Portland
Cement to 2 parts
of sand

W/C Ratio
(max)
-------------0.44

0.53

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c)

Stiff
mix

50 mm and over

One part Portland


cement to 3 parts
of sand

25.2

NON-SHRINK GROUT

25.2

Non-shrink grout where called for in the Schedule of Quantities or specified


on the drawings shall be provided in strict accordance with the manufacturers
instructions/ specifications on the drawings.

26.0

INSPECTION

26.1

All materials, workmanship and finished construction shall be subject to


continuous inspection and approval of ENGINEER. Materials rejected by
ENGINEER shall be expressly removed from site and shall be replaced by
CONTRACTOR immediately at no extra cost to OWNER.

27.0

CLEAN-UP

27.1

Upon the completion of concrete work, all forms, equipment, construction


tools, protective coverings and any debris, scraps of wood, etc. resulting from
the work shall be removed and the premises left clean.

28.0

ACCEPTANCE CRITERIA

28.1

Any concrete work shall satisfy the requirements given below individually and
collectively for it to be acceptable.
a)

properties of constituent materials;

b)

characteristic compressive strength;

c)

specified mix proportions;

d)

minimum cement content;

e)

maximum free-water/cement ratio;

f)

workability;

g)

temperature of fresh concrete;

h)

density of fully compacted concrete;

i)

cover to embedded steel;

j)

curing;

k)

tolerances in dimensions;

l)

tolerances in levels;

0.53

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m)

durability;

n)

surface finishes;

o)

special requirements such as :


i)
ii)
iii)
iv)
v)
vi)
vii)

water tightness
resistance to aggressive chemicals
resistance to freezing and thawing
very high strength
improved fire resistance
wear resistance
resistance to early thermal cracking

28.2

The ENGINEERs decision as to the acceptability or otherwise of any


concrete work shall be final and binding on the CONTRACTOR.

28.3

For work not accepted, the ENGINEER may review and decide whether
remedial measures are feasible and so as to render the work acceptable.
The ENGINEER shall in that case direct the CONTRACTOR to undertake and
execute the remedial measures. These shall be expeditiously and effectively
implemented by the CONTRACTOR. Nothing extra shall become payable to
the CONTRACTOR by the OWNER for executing remedial measures.

29.

MODE OF MEASUREMENT AND PAYMENT

29.1

The unit rate for concrete work under various categories shall be all inclusive
and no claims for extra payment on account of such items an leaving holes,
embedding inserts, etc. shall be entertained unless separately provided for in
the Schedule of Quantities. No extra claim shall also be entertained due to
change in the number, position and/or dimensions of holes, slots or
openings, sleeves, inserts or on account of any increased lift, lead of
scaffolding etc. All these factors should be taken into consideration while
quoting the unit rates. Unless provided for in the schedule of Quantities the
rates shall also include fixing inserts in all concrete work, whenever required.

29.2

Payments for concrete will be made on the basis of unit rates quoted for the
respective items in the Schedule of Quantities. No deduction in the concrete
quantity will be made for reinforcements, inserts etc. and opening less than
0.100 of a Sq.m, in areas where concrete is measured in sq.m. and 0.010
cu.m where concrete is measured in cu.metres. Where no such deduction for
concrete is made, payment for shuttering work provided for such holes,
pockets, etc. will not be made. Similarly the unit rates for concrete work shall
be inclusive or exclusive of shuttering as provided for in the Schedule of
Quantities.

29.3

Payment for beams will be made for the quantity based on the depth being
reckoned from the underside of the slabs and length measured as the clear
distance between supports. Payment for columns shall be made for the
quantity based on height reckoned upto the underside of slabs/beams.

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TITLE

CONCRETE AND ALLIED WORKS

29.4

The unit rate for precast concrete members shall include formwork,
mouldings, finishing, hoisting and setting in position including setting mortar,
provision of lifting arrangement etc. complete. Reinforcement and inserts
shall be measured and paid for separately under respective item rates.

29.5

Only the actual quantity of steel embedded in concrete including laps as


shown on drawings or as approved by ENGINEER shall be measured and
paid for, irrespective of the level or height at which the work is done. The unit
rate for reinforcement shall include all wastages, binding wires, chairs,
spacer bare etc. for which no separate payment shall be made.

29.6

Where the formwork is paid for separately, it shall be very clearly understood
that payment for formwork in inclusive of formwork, shuttering, shoring,
propping, scaffolding, etc. complete. only the net area of concrete formed
(shuttered) shall be measured for payment.

CONCRETE POUR CARD


CLIENT :
POUR NO. :

DATE :

PROJECT :

STRUCTURE :

CONTRACTOR :
SLUMP :
MM/

MAX AGGREGATE SIZE


MM

DRG. NO. :

START/COMPLETION TIME :

CONCETE GRADE/QUANTITY : M
SR.
NO.

ITEM
CENTERLINES CHECKED

2.

FORMWORK AND
STAGING CHECKED

3.
4.

5.

BEFORE CONCRETING

1.

M3

MIXING TIME :

CONTRACTORS
REP. SIGNATURE

ENGINEERS
SIGNATURE

YES/NO

YES/NO

REMARKS

REINFORCEMENT
CHECKED
COVER0000000 TO
REINFORCEMENT
CHECKED
VERFIED TEST
CERTIFICATE FOR
CEMENT /STELL

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TITLE

CONCRETE AND ALLIED WORKS


6.

ADEQUENCY OF
MATERIALS/EQUIPMENT
FOR POUR

7.

EMBEDED
PARTS
CHECKED
(LOCATION
& PLUMB)

YES/NO

YES/NO

CIVIL
MECHANIC
AL
ELECTRICA
L
POUR AUTHORISED SITE ENGINEER

8.

SOFFIT(S) AND POUR TOP(T)


LEVELS CHECKED BEFORE(B)
AND AFTER(A) FROM REMOVAL
(ONLY OF BEAMS OF OVER 10
M SPAN & IMPORTANT
STRUCTURES LIKE T.G. ETC.)

9.

CONSTRUCTION JOINT
LOCATION & TIME (IF NOT AS
PER DRAWING)

10.

CEMENT CONSUMPTION IN
KGS.

11.

NUMBER OF CUBES AND


IDENTIFICATION MARK

12.

TEST CUBE RESULTS (7 DAYS/


28 DAYS)

13.

CONCRETE CONDITION ON
FORM REMOVAL

S(B)

T(B)

S(A)

T(A)

V.GOOD/GOOD/FAIR/POOR
SITE-IN-CHARGE

NOTES:
1. EACH ITEM TO BE CHECKED & SIGNED BY THE RESPECTIVE ENGINEERS.
2. ITEMS 8 TO 13 (BOTH INCLUSIVE) TO BE FILLED BY ONLY TCE ENGINEER.
3. EACH POUR TO HAVE SEPARATE CARDS, IN TRIPILCATE ONE EACH FOR CLIENT,
TCE & SITE OFFICE. FORM 279
4. UNDER REMARKS INDICATE DEVIATIONS FROM DWGS & SPECIFICATIONS,
CONGESTION IN
REINFORCEMENT IF ANY, UNUSUAL OCCURENCES,
SUCH AS FAILURE OF EQUIPMENTS, SINKING OF SUPPORTS/PROPS, HEAVY
RAINS AFFECTING CONCRETEING, POOR COMPACTION, IMPROPER CURING,
OTHER DEFICIENCIES, OBSERVATION ETC.

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TITLE

SECTION : D6

SHEET 1 OF 40

REINFORCED CONCRETE CHIMNEY


1.0

SCOPE

1.1

This specification covers the general requirements for design and construction of
a reinforced concrete chimney of circular cross section including foundations,
RCC shell, brick lining, appurtenances, fixtures, fittings, conduit and other
embedments, lift where specified, etc., complete.

1.2

The scope of work shall not be deemed to have changed in case BIDDERS
drawings submitted with his bid do not show some part of the work as called for
in this specification and the attached bid drawings unless categorically agreed to
in writing before contract award. The CONTRACTOR shall not be entitled to any
extra claim on account of his having (in OWNERS opinion) mis-interpreted, misjudged or overlooked any aspect called for in this specification.

1.3

It is not the intent to specify completely herein all the details of design and
construction of the works involved under this specification. However, the works
shall conform, in all respects, to high standards of engineering, design and
workmanship.

2.0

APPLICABLE CODES, SPECIFICATIONS & REFERENCES

2.1

The following specifications, standards and codes are made a part of this
specification. These shall be the latest edition including all applicable official
amendments and revisions. In case of discrepancy between this specification
and those referred to herein, the former shall govern:
IS:6

Moderate heat duty fire clay refractories,Group-A.

IS:158

Ready mixed paint, brushing, bituminous, black, lead free; acid, alkali and
heat resisting.
IS: 195 Fireclay Mortar for laying fireclay refractory bricks-specification.
IS:456
IS:732

Code of Practice for plain and reinforced concrete.


Code of Practice for electrical wiring installations.

IS:800

Code of Practice for general construction in steel.

IS:875

Code of practice for design loads (other than earthquake) for buildings
and structures: Part 1 to 3.

IS:1526 Sizes and shapes for fire bricks.


IS:1528 Methods of sampling and physical tests for refractory material.
IS:1893 Criteria for earthquake resistant design of structures.
IS:1904 Code of Practice for design and construction of foundations in soils:
General requirements.

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REINFORCED CONCRETE CHIMNEY


IS:2042 Insulating bricks.
IS:2062 Steel for general structural purposes.
IS:2750 Steel scaffoldings.
IS:2932 Enamel, synthetic, exterior (a) under coating, (b) finishing.
IS:2933 Enamel, exterior (a) under coating, (b) finishing.
IS:3346 Method for the determination of thermal conductivity of thermal insulation
materials (two slab guarded hot-plate method)
IS:3696 Safety code for scaffolds and ladders.
(Parts 1 & 2)
IS:4014 Code of practice for steel tubular scaffolding.
(Parts 1 & 2)
IS:4289 Flexible cables for lifts and other flexible connections : Part 1 Elastomer
insulated cables.
IS:4456 Methods of test for chemical resistant mortars: Part 1 Silicate type and
Resin type.
IS:4687 Gaskets and packings - Gland packing asbestos.
IS:4832 Specification for chemical resistant mortars: Part- 1 silicate type.
IS:4860 Acid resistant bricks.
IS:4998 Criteria for design of reinforced concrete chimneys: Part 1 - Design
criteria - 1975
IS:4998 Criteria for design of reinforced concrete: Part 1 Assessment of loads1992
IS:8112 OPC Cement Garde 43
IS:8183 Bonded Mineral wool.
IS:8500 Structural steel - microalloyed (Medium and high strength qualities).
IS:13947 Low voltage switchgear and controlgear : Part 1 General rules
Annexure-14 International Standards and Recommended Practices Aerodromes International Civil Aviation Organisation.

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REINFORCED CONCRETE CHIMNEY


2.2

The following is the list of publications referred to in this specification.


Manohar,S.N Tall Chimneys-Design and Construction", Tata McGraw Hill
Publishing Co.Ltd., New Delhi, 1985.
Pinfold,G.M "Reinforced Concrete Chimneys and Towers",
Publication, Cement and Concrete Association, U.K., 1975.

View

Point

ACI 307 - 88 Standard Practice for the Design and Construction of Cast-in-place
reinforced concrete chimneys
2.3

SI units shall be adopted for all design and drawing work.

3.0

DESIGN REQUIREMENTS

3.1

The principal design parameters for this chimney are indicated in DATASHEET-A.

3.2

The design shall be based on working stress method.

3.3

The design and construction of the chimney and its foundation shall conform to the
requirements of all statutory rules and regulations of local and national authorities.
Where such requirements are less conservative than the corresponding
requirements of this specification, the latter shall govern.

3.4

The chimney and its foundation shall be designed to resist stresses due to the
most critical combination of any of the following:
(a)

Weight of the chimney with or without lining, platforms, accessories and all
other dead loads.

(b)

Wind loads (both along-wind and across wind) or earthquake forces


whichever is governing.

(c)

Temperature gradient across the chimney shell.

(d)

Eccentric loads from corbels/platforms supporting the lining, soot hopper, etc.

(e)

Live loads on platforms. Also weight of equipment and materials and other
live loads during construction.

(f)

For the foundation and portion of the shell below grade level, appropriate
earth pressures, hydro- static forces, surcharge etc., as applicable.

(g)

Local moments due to ovalling.

(h)

Forces from the lift and operating equipment.

(i)

Loads from flue duct supports, staircase, etc.

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REINFORCED CONCRETE CHIMNEY


(j)

Construction loads such as those due to plant and equipment, stacked


materials, live loads due to movement of plant, materials and personnel, etc.

3.5

The total design stresses at a section shall include all secondary effects, viz.,
corbel effect, eccentric loading due to platforms, secondary moments due to p-
effect, etc. The total design stress in no case shall exceed the permissible stresses
specified in clause 7.0 of IS:4998 (Part-1) 1975, except for (DL+WL) case, for
which the permissible stress 0.275fcu shall be if the circumferential tensile stress in
concrete due to wind induced ring moment exceeds the value specified in clause
7.1.1 (g) of IS : 4998 Part I, additional reinforcement shall be provided in 2 layers
limiting the stress in reinforcement steel to value specified in clause 7.1.2 (g).

3.6

The safety factor against over-turning under worst combination of loads, shall not
be less than 1.5 in any direction during construction and 2.0 after construction is
complete. For the purpose of calculating safety factor against overturning, only
90% of the dead loads as calculated from dimensions and densities of materials,
shall be taken into account. Also, at critical sections in the foundation, diagonal
tensile stresses and bending stresses about two orthogonal axis shall be checked.

3.7

For estimating the deflections of the chimney in lined and unlined conditions, the
modulus of elasticity of concrete shall be as per the mean value specified in clause
A-3.1 of IS:4998 (Part-1).

3.8

Stresses in the shell shall be shown to be within permissible limits at 10 metre


intervals along the height of the shell or at every corbel level whichever distance is
less and in addition at the critical locations across openings.

3.9

Air inlets shall be provided near the base as indicated in tender drawings. The
openings shall be provided with a GI wire mesh on the outside mounted on a GI
frame, so as to prevent dirt or tiny creatures entering the access void through the
opening. These openings shall be provided with aluminium louvred fins within
sloped up towards inside. Calculation of air inlet opening area shall be as per
IS:4998(Part-1)-1975.

3.10

Air outlets shall be provided near the top as indicated in the tender drawings with
proper SST (stainless steel) wire mesh mounted on SST frame at the outside, and
with aluminium louvres sloped up towards the inside. Area of air outlet opening
shall be same as area for air inlet opening.

3.11

Temporary openings, if any, required by the CONTRACTOR at the base or any


where along the height of the shell, for the purpose of placement of concrete,
access of material and personnel, to provide support platforms for material, etc.,
shall be indicated during bid stage and finalised before the award of the contract.
Only these openings finalised and shown in the released for construction
drawings approved by the OWNER shall be provided. These openings shall be
closed up after use at no extra cost by providing extra reinforcement and with the
grade of concrete same as that of the shell around the opening.

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REINFORCED CONCRETE CHIMNEY


3.12

Corbels, if required, shall be designed to take the load of platforms, lining,


insulation, hopper, etc., supported on them.

3.13

The maximum width of the openings shall normally be limited to an angle of not
more than 60 subtended at the centre of the concrete shell. Where the extent of
shell left between two openings is limited such that the subtended angle is less
than 45, procedures as normally adopted for column design, shall be adopted to
check the adequacy of the shell in this region.

3.14

The analysis of the windshield for wind and earthquake forces shall be done as per
the requirements of clause 13 and 14 of this specification.

3.15

The foundation shall be designed as a rigid member. The thickness of the


foundation below the shell shall not be less than 0.40 times the overhang of the
foundation beyond the shell, or 0.09 times the foundation diameter whichever is
more.

3.16

For the purposes of analysis/design, the following shall be assumed:


a)
b)

Stiffness of shell shall not be considered for design of the foundation.


Shell fixed to foundation for shell design.

3.17

Foundation design shall be based on the foundation criteria as indicated in Data


sheet-A. Permissible increase in safe bearing capacity of soil shall be 25% under
seismic load condition. Such increase shall be only on the net bearing pressure of
soil. No such increase in safe bearing capacity of soil will be permitted for wind
load combination.

3.18

For foundation design, no increase in permissible material stresses will be


permitted for wind load combination. Permissible increase in material stresses
shall be 33-1/3 % under seismic load condition.

4.0

REQUIREMENTS IN RESPECT OF CONCRETE

4.1

All concrete work shall be carried out strictly in accordance with the specification,
except as otherwise specified hereunder.

4.2

The source and type of the basic ingredients of concrete, viz., cement, aggregates,
water and approved admixtures, if any, shall be unchanged throughout the
construction of the chimney shell, particularly in case, slipforming technique is
adopted for shell construction.

4.3

The maximum size of coarse aggregates, unless specified otherwise, shall not be
larger than 1/8th the narrowest dimension between forms nor larger than one-half
the minimum clear distance between reinforcing bars nor more than 20 mm.

4.4

Natural gravel and rounded aggregates of acceptable quality shall be preferred to


broken stone with sharp angular corners for slipformwork, in particular.

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TITLE

SECTION : D6

SHEET 6 OF 40

REINFORCED CONCRETE CHIMNEY


4.5

When slipforming is adopted, the slump shall be between 100 mm and 150 mm at
the point of placement. However, precise requirements in this regard shall be
established from field tests and shall be subject to ENGINEERS approval.

4.6

If necessary, approved admixtures such as retarders/ plasticizers to maintain the


workability shall be used with the prior consent of the ENGINEER. Such
admixtures shall be identified after preliminary tests to prove their satisfactory
performance and compatibility with the particular type of cement envisaged to be
used in the shell construction. After identification and determination of dosage for
varying weather conditions, the total quantity of admixture required for the
complete work shall be estimated and shall be procured in batches to ensure that
the same is utilised before expiry of its shelf life. In no case shall the admixture be
used if its shelf life has expired due to delay in construction activities. No additional
payment shall be made to CONTRACTOR for providing and using
retarders/plasticizers.

4.7

The minimum cement content and maximum water cement ratio shall be as given
in Table 5 of IS:456-2000. Maximum cement content shall be limited to 450
kg/cum. Degree of exposure for foundation shall be moderate for foundation and
sevre for wind shield.

4.8

The minimum thickness of the concrete shell shall be 250 mm.

4.9

The clear concrete cover over the vertical reinforcement in the shell shall not be
less than 50 mm. In foundations, the clear concrete cover shall be 75 mm.

4.10

Minimum grade of concrete for chimney shell and minishell shall be M30. For
foundation, platform, slab, beams, corbels, hopper and other structural work,
minimum grade shall be M25. Maximum grade of concrete shall be M40.

4.11

While concreting shell at corbels and platform levels, care shall be taken to ensure
that the dowels for corbels and platforms are initially bent within the wall thickness
and concrete of specified grade for shell at that level is placed and well compacted.
The dowels may be later exposed by chipping the shell surface only after the
concrete is well set. On no account will the method by packing the area with sand
or any other material be allowed for the purpose of exposing dowels at a later date.

5.0

REQUIREMENTS IN RESPECT OF REINFORCEMENT

5.1

The minimum vertical reinforcement on each face with deformed bars shall be
0.125% of the concrete area of the section under consideration. For mild steel
bars, the minimum reinforcement to be provided on each face shall be 0.15% of
the concrete area of the section under consideration. The minimum diameter of
vertical reinforcing bars shall be 12 mm and they shall not be spaced at more than
300 mm centres.

5.2

Laps for the vertical reinforcement shall be staggered. Not more than one-third of
the bars shall be lapped at any one level. The laps at a level should be distributed
around the perimeter and not concentrated in only one part of the perimeter of the
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TITLE

SECTION : D6

SHEET 7 OF 40

REINFORCED CONCRETE CHIMNEY


shell. Where vertical reinforcement is required to be lapped above openings, lap
shall be allowed only after a height of B/2 above the opening for the whole section,
where B = width of opening.
While curtailing reinforcement above openings, care shall be taken to ensure
proper transfer of tensile forces if present in the section to the subsequent section
by provision of adequate reinforcement. The bars shall not be curtailed abruptly
and an adequate development length shall be provided.
5.3

The circumferential reinforcement on each face of shell, for deformed bars, shall
not be less than 0.1% of the concrete area of the section. When mild steel bars are
used, the percentage on each face shall be 0.125. The minimum diameter of these
reinforcing bars shall be 10 mm and they shall be spaced at a centre to centre
distance not exceeding 300 mm or the shell thickness whichever is less.

5.4

Circumferential reinforcement shall be evaluated so as to satisfy the minimum


requirements as mentioned above and to safely withstand the circumferential
forces and moments. However, for a height from the top equal to half the shell
outer diameter or 3 metres whichever is more, the quantity of circumferential
reinforcement shall be twice that arrived at as stated above.

5.5

Circumferential reinforcement shall be placed around the exterior of and securely


wired or welded to the vertical bars at an interval of not more than 600 mm.
Particular attention shall be paid to placing and securing the circumferential
reinforcement so that it cannot bulge or get displaced during the placing and
working of the concrete.

5.6

Dowels, wherever provided, shall extend on either side of the construction joint by
a length equal to the full development length of the bars in tension.

5.7

The reinforcement for corbels and dowels for platform reinforcement shall be of
mild steel and of size not larger than 12 mm diameter.

5.8

In addition to the reinforcement determined from structural considerations as well


as to meet temperature and other stresses, extra reinforcement shall be provided
around and at corners of openings. The extra reinforcement shall be placed near
the outside surface of the chimney shell as close to the opening as proper detailing
of reinforcement will permit. Unless otherwise specified, all such extra
reinforcement shall extend past the opening to a length equal to its development
length in tension.

5.9

At each side of the openings, the extra vertical reinforcement shall have a total
area equal to the design reinforcement for one-half of the width of the opening.
This steel shall be placed on each side of the opening within a distance not
exceeding 1.5 times the shell thickness wherever column design procedure
specified in clause 3.13 above is not applicable. The extra reinforcement shall
extend past the opening by a length equal to 1/2 the width of opening plus its
development length in tension.

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TCE FORM NO. 329 R4

SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

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TITLE

SECTION : D6

SHEET 8 OF 40

REINFORCED CONCRETE CHIMNEY


5.10

At both top and bottom of each opening, extra horizontal reinforcement shall be
placed having an area atleast equal to one-half of the design circumferential
reinforcement interrupted by the openings but the area 'As' of this extra
reinforcement shall not be less than that given by the following :
As (mm2) = fck.t.s/c
Where,
fck
t
s
c
steel

characteristic strength of concrete


in N/mm2,
= shell thickness at opening in mm,
= width of opening in mm,
=
16000 and 13000 for high yield strength deformed bars and mild
bars, respectively.

5.11

One half of this extra reinforcement as stipulated in clause 5.10 above, shall
extend completely around the circumference of the chimney and the other half
shall extend beyond the opening to a length equal to the development length of the
bars in tension. This steel shall be placed within a height not exceeding the
thickness of the shell.
5.12.1 For shell thickness greater than 250mm, diagonal reinforcement with a total cross
sectional area in sq.mm of not less than 5 times the shell thickness (in mm) shall
be placed at each corner of an opening. These bars shall also extend on either
side of the corner a distance equal to the development length of the bars in
tension.
5.12.2 For the shell of thickness less than 250 mm additional steel of a total cross
sectional area in sq. mm of not less than 3.5 times the shell thickness (in mm) shall
be placed horizontally/vertically. These bars which shall extend to a distance equal
to the development length in tension on either side shall be in addition to the entire
steel already provided as per clauses 5.8 to 5.11.
5.13

Foundation of chimney shall be provided with a minimum layer of reinforcement at


top and same shall not be less than 12 mm deformed bars at 250 mm centres
placed orthogonally.

5.14

Temporary openings, if any, required by the CONTRACTOR along the height of


shell, for the purposes of access to material and personnel, placement of concrete,
for supporting temporary platforms while laying of bricks, etc. shall be allowed only
on the approval of the ENGINEER. They shall be designed as permanent openings
with provision of extra reinforcement as per the requirements of clauses 5.8 to
5.12. The edges of openings shall be provided with suitable MS rods as dowels
which shall be bent and exposed as per the requirement of clause 4.12. Additional
bars if required, shall be tied to the dowels to form a reinforcement mesh work
within the opening and the opening later filled with concrete of same grade as of
the surrounding shell. The maximum width of temporary opening shall be as per
the requirement of clause 3.13.

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TCE CONSULTING ENGINEERS LIMITED

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TITLE

SECTION : D6

SHEET 9 OF 40

REINFORCED CONCRETE CHIMNEY


6.0

BRICK LINING

6.1

The chimney shall be lined with fire/acid resistant bricks for the full height of the
chimney above the hopper. The lining shall be supported on concrete platforms at
intervals of not more than 10 metres unless otherwise shown in the tender drawing.

6.2

Lining bricks shall be hard, uniformly well burnt, uniform in colour, of correct shape
and size, homogenous in texture and free from cracks, voids and other flaws and
shall be of material suitable to withstand the service conditions. No broken bricks
shall be allowed to be used except for closing the course. Each brick shall be
clearly marked with the MANUFACTURERS name and trade mark.

6.3

(a)
The sizes and shapes of fire clay bricks shall conform to IS :1526 and shall
be of Group-A Type 1 conforming to IS:6. These bricks shall be laid in air setting
mortar and cured as per MANUFACTURERS specification. The mortar for laying
fireclay refractory bricks shall be of grade-2 conforming to IS:195.

(b) Prior to despatch of mortar material from MANUFACTURER, at least five (5) samples
of the lot to be despatched shall be tested for bond strength as specified above,
and the test reports submitted to OWNER/CONSULTANT for approval and
permission for despatch of material. Similarly, five (5) samples of the lot to be
despatched shall also be tested for chemical resistance as per IS:4456 (Part-1)
and loss in weight and loss in compressive strength of the test specimen shall not
exceed 5 %. The test reports on chemical resistance shall be reported as per
clauses 10.11.2 and 10.11.3 of IS:4456 (Part-1).
6.4

The acid resistant bricks shall conform to Class I of IS:4860 and the mortar for this
brickwork shall conform to IS:4832 (Part 1) - Silica type with potassium silicate
liquid binder.

6.5

In the case of Acid resistant Brick lining, the mortar joints shall be cured with 25%
dilute HCl for a minimum period of 3 days and as per MANUFACTURERS
specification after which exposed face shall be thoroughly cleaned with water.

6.6.1

The value of the coefficient of thermal conductivity for fire clay and acid resistant
lining bricks shall not exceed K = 1.25 Kcal/m/hr/C and shall be considered as K =
1.25 Kcal/m/hr/C for the purpose of design of shell for temperature effects.

6.6.2

Prior to despatch of bricks from MANUFACTURER at least five (5) samples of the
lot to be despatched shall be tested for K-value at an approved laboratory and test
reports submitted to ENGINEER for approval and permission for despatch of
material. While testing, the hot-face temperature of the bricks shall be 300C.
Similarly, test certificates for acid resisting properties shall also be furnished for
acid resisting bricks.

6.7

Provision shall be made for differential vertical expansion at the lining support.

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TITLE

SECTION : D6

SHEET 10 OF 40

REINFORCED CONCRETE CHIMNEY


6.8

The thickness of lining shall be as shown on the bid drawings. The radial joints
shall be broken in each course. Lining shall be strapped with circumferential and
vertical galvanised mild steel bands having a minimum dimension of 75x6 mm and
50x6 mm respectively, both spaced at one metre centres, on the exterior of the
brickwork throughout the full height of the lining.

6.8.1

The vertical and horizontal bands shall be joined together by either (a) suitable
spot welding and all weld joints painted with 2 coats of zinc rich aluminium paint
over a coat of compatible primer as per the requirement of the MANUFACTURER,
or (b) fixed by bolting arrangement, with counter sunk bolts and slotted holes as
indicated in relevant bid drawings.

6.9

Special care shall be taken to ensure proper laying of bricks to cover the RCC
platforms so as to protect them from the action of gases. Glass/mineral wool
insulation of 25 mm thick shall be provided between the face of the platform and
brick lining with a sealing by 2 Nos. 25 mm dia asbestos chords conforming to
Grade 3 of IS: 4687. Bricks shall be laid on corbels on 12 mm thick asbestos
sheet.

6.10

Mortar for lining shall be used within the initial setting time and no retempering
shall be permitted. Joints shall be properly filled and at a given cross section, the
thickness of the joint shall not be more than 2 mm along the inner periphery of the
lining and not more than 12mm along the outer periphery. In case where the inner
diameter of the lining is less than 4500, shaped bricks shall be used to maintain
the thickness of joints mentioned above.

6.11

The lining shall be as specified in the bid drawing.

7.0

INSULATION AND PACKING

7.1

All insulation and packing shall be of dimensions specified on the drawing. The
materials for insulation and packing shall be mineral/glass wool, asbestos rope,
asbestos mill boards, insulation bricks, etc., of approved quality.

7.2

The mineral/glass wool shall be of resin bonded type conforming to IS:8183 or


equivalent with a maximum coefficient of thermal conductivity of 0.060
Kcal/m/hr/C at a mean temperature of 150C. The material shall have a minimum
density of 0.80 kN/m3.

7.3

The diameter of the asbestos rope conforming to Grade 3 of IS:4687 shall be


25 mm unless otherwise specified on the drawing. The strands shall be long, well
twisted and stranded and no torn fibre shall stick out. The rope of approved quality
shall be firmly packed so as to prevent gas leakage at all locations where the lining
overlaps.

7.4

Asbestos mill board shall be 12 mm thick, unless otherwise specified on the


drawing. It shall be plain, dense and have a homogenous texture, without cracks,
flaws or any other manufacturing defect. It shall be laid directly over the concrete
after removing all loose materials but without any mortar/plaster bedding.
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TITLE

SECTION : D6

SHEET 11 OF 40

REINFORCED CONCRETE CHIMNEY

7.5

The base for acid resistant brick lining in hopper portion shall be either cellular
concrete or insulating bricks of Grade 'C' conforming to IS:2042 or equivalent
unless otherwise specified on the drawing.

7.6

22 gauge GI sheet covers shall be provided all around the insulation wrapping
around the lining of flues and ducts. The sheeting shall be in three segments with
all necessary fixing arrangements with rivets including overlapping and work shall
be executed as per drawings and as directed by the ENGINEER.

8.0

ACCESSORIES

8.1

CAP
To prevent gas-entrained matter from falling into the space between the liner and
the mini shell and also to prevent the chimney top from chemical attack of flue
gases, a sectional grey cast-iron cap of minimum 12 mm thickness over 25 mm
thick asbestos shall be provided, unless otherwise specified on the drawing. The
cap shall cover the concrete shell, brick lining and air space between them. The
cap shall slope towards the inside of the chimney at approximately 30 to the
horizontal. All sections of the cap shall be anchored in place with bronze bolts and
bronze rag bolts respectively.

8.3

LADDER

8.3.1 The chimney shall be provided with a hot dip galvanised steel ladder as shown in
bid drawing.
8.3.2

The ladder shall consist of 75 x 12 mm stringers and 75 x 8 mm cage rings and


cage verticals. The stringers shall be spaced 400 mm clear inside width with 25
mm dia rungs. The rungs shall be spaced 300 mm on centres and shall be atleast
230 mm away from the chimney surface. Each ladder section shall be bolted
together with the next section.

8.3.3

The ladder shall be provided with stays of same section as the stringers spaced
1000 mm on centres. These shall be bolted/welded to the stringers and fixed to the
chimney shell with 22 mm dia GI rag bolts/dash bolts 150 mm long. The ladder
shall have straight sides and its construction shall conform to all state and local
laws and regulations governing such installations. The ladder shall be provided
with a safety cage made up of hot dip galvanised steel flats as shown on the bid
drawings. All inserts shall also be hot dip galvanised.

8.3.4

The ladder and its connection shall be designed to support a concentrated load of
175 kg at any location.

8.4

DOORS
The number and size of doors to be provided shall be as specified herein. These
doors shall be fabricated from mild steel sections with steel plates. The minimum
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TITLE

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SHEET 12 OF 40

REINFORCED CONCRETE CHIMNEY


thickness of mild steel shall be 3 mm for sheets and 6 mm for rolled sections. In all
cases, the surface preparation and painting thereafter shall be as per paint
MANUFACTURERS requirement and shall be subject to ENGINEERS approval.
8.4.1

Access Door
One access door of size 1000 x 2100 mm size shall be provided at ground level,
300 mm above grade elevation. The door shall be hinged and provided with an
aldrop. It shall be painted with acid and heat resistant paint conforming to IS: 158
Type-1 to give a dry film thickness of 75 microns in three coats.

8.4.2

Clean Out Doors

8.4.2.1 Two pairs of doors comprising of 750 x 900 mm door in the concrete shell and
650 x 825 mm door in the lining shall be provided for cleaning soot hoppers and for
access to inside of the flue. Doors shall properly seal the escape of flue gases by
suitable construction and same shall be acceptable to the ENGINEER. The door in
the concrete shell shall be provided with three coats to give a dry film thickness of
75 microns of acid and heat resistant paint conforming to IS:158 Type-1 and that in
lining shall be painted with high heat resistant bitumen paint to give a dry film
thickness of 75 microns in three coats.
8.4.2.2 The doors shall be hinged and provided with a locking device in addition to swivel
studs with wing nuts on the remaining three edges at spacings not more than 500
mm.
8.4.2.3 Suitable castable refractory lining 230 mm thick, covering the shell, air gap and
lining shall be provided all round the doors.
8.4.4

Four (4) no. maintenance doors (2 in each flue) of 750mm x 600mm size shall be
provided in the flue at every external platform level. Details of the door shall be
similar to the clean out door provided in the flue

8.4.5

One no. mechanically operated rolling shutter of 4000mm x 5000mm size shall be
provide at ground level. Complete details of rolling shutter shall be as per IS:6248.

8.5

SOOT HOPPER

8.5.1

This shall be of reinforced concrete and lined with acid resistant brickwork laid in
acid resistant mortar. Only shaped acid resistant bricks shall be used in the hopper
portion. The bricks, mortar and details of laying and joining shall conform to the
requirements laid down for acid resistant brick lining.

8.5.2

Between the reinforced concrete hopper and acid resistant brick lining, 75 mm
thick (unless otherwise specified on the drawing) insulation bricks of Grade C
conforming to IS:2042 or equivalent cellular concrete shall be provided. At the
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SECTION : D6

SHEET 13 OF 40

REINFORCED CONCRETE CHIMNEY


bottom of the hopper, CI flanged pipe with puddle flange of specified dia and length
shall be embedded as shown on the drawing. Inside of this pipe sleeve shall be
coated with sodium silicate.
8.6

CASTABLE REFRACTORY LINING

8.6.1

Castable refractory lining material at duct opening, around door etc., shall have the
following properties :
Grain size

5mm down graded

Porosity

20% when hand applied


16% when gunited

Thermal conductivity

0.8 Kcal/m/h/C

Setting

At ambient temperature

8.6.2

MANUFACTURERS certificates shall be submitted to OWNER/ CONSULTANT for


approval prior to use in the works.

8.7

INTERIOR PLATFORMS

8.7.1

The platforms for the brick flue chimney shall be of RCC with slab and steel beam
arrangement. The minimum grade of concrete shall be M25. The platforms shall
be seated / supported on the wind shield by means for pockets. The platform shall
be designed for its self weight, liner loads and live load of 5.0kN/m2. The
fabrication work of all steel beams shall be completed by the CONTRACTOR well
before the completion of the wind shield at that level so that beams could be
erected. No extra cost shall be payable to the CONTRACTOR for design, supply,
fabrication and erection of structural steel beams for internal platforms immediatly.
The structural steel beams shall be designed to carry self weight of platform slab,
live load of 500 kg/m2, self weight and liner loads. It shall also be designed for
movement due to temperature. The complete workmanship for these structural
steel beams shall be as per specification. Structural steel work shall be painted
with 2 coats of zinc rich red oxide paint and 3 coats of synthetic enamel paint.

8.7.2

Elastomer bearing pads shall be provided below the steel beams, to transfer the
loads to shell. These bearings shall be designed for all the loads it is subjected to
and the design shall conform to IRC:83(Part-II).

8.8

HAND RAILING
The hand railing shall be of medium quality 32 mm NB GI pipe conforming to
IS:1161 in 3 rows with railing post of 90 x 90 x 6 mm MS angles spaced at
approximately 1300 centre to centre. Hand railings shall be provided at locations
as shown on drawings and for all platforms.

8.9

FLUE OPENINGS
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TITLE

SECTION : D6

SHEET 14 OF 40

REINFORCED CONCRETE CHIMNEY

8.9.1

The number, size and location of flue openings in shell shall be as shown on the
drawing. The size of duct, number and type of bolts/inserts for connecting the duct
outside the chimney including the mating flange shall be as per the requirement of
boiler vendor. All inserts in concrete shall be hot dip galvanised.

8.9.2 The concrete shell at the flue entries and at openings shall be adequately protected
against high temperature by brick lining/castable refractory lining. Adequate
arrangement shall be made to seal the air gap between the shell and lining against
ingress of flue gases
8.10

DUCT WORK

8.10.1 The connection between MS flue duct and chimney flue shall be as indicated in the
bid drawing. Gap between the MS duct and chimney sheel shall be properly sealed
to prevent ingress of water.
8.10.2 The CONTRACTOR shall be responsible for furnishing, design, fabricating, shop
painting and delivery of ducting which shall run from the chimney liner to the flange
of the boiler vendors duct including all necessary auxiliary ducting.
8.10.3 The ducting material inclusive of stiffeners, flanges, bolts, suspension elements
shall be of mild steel confirming IS:2062 (Grade A).
8.10.4 The duct shall include all necessary stiffeners, flanges, sealing materials, bolts,
suspension elements, temperature and pressure measuring points, test ports for
flue gas analysers, supports and access doors. Baffle or bellow type expansion
joints may be provided to cater for expansion and slip type joints made by lapping
will not be permitted.
8.10.5 The ducts shall be constructed in such a manner that they are true to the tolerance
levels indicated.
8.10.6 The duct work shall be insulated as per the requirement of clause 7.0 but with 100
thick insulation ( 2 layers of 50 thick sheets) and provided with aluminium foil of
minimum 1 mm thickness as indicated in relevant bid drawing and access doors
shall be provided for the ducting as per the requirement of clause 8.4 where
required for inspection and cleaning.
8.11

CHIMNEY ROOF

8.11.1 The chimney roof shall be of a RCC slab suitably supported on a grillage of
structural steel beams for brick flue chimney. The roof shall be sloped towards rain
water down take pipes to provide positive draining. CONTRACTOR shall ensure
that the roof is built conforming strictly to the tolerance limits as required in this
specification.
8.11.2 The roof shall be provided with a hatch for access from the flue support platform.
The hatch shall have a single leaf door with a minimum thickness of 6 mm to cover

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SHEET 15 OF 40

REINFORCED CONCRETE CHIMNEY


a clear opening of 750 mm x 1000 mm. The hatch shall include the door, metal
curb, draft seal, spring latch, hold open device and all hardware. All joints shall be
welded and ground smooth. The curb shall be 300 mm in height with a suitable lip
which shall include a continuous neoprene seal strip to make the hatch air tight
when the cover is closed. The hatch shall be operable from both inside and
outside and shall be provided with automatic hold open arm, easy one hand
release and spring latch.
8.11.3 The roof slab shall be lined with acid proof / chemical resistant tiles bedded on acid
proof / chemical resistant mortar. The mortar which shall be laid to the full height
of the tiles shall have the same properties of the tiles with regard to acid proof /
chemical properties; fixing shall be done in accordance with the
MANFACTURERS requirements and / or as approved by the ENGINEER.
8.11.4 The tiles shall be unglazed and conform to IS:4457 and be of vitreous ware and
free from deletrious substances. They shall be of I class quality and free from
manufacturing defects and be true to size. The tiles shall be of size 198.5 sq x 40
mm with grooves not exceeding 3 mm deep provided at the underside.
8.11.5 The tiles shall be tested for squareness, warpage, water absorption, compressive
strength, flexural strength, resistance to acid and abration as per requirements and
methods specified in IS : 4457
8.11.6 The cement should be acid-proof, chemical resistant and water-proof. It shall be in
particular resistant to sulphuric acid and hydrochloric acid and shall have the
properties listed out hereinafter.
8.11.7 The bedding mortar shall conform to the requirements of IS:4832 (part-I) and be of
potassium silicate base having a minimum flexural strength of 4 N/mm2 and
compressive strength of 15 N/mm2 both at 7 days. The mortar shall have a
minimum bond strength of 0.5 N/mm2. The mortar shall be tested for the above
requirements, working time and absorption of toulence in accordance with IS:4456,
Part-I.
8.11.8 The tiles shall be pointed using a phenolic based resin cement conforming to IS :
4832 (Part 2) having a minimum flexural strength of 7.5 N/sq.mm and
compressive strength of 35 N/sq.mm both at 7 days . The mortar shall have a
minimum load strength of 1 N/mm2. Apart from the above, the mortar shall be
tested for working time and absorption in accordance with the requirements of IS :
4832 (Part 2) and IS : 4456 ( Part I ).
8.11.9 The bedding mortar and phenolic based resin mortar should be acid proof,
chemical resistant and water proof. They shall, in particular, be resistant to
sulphuric acid and hydrochloric acid.
8.11.10 CI/HDPE rain water pipes shall be provided within the interior of the shell to
remove rain water collected on the roof cap. Rain water inlet into the pipes at roof
slab level shall be provided with CI grating and connected to the CI/HDPE

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TCE FORM NO. 329 R4

SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE- 5607A-H-CCH-400

TITLE

SECTION : D6

SHEET 16 OF 40

REINFORCED CONCRETE CHIMNEY


downtake pipe along with wall/any other permanent structure by providing suitable
bend at roof level as indicated in relevant bid drawings.
8.12

LOUVRES

8.12.1 Air inlet and outlet louvres shall be provided as per the requirement of this
specification and as indicated in relevant drawings. The louvre fins shall be of Zshape in cross section and made from anodised aluminium plates of a minimum
thickness of 5 mm. The frame work supporting the louvre fins shall be made from
extruded aluminium sections of minimum thickness 6 mm. The louvres shall be
mounted in the form of panels. The fins shall be closely spaced to cut off any
driving rain entering the chimney wing shield. All panels must be approved by the
ENGINEER before installation.
8.13

FITTINGS FOR AVIATION LIGHTS, AND LIGHTING

8.13.1 Hatches of size and location as indicated in bid drawings shall be provided in the
shell at each platform level for the purpose of mounting aviation warning lights. The
light fittings shall be mounted on MS brackets welded to MS doors of minimum
thickness 3 mm. The inner face of door frame shall be provided with adequate
stiffners comprising of structural members of minimum thickness 6 mm. The door
frame shall be side hinged and have a locking system easily accessible and
operable. The door and fittings shall withstand the prevailing wind and access void
pressure. The MS doors and frame work shall be painted with 2 coats of zinc rich
red oxide primer and 3 coats of synthetic enamel paint.
8.13.2 Light fittings for the staircase shall be suitably clamped to the staircase column as
indicated in bid drawings and platform light fittings shall be suitably fixed to the
handrailing at each level.
8.13.3 All brackets, embedded parts, bolts, nuts, washers etc. used for the purpose of
fixing of lighting units shall be hot dipped galvanised.
8.16

STAIRCASE
A steel staircase shall be provide internally within the shell from the bottom to the
top to provide access to all platforms. It shall be fabricated from MS rolled I or
channel section stringers. Treads shall be of steel grating designed for self weight
and a live load of 500 kg/m2. Treads shall be provided with an approved antislip
nosing set flush with the stairs tread. Handrailing shall be provided for the stairs for
the whole height. The staircase shall be of a steel frame work supported from each
platform independently with all members connected with suitable bolted / welded
connections. The supporting structure shall be painted as per the requirements of
IS : 1477 with 2 coats of zinc rich redoxide paint and 3 coats of synthetic enamel
paint of approved shade. The steel treads shall be hot dip galvanised.
The
fabrication work of staircase shall be completed by the CONTRACTOR well before
the completion of the intermediate plat forms. Minimum clear width of each flight
shall be 750mm.

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TCE FORM NO. 329 R4

SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE- 5607A-H-CCH-400

TITLE

SECTION : D6

SHEET 17 OF 40

REINFORCED CONCRETE CHIMNEY

9.0

PAINTING

9.1

Inside surface of concrete shell including corbels, platforms, hopper, ring beams CI
cap shall be provided with four coats of acid and heat resisting paint. The paint
shall conform to the requirement of IS:158 an the work shall be done as per
MANUFACTURERS recommendations :
Top 15mts or two-thirds of diameterof shell at top most level whichever is higher of
the external portion of the chimney, external platform, handrails, embedments etc
shall be painted in alternate bands (with a band width of 2.5mts) of colours signal
red and pure/bright white. Painting system shall be acid and heat resistant and
shall comprise of two primer coats of clear epoxy paint and minimum two finish
coats of acrylic polyurethane paint.

9.2

Remaining portion of external surface of chiney shell shall be painted with single
pack polyurethane enamel paint in a colour / shade / pattern as per the prevailing
norms specified by Aviation authorities. This painting system will comprise of two
coats of single pack acrylic polyurethane enamel paint over two coats of primer as
per manufacturers requirements.

9.3

External painting shall commence immediately after the shell construction/platform


is completed and the concrete is well cured. The painting shall preferably be
started from the top. This is to ensure visibility of stack to low flying aircraft at day
time even during the period of construction of the internals of the chimney.

10.0

STRAKES

10.1

Strakes shall be provided based on design requirement.

10.2

The strakes shall be designed for a pressure three times the maximum wind
pressure expected at top of chimney.

10.3

Strakes, if required, shall be made up of hot double dipped galvanized (qith 700
gms/sqm) mild steel plates and rolled sections of thickness not less than 6 mm. A
corrosion allowance of 1.5 mm in the structural members shall be provided for,
beyond the design values.

10.4

A minimum gap of 500 mm between the top of strake and the bottom of external
platform/landing, shall be ensured.

10.5

Fixing arrangement of strakes to the chimney shell shall ensure full fixity for the
design load. All strakes, embedded parts, bolts, nuts, washers, etc., shall be hot
dip galvanised.

11.0

DESIGN AND DRAWINGS

11.1

The CONTRACTOR shall submit his method of analysis, design parameters,


allowable stresses, method and sequence of construction including staging, details
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TCE FORM NO. 329 R4

SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE- 5607A-H-CCH-400

TITLE

SECTION : D6

SHEET 18 OF 40

REINFORCED CONCRETE CHIMNEY


of proposed site testing facilities, etc., strictly as per specifications for the
CONSULTANTS review and approval within 15 days from the date of issue of
Letter of Intent or Purchaser Order, whichever is earlier.
11.2

The CONTRACTOR shall submit his design/drawing submission schedule and a


construction schedule giving the monthwise requirement of materials to be
supplied by the OWNER; within 15 days from the date of award of work.

11.3

The CONTRACTOR shall submit, detailed working drawings/design for the


foundation (with dowels for the shell), complete and detailed general arrangement
drawing for the CONSULTANTS approval within 15 days from the date of issue of
Letter of Intent or award of contract whichever is earlier. The remaining drawings
shall be submitted in a progressive manner within six months from the date of
award of contract. These design/drawings will be returned after the
CONSULTANTS review within about one month from the date of receipt by
CONSULTANT. No claims shall be entertained due to delay in review of the
CONTRACTORS drawings.

11.3.1 All drawings shall accompany with bar bending schedule & Bill of materials.
11.4

In case the CONTRACTOR adopts computerised designs, only validated computer


programs shall be used for the analysis and design. The computer output listing
should include all input data covering the loads and load combinations. The
CONTRACTOR shall submit typical manual calculations in order to validate the
computer program / Spread sheets used for analysis / design.

11.5

Timely submission of design/drawings to the CONSULTANT for review is the sole


responsibility of the CONTRACTOR and postal or other delays will not be
entertained as reasons for late/non-submission of design/drawings.

11.6

All modifications suggested by the CONSULTANT to meet specification


requirements and sound engineering practice, shall be incorporated by the
CONTRACTOR at no extra cost to the OWNER. In this respect, the decision of the
OWNER shall be binding on the CONTRACTOR. The CONSULTANT will accord
his approval only after the CONTRACTOR has incorporated in his design/drawings
all modifications required by the CONSULTANT.

11.7

Any modifications/change in subsequent revisions of design/drawings shall be


clearly marked and identified with a revision for the ENGINEERS review/approval.

11.8

Construction of work shall commence only after the written approval of drawings by
the CONSULTANT. However, the CONSULTANTS approval of the
design/drawings shall not absolve the CONTRACTOR of his responsibility for
correctness of design, accuracy of dimensions, loadings, details, etc., or safety and
stability of the structure including foundations, accessories, appurtenances, etc.

11.9

The CONTRACTOR may have to support flue duct supporting columns from the
chimney foundation. The design loads for these columns shall be provided by the
CONSULTANT.

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TCE FORM NO. 329 R4

SPEC NO.

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TCE CONSULTING ENGINEERS LIMITED

TCE- 5607A-H-CCH-400

TITLE

SHEET 19 OF 40

REINFORCED CONCRETE CHIMNEY

11.10 The CONTRACTOR shall distribute copies of drawings/schedules, etc., prepared


by him in accordance with the schedule given below :

PRELIMINARY

SCHEDULES DESIGN

COMMENTED

DWG

DESIGN

FINAL

DWG

SCHEDULE
S

DESIGN

DWG

OWNER
(HEAD
OFFICE)

2P

1P

1P

2P

1P

10
P+
1C

OWNER
(SITE
OFFICE)

2P

---

1P

---

2P

---

1P

TCE

2P

6P

6P

1P

3P

3P
+1
C

VENDOR

LEGEND
P Prints
S Source
C Soft copy in CD
The CONTRACTOR shall send one copy of all correspondence to OWNERS head
office and site office. The cost of these and that due to design/drawings
submission as per distribution schedule specified above is deemed to have been
included in his quoted rates.

12.0

CONSTRUCTION

12.1

GENERAL

12.1.1 CONTRACTOR shall ensure that the excavation and sub- structures are free from
water during construction and shall take all necessary precautions and measures
to prevent ground water, storm water, etc., from entering the excavation so as to
carry out the work in reasonably dry conditions in accordance with the
construction schedule.

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SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE- 5607A-H-CCH-400

TITLE

SECTION : D6

SHEET 20 OF 40

REINFORCED CONCRETE CHIMNEY


12.1.2 The CONTRACTOR shall dewater and maintain reasonably dry, the excavation for
structures and all other areas of the site, where build up of water (in the opinion of
ENGINEER) is likely to obstruct the progress of work, or lead to insanitary
conditions by stagnation, or retard the speed of construction, or is detrimental to
the safety of men, materials and equipment or is undesirable due to any other
reasons.
12.2

STAGING

12.2.1 Design and erection of staging shall conform to the requirements of all relevant IS
Codes and National safety standards/regulations.
12.2.2 CONTRACTOR, at his own cost, shall prepare a detailed erection scheme. If called
upon, he shall submit to the CONSULTANT detailed drawings with supporting
calculations showing all details of formwork, staging, scaffolding, member sizes,
connection details and other arrangements for slipforming and for the concreting
work and submit the same for review. Any suggestions/ comments on the
scheme/details conveyed to the CONTRACTOR shall be carried out by the
CONTRACTOR at no extra cost. Scheme submitted for approval shall incorporate
separate provision of material hoists and a passenger hoist.
12.2.3 As the staging serves a dual purpose, viz., as an access tower and as a bearing
structure to support construction loads, it shall be designed for all possible loads
that could be imposed on it such as self-weight, weight of ladder and timber
platforms at all levels, weight of men, weight of construction materials and
equipment, wind loads, seismic loads, etc.
12.2.4 Minimum live load on staging due to labour and personnel movement shall be
considered at 300 kg/m2. It may be taken as 150 kg/m2 when earthquake loads
are also taken into account. No increase in stresses shall be considered for wind
and seismic conditions.
12.2.5 Special inspection hoist of approved make shall be provided by the
CONTRACTOR for regular inspection, checking of scaffolding members, joints,
etc. Fortnightly detailed inspection record shall be maintained by the
CONTRACTOR and shall be produced to the ENGINEER whenever required for
his verification.
12.2.6 Notwithstanding the approval from the ENGINEER, the CONTRACTOR will be
solely responsible for the safety, security and proper functioning of the staging
and formwork.
12.2.7 Where conventional/jumpform shuttering is provided, minimum stripping time of
formwork shall not be less than 12 hours for sides of RCC shell. However, the
stripping time to be adopted on the works shall be subject to the ENGINEERS
approval. The CONTRACTOR shall not be permitted any increase in construction
period if the stripping time for shell exceeds 12 hours.
12.3

SHELL CONSTRUCTION

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TCE FORM NO. 329 R4

SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

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TITLE

SECTION : D6

SHEET 21 OF 40

REINFORCED CONCRETE CHIMNEY

12.3.1 The CONTRACTOR shall prepare and submit a detailed quality assurance plan
within one month of award of work. This plan shall include the following :
a)

Design criteria
The CONTRACTOR shall give the criteria to be adopted for design of
various temporary works and the slipforms. The following requirements
shall be met.
i)

Staging materials shall conform to IS:2062.

ii) Minimum design live load from personnel shall be 500 kg/sq.m. To
this shall be added the self- weight and weight of construction
materials and equipment, etc.
iii) The staging shall be designed as per the requirements of IS:800 (for
conventional type) and IS:4014 (for tubular scaffolding type).
The CONTRACTORS design calculations shall be based on normally
accepted calculation techniques for the structural forms which the
CONTRACTOR adopts for staging.
b)

Statement of detailed 'Construction Method'


This shall include atleast the following :
i)

Structural analysis providing adequacy of jacks, slipforms, and their


supports and staging.

ii) Planned interruptions. Also the operations during planned


interruptions such as retrieval of jack rods, resetting of form panels,
etc., shall be stipulated.
iii) Method of preparing, transporting, pouring, vibrating and finishing
concrete.
iv) Quantity of various materials required during each stage of
construction including inserts, cutouts, reinforcement, dowels, etc.,
for procurement and timely supply.
v) Properties of concrete such as w/c ratio, strength, workability, etc.
vi) Rate of slipping which shall be adopted.
vii) Treatment at construction joints during unplanned interruptions.
c)

Construction Equipment

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SPEC NO.

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TITLE

SECTION : D6

SHEET 22 OF 40

REINFORCED CONCRETE CHIMNEY


The CONTRACTOR shall furnish a detailed description of the following
:
i)

The type and number of equipment and facilities to be used for


slipforming such as jacks, working platforms at various levels,
yokes, walers, etc. There shall be atleast a 50% standby capacity of
jacks, jack rods, hydraulic pump, hose pipes, etc.
ii) Provision, including standby, of concrete mixing units and pumps to
cater to the planned rate of progress of slipping.
iii) Material hoists and buckets for transport of concrete, reinforcement,
scaffolding components, etc.
iv) Curing arrangements consisting of pumps, pipelines, etc. There
shall be atleast 50% standby pumps
v) Provision of precision survey instruments including lasers for
verticality check. The laser instrument shall emit a long range visible
laser which has a self-levelling platform which electronically levels
the instrument and has a fail-safe system that shuts off the beam
when out of level. There shall be a standby.
vi) Stipulation of power requirement for operation and the
CONTRACTOR shall provide adequate standby diesel generating
sets. Details of night lighting shall also be specified.
vii) Communication arrangements between ground and working deck.

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TCE CONSULTING ENGINEERS LIMITED

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TITLE

SECTION : D6

SHEET 23 OF 40

REINFORCED CONCRETE CHIMNEY

12.3.2 Concreting
a)

Particular attention must be given to concrete placement because of the thin


wall section and the presence of reinforcing steel. Compaction of concrete
shall be by vibration.

b)

Under no circumstances shall the point of discharge of the concrete into the
forms be more than 1.5 m above the concrete surface on which it is to be
deposited. Also, not more than 2 metres height of chimney shall be concreted
on any one day if permission is given to proceed with jump forms.

c)

Concrete in the shell shall be poured in about 200 mm layers uniformly. The
concrete in each lift (where jump form is used) shall be laid in one continuous
operation for the full circumference of the shell so that there will be no vertical
or inclined construction joints. Horizontal construction joints shall be
maintained at uniform spacing throughout the height of the chimney.

d)

If the ENGINEER so requires, the CONTRACTOR shall make immediate


arrangements, through an approved agency, to undertake ultrasonic tests to
prove the quality of concrete. The quality of concrete shall be considered as
satisfactory if it meets specification requirements and the sonic velocity is
atleast 4000 m/s. If the tests prove that the quality of concrete is not
satisfactory, then all costs associated with the tests and any rectification shall
be borne by the CONTRACTOR.

e)

The interior and exterior surfaces of the shell shall be kept moist for 14 days
after exposure from the forms as the chimney construction progresses
upwards. For this purpose, circumferential perforated pipes shall be hung
from immediately below the forms and raised along with them.

f)

The vibrator needle size should normally be 62 mm dia, however the size
shall be restricted to 37 mm dia for sections wherein the use of 62 mm dia
needle size vibrators are not amenable to use. Standby vibrator units shall be
maintained on top of the working deck at all times during the slipforming
operation.

g)

The vibrator poker shall only be lowered into the concrete to a depth
corresponding to the height of the last placed layer of concrete. During the
first pouring, when the forms are empty, vibration should be avoided or
carried out with utmost care in order to prevent bending of the yokes.
To achieve good bond between the foundation and the first lift of the shell, or
at horizontal joints caused by interruptions to sliding, an initial layer of rich
mix cement/sand slurry of 1:1 proportion shall be placed.

h)

The slipping rate of the forms shall be such that the concrete, when exposed
has already achieved enough strength to support the vertical pressure from
the concrete still in the forms as well as to withstand lateral pressure caused

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SHEET 24 OF 40

REINFORCED CONCRETE CHIMNEY


by wind, inclination of walls, etc. The slipping rate shall be limited to
200mm/hour.
i)

Small openings and pockets less than 600 x 300 mm can be formed by
inserting blocks. Larger openings shall be formed using frames which shall
be formed well in advance of the sliding. All frames, blocks, bolts, tubes, etc.,
must be 12-15 mm narrower than the nominal wall thickness to allow for form
taper. When jacking rods unavoidably have to pass through openings more
than 600 mm high, the jacking rods must be braced laterally against buckling.

12.3.3 Physical Checks


Some of the mandatory physical checks to ensure that construction tolerances are
met with shall be carried out by the CONTRACTOR, as under :
a)

The twist or rotation of the slipform every 60 minutes.

b)
c)

Level of top of jacks every thirty minutes.


Verticality with the help of lasers atlease once in four hours.

d)

Inside and outside diameters/dimensions and wall thickness, once in each


shift of 8 hours.

e)

Level of top of form panels once initially and subsequently after each
interruption.

f)

Level of working platforms once initially and subsequently after each


interruption.

g)

Batter of the form panels and yoke legs once on erection and subsequently
after each interruption.

h)

Condition of jack rods for ovality, indentation, buckling, moving out of


alignment, etc., before fixing each rod.

i)

Bracing of jack rods passing through openings.

j)

Live load on working deck to avoid accidental overloads.

k)

Workability of concrete at mixer and at point of placement, once an hour.

l)

Temperature of concrete, once in 4 hours.

12.3.4 Construction Tolerance


The following shall be the limiting construction tolerances to be strictly adhered to
by the CONTRACTOR.

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TITLE

SECTION : D6

SHEET 25 OF 40

REINFORCED CONCRETE CHIMNEY


a) Verticality

1 in 1000 subject to a maximum of 75 mm. In


addition, no two points 10 m apart vertically shall
be more than 20 mm out of plumb wrt each other

b) Wall thickness

+ 10 mm, - 0.

c) Shell diameter

+ 10 mm for every 3m diameter without any


abrupt changes but in no case more than 40
mm.

d) Spiralling

Rate of spiralling of forms not greater than 10 mm


cir- cumferential rotation at the outer face of the
concrete per metre of vertical travel.

e) Openings, inserts,
pocket
:

12 mm

f)

+ 5 mm, - 0.

Cover

g) Level of any part


of structure
:
12.4

20 mm

CONSTRUCTION TOOLS AND MATERIALS

12.4.1 CONTRACTOR shall provide and maintain at the site necessary number and type
of machinery and equipment including survey instruments in good working
condition for proper setting out and timely completion of the works covered under
this specification. All arrangements for transporting the equipment to and from the
site shall be done by the CONTRACTOR at his own expense.
12.4.2 It shall be ensured by the CONTRACOR that work shall proceed uninterrupted
even in the event of power failures. As such, adequate number of diesel generator
sets and diesel operated equipment (such as concrete mixers, vibrators, etc.) shall
be provided by the CONTRACTOR, as an alternative arrangement.
12.4.3 All materials supplied by the CONTRACTOR shall be of the best quality and shall
conform to this specification.
Approval in writing shall be obtained from
ENGINEER, before any alternative or equivalent material is proposed to be used
by the CONTRACTOR.
12.4.4 CONTRACTOR shall furnish MANUFACTURERS test certificate for the materials
supplied by him. Where such certificates are not available, the specimen of the
material shall be got tested at a recognised testing laboratory at CONTRACTORS
cost.
12.4.5 Climbing or slip-forms shall be controlled by linked hydraulically operated jacks that
are reversible, driven by an electrically operated pump and with provision for
manual operation in the event of a break down.

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12.4.6 CONTRACTOR shall provide all fuels and lubricants required for the operation and
maintenance of construction machinery and equipment as well as for his transport
vehicles.
12.4.7 CONTRACTOR shall, at his cost, arrange for all his requirements of materials such
as, but not limited to, oxygen, acetylene, welding electrodes, ropes, form ties, turnbuckles, clamps, wiping rags, sand paper, etc., which are required to satisfactorily
perform his work.
12.5

WORK EXECUTION AND SUPERVISION

12.5.1 CONTRACTOR shall have at the site accredited and qualified engineers and
foremen/supervisors with adequate number of years of experience in execution of
similar works and operators of machinery and equipment, for satisfactory progress
and timely completion of the works. The number, qualification and experience of
such staff shall be subject to OWNERS approval.
12.5.2 All temporary electrical installation shall be supervised by a qualified electrical
supervisor of the CONTRACTOR.
12.5.3 CONTRACTOR shall be fully responsible for the correctness and accuracy of the
works, which shall be executed in a professional manner.
12.5.4 The OWNER reserves the right to order from time to time, during progress of the
work, removal and re-execution of any work which is not, in the opinion of the
ENGINEER, in accordance with the specification.
12.5.5 During inclement weather, rains, etc., CONTRACTOR shall suspend concreting for
such time as the ENGINEER may direct and shall protect from damage all work
already in progress or completed just then. All such temporary protective
measures shall be at CONTRACTORS cost and any damage to works shall be
made good by the CONTRACTOR at his own expense.
12.5.6 Should the work be suspended by reason of strikes/riots by CONTRACTORS own
employees or any other cause whatsoever, save and except the force majeure
condition, CONTRACTOR shall take all precautions necessary for the protection of
works and make good, at his own expense, any damage arising from any of these
causes.
12.5.7 In the event of occurence of any accidents at/or near the site of the work or in
connection with execution of the work, a report shall be made within 24 hours to
the ENGINEER, giving full details of the accident. He shall also report promptly
such accidents to all the competent authorities wherever such reports are required
by them.
12.5.8 One hoist for passengers/supervisory staff and one for transport of goods shall be
provided by the CONTRACTOR. These hoists shall be operational not later than
the time when construction first reaches 10 m and should be available throughout
the construction period. Access between various working levels shall be provided

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by an approved system of ladders. Under no circumstances shall staging or
scaffolding be relied upon to provide such access. The CONTRACTOR shall give
enough notice to ENGINEER of his intention to remove access to the various areas
of work as construction proceeds which would therefore be rendered inaccessible,
to allow final inspection by ENGINEER.
12.6

FOUNDATION REQUIREMENTS

12.6.1 In case any ID duct supports are fouling with the chimney foundation, the
CONTRACTOR shall design his foundation according to these loads.
The
CONTRACTOR shall include in his lumpsum price, the design and construction of
these supporting pedestals complete in all respects. Also the CONTRACTOR if
required shall supply and use templates to hold any anchor bolts for ID duct
supports on foundation.
12.6.2 All brackets, projections, insert plates required to be provided from the outside of
the shell to support ID duct of boiler supplier, shall be provided by the
CONTRACTOR as per loads indicated by the boiler supplier. Also, the supply,
fabrication and erection of the ID duct piece connecting the flue to the main ducts
is in the scope of the CONTRACTOR upto the match point.
12.6.3 The foundation shall be constructed in a maximum of four pours or as per the
directions of the ENGINEER. The CONTRACTOR shall not be paid any extra
amounts in case the foundation has to be constructed in less than four pours as
per project requirement.
12.6.4 The foundation sections shall be sized / designed and reinforced adequately for
circumferential and radial moments and shear stresses.
12.6.5 There should be no uplift under any portion of the foundation for any loading
condition.
12.6.6 A 100 mm thick levelling course of plain cement concrete (1:4:8) shall be provided
before casting the foundation.
12.7 SAFETY PRECAUTIONS
12.7.1 The Bidder shall provide all safety requirements for the personnel as per the
standard for the high altitude work.
12.7.2 If the sequence of work recommended by the ENGINEER so requires that the
Bidder shall have to carry out work simultaneously at different levels, the Bidder
shall provide all safety measures required to ensure the safety of the personnel
working at lower levels.
12.7.3 The CONTRACTOR shall take a comprehensive insurance policy including third
party riskes at his own cost before start of the work. The OWNER shall not make
any such payments.

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13.0

WIND LOAD ANALYSIS

13.1

WIND SPEED
The basic wind speed (Vb) for the location of the project shall be as indicated in
DATA SHEET- A. The estimation of wind speed/pressures shall conform to the
requirements of IS:875 (Part-3).

13.1.1 3-sec Gust Wind


Vz = Vb K1 K2 K3

.......... (1)

here,
K1 = a probability factor as obtained from Table-1 of the Code.The
mean probable design life of the structure may be taken as:
a) 25 years for shell alone condition;
b) 100 years for completed chimney condition
K2
= Terrain category factor obtained from Table-2 of the Code. The
terrain category for the project and class of the structure shall be as indicated in
DATA SHEET- A
K3

Topography factor shall be as indicated in DATA SHEET- A.

13.1.2 Mean Hourly Wind


Vz = Vb K1 K2 K3 ........ (2)
here, K1 and K3 shall be as in clause 14.1.1.
K2 as per Table-33 of the Code depending on the terrain category as
indicated in DATA SHEET- A.
13.2

WIND PRESSURE
Pz = 0.60 V 2z ........... (3)

13.3

ALONG WIND RESPONSE


This response will be evaluated by the following two methods:
Method-1
For 3-sec gust wind,
Fz = 0.60 Cd Dz V 2z ............ (4)
Here,
Cd = Coefficient of drag
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SPEC NO.

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TITLE

SECTION : D6

SHEET 29 OF 40

REINFORCED CONCRETE CHIMNEY

DZ = Diameter of chimney at height Z


Deflections, moments and shears shall be evaluated for lateral loads Fz
acting on the chimney as a cantilever. Vz to be as per clause 14.1.1
Method-2
For mean hourly wind analysis the Gust factor Approach as outlined in
clause A.5 IS:4998 (Part 1)-1992 shall be followed.
Deflection, moments and shears shall be evaluated for the lateral loads Fz
(Load per unit height at an height 'Z' on the chimney) acting on the chimney
as cantilever. Vz to be as per clause 14.1.2.
13.4

ACROSS WIND RESPONSE


The across wind response shall be evaluated for the first two modes as per
requirement of clause A.5.3 a) of IS:4998 (Part 1)-1992 for chimney having taper
less than or equal to 1 in 50. If chimney taper is more than 1 in 50 then procedure
outlined in paper by Vickery B J and Basu R I as indicated in clause 2.2.

13.5

COMBINATION OF RESPONSE
This shall be checked as under :
(a) The critical wind velocity for across wind response shall be evaluated
from:
ni Dc
Vcc = -------S

...... (5)

Here,
Vcc = Critcal wind speed
ni

= Natural frequency of chimney in the ith mode of

vibration
Dc = Effective diameter of chimney
S

= Strohal number

(b) Knowing the height (Zc) at which Vcc acts, corresponding value of K2 is
read from table 33 of the Code for the particular terrain category.
Vcc
V b' = ----------

(6)
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TITLE

SECTION : D6

SHEET 30 OF 40

REINFORCED CONCRETE CHIMNEY


K1 K2 K3
V 'Z = V b' .K2 K3

(7)

Then, response will be evaluated by equation (4). substituting V 'Z


Vz

for

(c) Response evaluated as per 14.5 (b) above will be vectorially combined
with that obtained for the particular condition outlined in clause 14.4
above.
NOTES
The response under wind load at any level to be used for design shall be
the highest of the following values:
a) As obtained for 3-sec gust wind, as per Eqn. (4)
b) As obtained for mean hourly wind, as per clause 14.3 Method 2
c) As obtained vide description in Cl.14.5(c), above.
14.0

SEISMIC ANALYSIS
Seismic analysis shall be done as per the procedure outlined in IS: 1893(Part 4).
Model analysis shall be used and seismic accelaeration spectra as give in IS:
1893- Part 4 shall be iutilised. The analysis shall be furnished for a minimum of five
models. An importaince factor of 1.75 and damping coefficient of 5% shall be
considered for analysis. Seismic design data shall be as per DATA SHEET- A.

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ELECTRICAL AND I&C REQUIREMENTS

TCE. 5607A-H-CCH400

1.0

SECTION:
SHEET 1 OF 15

REINFORCED CONCRETE CHIMNEY

GENERAL
This specification lays down broad nature of work to be executed. The Bidder
shall however include all such items of work whether specifically mentioned
here or not but are essential to make the individual equipment / system
complete in all respects for satisfactory completion of the proposed scheme.
This specification shall be read in conjunction with the bid drawings and other
particulars covered in general conditions of contract.
The make of all items shall be as per the list of "preferred makes of
equipment" and duly approved by the purchaser / consultant and fixture of
one type shall be identical and of one make.
All equipment / fittings shall be easily approachable for maintenance /
replacement.
All equipment and accessories covered under this specification shall conform
to Technical specification given in this document. The purchaser however,
reserves the right to accept or reject the proposal without assigning any
reason.
All safety measures as required to be adopted as per the statutory regulations
and the safety rules of the plant shall be strictly followed by the Bidder during
execution of the contract.
The Bidder will be provided 415V construction power supply at only one point.
Bidders scope shall start from outgoing terminals of construction power
distribution board under Purchasers scope. Supply laying & termination of
incoming cable to Normal Lighting Distribution Board and Emergency lighting
Distribution Board shall be under Bidders scope. Size of cable and MCCB/
switch fuse unit shall be decided by the Bidder based on his requirement.

2.0

SCOPE AND BRIEF DESCRIPTION OF WORK


The scope of work includes design, detail engineering, procurement of items,
shop testing, packing, transportation, loading and unloading, delivery at site,
storage, handling, erection and commissioning.
The Bidders scope of work shall include :
Earthing & Lightning protection of RCC Chimney
Aviation warning system of RCC chimney
3 General illumination of RCC Chimney
The lighting system for chimney shall comprise the following categories.
a)

Normal lighting system

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b)

Emergency lighting system

c)

Aviation warning lighting system.

NORMAL LIGHTING SYSTEM:


In this system, the lighting circuits shalll be fed by the 3 phase, 4 wire normal
AC supply from the normal lighting Panel. All the lighting fixtures connected
to this system shall be available as long as supply is available from normal
source through lighting transformer. The 63A receptacles located at each
platform shall also be fed from the LDB. The normal lighting distribution board
shall be fed from Purchasers LT Switchgear located in ESP Control Room.
Supply, laying and termination of incoming cable is included in Bidders
scope.
EMERGENCY LIGHTING SYSTEM:
In this system, the lighting circuits shalll be fed by the 3 phase, 4 wire AC
supply from the emergency lighting distribution boards. The lighting fixtures
indicated in the drawing shall be connected to this system. The emergency
lighting distribution board shall be fed from Purcghasers Emergency lighting
distribution board located in Main Plant building. Supply, laying and
termination of incoming cable is included in Bidders scope.
AVIATION WARNING LIGHTING SYSTEM:
The aviation warning lights shalll be fed by the 3 phase, 4 wire AC supply
from the Emergency lighting distribution board. Supply, laying and termination
of incoming cable is included in Bidders scope.
Required number of lighting panels/JBs for staircase and platform lighting
shall be provided.
The incoming cable from Ash handling switchgear and station building shall
be laid in cable rack/ trench. Whereever existinmg Purchasers cable
trench/rack shall be employed. Size of the cable trench shall be depending on
the number of cables. Bidder shall consider suitable protection arrangement
such as laying in GI pipe etc. for road, drain and pipe crossings on a cable
route. However crossing arrangement shall be provided as per the actual site
condition.
For installation of fixtures etc, the Bidder shall have to arrange tools, tackles,
welding sets, pipe bending machine, cable crimping tools etc.
The Bidder shall be responsible for supply and fixing of all accessories
required for installation of earthing & lightning protection equipment, aviation
lighting system equipment, normal & emergency lighting system, distribution
panel etc. on required places even though every individual item necessarily
may not have been detailed out explicitly in the specification.
The main items shall be as follows.
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SHEET 3 OF 15

REINFORCED CONCRETE CHIMNEY

AC distribution board with lighting transformer

Emergency lighting distribution board

Lighting panels/JBs for staircase and platform lighting

Cables

Air termination rods

- GI strips - 65x 10 mm, 50X8 mm, 25X6 mm, 25X3 mm, 8 SWG GI wire, 12
SWG GI wire
-

Earthing electrodes 36 mm dia

Aviation warning lights with control system

Photo electric light detector

1 x 70 W HPSV light fittings.

63 A power receptacles,

15/5A single phase power receptacles for I&C requirements

Bidder shall supply approved type danger boards in English, Hindi and Oriya
Bidder shall supply fixing accessories such as nut bolts, check nuts, bushes,
clips, nails, hoopers, clamps, screws, conduits, etc.
Bidder shall have to take approval on following data / drawing
- GA drawing of LDB/Emergency LDB
- Lighting calculations and lighting layout
- Earthing and lightning protection layout
- Single line diagram of the power distribution network
- Incoming cable route layout with sections
- Make of the items
Bidder shall be responsible to maintain all fittings/ equipment till handing over
the chimney and shall change free of cost any fitting /equipment / accessories
if found not in working condition.
Bidder shall be responsible for taking approval of the installation and
permission to energise the system from statutory authority.

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ELECTRICAL AND I&C REQUIREMENTS


SHEET 4 OF 15

REINFORCED CONCRETE CHIMNEY

Bidder shall be responsible for storage and safety of equipment at site.


Bidder shall supply and install GI pipe conduit risers of 38 NB diameter or
larger as required, cleated on inner face of the concrete shell. Following
minimum number of conduit risers shall be provided.

One conduit riser to carry the cables to the aviation warning lights to be
provided at the platforms, the tentative levels of which are specified in
the drawing.

Another conduit riser to carry the power supply cable to lighting fixtures
to be provided on platforms.

The third set of two conduit risers shall be provided for power supply to
receptacles.

The fourth set of conduit riser shall be for lift cables.

Three more conduit risers shall be provided, two for I&C and one spare.
GI pull boxes, provided on inner face of the concrete wall by suitable anchor
fastners shall be installed at 2.5 metre intervals vertically, unless specified
elsewhere. The lowest pull box shall be located 450 mm above grade. Each
conduit riser shall run from the lowest pull box to the highest junction box. The
conduit risers shall run adjacent to the stair case such that pull boxes are
easily accessible. Suitable surface cleated pipe / conduits shall also be
provided from the lowest pull box to a suitable outlet point at the base of the
chimney to receive cables.
Each conduit riser other than those provided for instrumentation and lift shall
be connected to a circumferential conduit at each platform level. The
circumferential conduit at each level for the platforms shall be provided with
necessary GI junction boxes, equally spaced, at the location of the aviation
warning lights or lighting fixtures as the case may be. Suitable surface cleated
conduits shall also be provided from the junction box to the respective light
point. The GI pull boxes and junction boxes shall be fabricated from 16 SWG
sheet steel and shall be of size 200X200X100. The pull boxes shall be
provided on the concrete shell over the inner face. The supply and installation
of cable from pull boxes to junction boxes near the fixture shall be included in
Bidders scope.
Bidder shall provide two numbers of embeded conduit for instrument air to
respective analyzer. Purchasers terminal point for instrument air shall be at
the ground level at one point. Further distribution till the analyzer shall be
included in Bidders scope.
The make of equipment shall be limited to preferred makes as given in
preferred makes of equipment. If the equipment/components are outside from
preferred makes separate approval from the purchaser shall be obtained for
the list.
For lightning protection, Bidder's scope of work shall include supply and
installation of the complete system up to and including the earth electrodes /
mat and air termination rods.
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SHEET 5 OF 15

REINFORCED CONCRETE CHIMNEY

The Bidder shall furnish a detailed drawing of the lightning protection system
and earthing system and execution of work shall be commenced only after
obtaining approval to this from the owner.
Additional corrosion protection for grounding material, underground piping and
other equipment shall be provided.
For aviation warning system Bidder's scope of work shall include supply and
installation, testing & commissioning of the complete aviation warning system
including power receptacles and cabling between main board / switch and
aviation warning beacons.
Aviation lighting system shall be test operated by the Bidder for not less than
60 days. Equipment and work which fails during the test period shall be
repaired or replaced at the option of the owner. Upon any failure in this
system during the test period, a new test period shall be required after repair
or replacement of the equipment which failed.
The scope shall also include the civil works associated with aviation lighting.
The Bidder shall furnish a detailed drawing of aviation warning system and
associated control system scheme, power distribution scheme and execution
of work shall be commenced only after obtaining approval to this from the
owner/consultant.
For general illumination of RCC Chimney, scope of work includes supply and
installation of complete illumination system including power receptacles and
cabling.
The Bidder shall also furnish a detailed drawing of illumination system and
associated power distribution net work.
3.0

TECHNICAL SPECIFICATION
INSTALLATION
EARTHING SYSTEM

DETAILS

OF

EQUIPMENT

AND

Separate earthing conductors of 65 x 10 G.I shall be run in the outer side of


RC shell, supported at 2500mm interval. Only risers shall be brought out at all
platforms for equipment earthing.
A circular earth mat of 36mm dia MS round bar shall be provided at 600mm
below the ground.
The earth mat shall be connected to the earth electrodes and shall be
connected to plants earth grid through Test pits.
The Earth electrode shall be of 36mm dia, 3M long GI round bar.
The earthing resistance of earthing system shall be less than 1 Ohm. If the
earth resistance is found as more than one ohm, Bidder shall provide
additional earth electrodes or mat to bring down the earth resistance to a
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REINFORCED CONCRETE CHIMNEY

value of less than one ohm.


All welded joints shall be protected against corrosion. The joint portions shall
be thoroughly cleaned before welding.
All metallic parts, lighting fixtures, JBs , Lift motor, Handrail etc., shall be
earthed to the nearest earthing grid by using suitable earth conductor at two
points.
JBs, lighting fixtures, handrail ---- 8 SWG & 12 SWG GI wire
DB, LP & metallic structure ---------25x6 GI flat
2.2

AVIATION WARNING SYSTEM


Bidder shall supply and install, including wiring, Medium and low intensity
aviation warning lights with all associated accessories such as sockets,
special cables, electrical controllers / Flashers and necessary mounting
brackets/supports.
The aviation warning lights shall be provided at the locations shown in the
drawing.
Aviation lighting fixtures securely mounted at the top of the chimney shall be
within the zone of protection of vertical air terminations.
The aviation warning lights shall meet the recommendations of ICAO, FAA
and Director General of Civil Aviation, India. The arrangement of lights shall
be marked such that the object is indicated from every angle in azimuth. The
aviation warning lighting system shall also confirm to the latest Indian
standard, IS 4998.
All the aviation light fixtures shall be weatherproof and outdoor type suitable
for highly
humid and flue ladden atmosphere.
The Medium Intensity aviation warning beacons shall generally meet the
following requirements:
a) Type of Lamp

b) Type of fitting
(Type B)

Medium intensity flashing type

c) Control of flash
intensity operation

Automatic for day and night

d) Intensity of flash

1600 cd (minimum) of red light

e) Frequency of flashes

20 to 60 flashes per minute

f)

Type of flashes

Red coloured LED

Synchronised flashing of all the


lights
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g) Rated power supply
voltage & frequency

240V, 1 phase and 50 Hz

h) Type of enclosure

Weather proof conforming to IP


55 classification as per IS:13947

The Low Intensity aviation warning beacons shall generally meet the
following requirements:
a) Type of Lamp

Red coloured LED

b) Type of fitting

Low intensity fixed type (Type B)

c) Control of flash
intensity operation

Automatic for day and night

g) Rated power supply


voltage & frequency

240V, 1 phase and 50 Hz

h) Type of enclosure

Weather proof conforming to IP


55 classification as per IS:13947

Wiring of aviation warning lights and other light fixtures shall be carried out
using 1100V grade, copper/Aluminum conductor, XLPE insulated and overall
HR PVC-FRLS sheathed cables. The cable shall be clamped by the side of
the ladder at 750 mm centres by means of GI clamps. Weather proof terminal
boxes with cable glands made of brass, tin plate shall be provided at the
location of each of the aviation warning lights for termination of cables
Normal lighting distribution board with lighting transformer shall consist of an
incoming MCCB/ switch-Fuse unit of 415V, 100A, TPN and required number
of outlets of 63A, 32A & 16 A TPN MCBs shall be supplied, installed and
commissioned at a height of 1.5 meter from grade level on a supporting
structure with proper grouting. In addition to the feeders required for lighting
circuits and receptacles, minimum 3 nos. 10 A SPN MCB for instrument
supply shall be provided in LDB. Atleast 20% of outgoing feeders for each
type and rating with minimum of one number shall be provided as spare.The
distribution board shall be supplied with tinned brass glands and tinned
crimping type cable lugs for termination of cables. The panel shall have two
distinct earthing terminals and shall be earthed at both points.
The distribution boards shall confirm to IP: 55 class of enclosure and
provided with suitable rain canopy over the top. Sheet steel thickness of
distribution board shall not be less than 2mm for load bearing structures and
1.6 mm for others.
The board shall be painted with one coat of zinc chromats primer (yellow)
and two coats of synthetic enamel paint of approved shade.
The switches shall be of heavy duty type conforming to the requirements of
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REINFORCED CONCRETE CHIMNEY

IS:13947. The fuses shall be HRC link type.


Aviation lights supports etc. shall be fitted to the chimney by GI nuts on to GI
inserts projecting from concrete surface. All bolts clamps etc used shall be
hot dip galvanised. For the top platform for fixing aviation warning lights
suitable mounting arrangement shall be provided as shown in the drawing.
Aviation lighting system shall be fed from separate distribution board which
shall be fed from emergency LDB. The aviation light circuits shall be
distributed among R.Y and B phase of 3 phase, 4 wire supply.
The Bidder shall install weatherproof terminal boxes with MCBs and cable
glands on each platform of the chimney at location close to the aviation
warning beacons. The maximum conduit fill shall not exceed 60%. Suitable
pull boxes shall be provided at convenient locations. All aviation light fixtures,
conduits and junction boxes etc, shall be properly earthed. Earth wire shall
run inside along the entire length of conduit between the fixtures and
distribution board where it shall be connected to earth.
For aviation warning during daytime the external surface of the top of the
chimney shall be painted with special paints as approved by the owner. The
depth of the painting and type to be used (chequered or stripe) shall meet the
aviation requirements of civil aviation department and owners approval.
Temporary warning lights shall be installed during construction to meet the
requirement of civil aviation department. The temprory warning lights
installed during construction shall be shifted up as the construction
progresses. These lights need be installed only after the level of obstruction
is greater than 40 m above the grade level. Lightning protection and earthing
required during the construction stage of the chimney shall also be provided
by the Bidder.
Temporary warning lights shall be four fixtures (Low intensity type A) each
with not less than 10 candelas of red light. Power for operation of the
temporary lights shall be obtained from the construction power system.
Supply circuits for these lights shall be furnished, installed and maintained by
the Bidder. These lights shall be operated right from sunset to sunrise. The
Bidder shall provide sufficient hand railing ladders platforms to attend any
maintenance work.
2.3

GENERAL ILLUMINATION
Each landing of the staircase shall be provided with one 1x70 watt HPSV bulk
head dust proof light fixture.
The Bidder shall provide suitable mounting arrangement for the above fixtures
capable of withstanding high wind pressure.
General lighting system of chimney shall be fed from a separate feeder of
distribution board mentioned above.
The cables for wiring all lighting fixtures and power receptacles shall be sized
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considering the voltage drop. The cables shall be clamped by the side of the
ladder at 750 mm centres by means of GI clamps.
Lighting fixtures, conduits junction boxes etc. shall be properly earthed using
galvanised steel wire of 12 SWG. Earth wire shall run inside along the entire
length of conduit between the fixtures and distribution panel where it shall be
connected to the earth.
One number of 63A, 3 Phase, 4 pin industrial type power receptacle with
controlling switch and loose matching plug mounted in weather proof and dust
tight box shall be supplied and installed at each of the platform near access
doors. The box shall be fabricated of galvanised sheet steel having suitable
hinged door properly gasketed to make it dust proof.
The 400V, 3ph, power cables will be 1100V grade, single / multi-core,
stranded aluminium conductor grade H4 Class 2, XLPE insulated, with
extruded PVC inner sheath Type ST2, armoured and outer sheath made of
specially formulated FRLS extruded PVC Type ST2 compound. Minimum
cabling requirement shall be as follows. For cabling of aviation lights, LPSV
lamps and receptacles, armoured cables shall be laid on vertical trays.
One run of 4C x 10 sqmm Al cable for receptacles for each platform.
One run of 4C x 10Sqmm Al cable for each of the two Aviation lights circuits
and further distribution to each platform by 2C x 2.5 sqmm cables. One run
each of 2C x 2.5 sqmm cable for HPSV lights on each platform.
Photoelectric light detectors shall be furnished and installed at bottom of the
chimney and above the distribution board to monitor the light intensity. The
detector shall cause the control unit to energize the lighting system when the
illuminance on a vertical surface decreases to less than 35 candela. Lights
shall be deenergised when the illuminance on a vertical surface increases to
more than 58 candelas. The lighting system may be energized during short
periods of decreasing illumination due to abrupt periods of shadow during day
light hours, but shall not be deenergised as the result of short periods of
increasing illumination levels due to lightning flashes or stray light sources
when overall illumination level is such that the system has to operate. In case
of malfunction of photoelectric circuit, manual bypass arrangement through
bypass switch shall be provided.
The lighting fixtures and receptacles shall be fed such that loading of all the
three phases is balanced. The lamp on the same vertical line shall be fed from
different phases, so that failure any one phase shall not cause total block out
on one side.
2.4

INSTRUMENTATION & CONTROL REQUIREMENT


1. For each flue six (6) number sampling ports for measurement of NOx,
SOx and opacity (SPM) of flue gas through openings (SS pipes with
flanges with necessary fittings) will be installed in liners at height as
required during detailed engineering/design. The pipe & flange details
also shall be provided to bidder during detailed engineering. Suitable
operating platform shall be provided. Perforated cable trays as
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suitable shall be provided for routing the sample probe/tube, cables
from chimney sampling height to stack analyzer room.
2. Twelve gas sampling ports, six on each vertical face of MS flue duct,
for mounting particulate emission monitor and one port for laboratory
gas sampling fabricated from SST or MS pipes as the case may be
with flanged ends shall be provided for each flue as indicated in the
bid drawings, including proper insulation, blank plates, nuts, bolts,
etc. The location, orientation and level of ports inclusive of size and
thickness of material to be used shall be as per the details indicated
in the tender drawing. The sampling equipment is not in the scope of
this contract. The CONTRACTOR shall, however, provide all the
necessary fittings required for the port holes. The number & locations
of these ports indicated in the bid drawings are tentative and actual
number and locations will be indicated during detail engineering. The
cost of these provisions shall be included in Bidders lumpsum price.
It shall also include providing a power connection with 15/5 Amps,
230V AC plug sockets near every port hole. The load shall be 1000
Watts. Access platforms for installation/maintainance of sampling
ports shall be provided by the contractor as indicated in the tender
drawing.
3. Bidder shall provide for the purposes of instrumentation other than the
sampling ports mentioned in clause 2 above, required number of 38
NB conduits including pull wires, junction boxes and pull boxes, all
securely tacked / anchored to internal of shell and SS 316 L plates
below each pipe insert for fixing of measuring instruments.

2.5

LIGHTNING PROTECTION
Air terminals of 20 mm dia, 2000mm long, lead coated copper rod with dom
and spike, projecting not less than 750 mm above the highest part of th
chimney and securely anchored and braced with at least two lead covere
copper alloy anchors spaced not more than 750mm shall be provided. A
terminal shall be equally spaced at a maximum of 2500 mm centres around th
outside circumference. Air terminals shall be mechanically and electricall
connected by the use of pressure type fittings to the Chimney shell peripher
and to a continuous circumferential conductor. The installation work sha
conform to IS:2309. The ohmic resistance of the lightning conductor system
complete with air termination, but without the earth connection, shall be
fraction of an ohm.
The circumferential conductor shall be 65 x 10 mm GI flat lead covered formin
closed loop at 600mm below the top of the shell.
Each segment of cap of the chimney shall be connected to the circumferentia
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REINFORCED CONCRETE CHIMNEY

band by means of tightly bolted connections.


The joints in the lightning / ground conductors shall be kept to a minimum an
there shall be no joint in the underground portions of conductors. Overlapping o
conductors at straight joints shall not be less than 150mm.
Brass rods shall be used for brazing.
The down comers of 65 x 10 mm GI flat shall be run on outer side of th
concrete shell. Down conductors shall be connected to the circumferentia
conductor at the top of the chimney and to the testing point at the chimney base
Lapping of down conductor by bolting is not acceptable.
The circumferential band shall be supported at intervals of 600mm and dow
comers shall be supported at interval of 2500mm.
The down comers shall come out from the shell to facilitate connection with th
test link.
The down conductors shall be spaced atleast 2000 mm away from the vertica
conduit risers as well as the ladder.
Lightning system grounding shall be distinct from the plant grounding system
Lightning down conductors shall be separately ground through earth electrod
rods.
The connection between Earth electrode and Earth mat shall be of 40mm dia G
pipe test pit
The conductor from earth electrode to a height of about 250mm above groun
level shall be of 36 mm dia MS round bar and thereafter 65x 10 GI flat.
All vertical reinforcing bars at the top and at the bottom of the chimney shell sha
be electrically connected to the nearest horizontal reinforcing rods and thes
rods shall in turn be connected to the down conductors. Where vertica
reinforcing bars are spliced, each spliced bar shall be electrically connected to a
least one horizontal reinforcing bar which in turn shall be electrically connecte
to each of the down conductors.
All the metallic parts such as platform, railings, pull boxes, junction boxes etc
shall be grounded using 8 SWG GI wire to the nearest 65X10 mm GI fla
provided by Bidder.
During construction, temporary lightning protection should be maintained b
connecting the concrete reinforcement to two permanent electrical groundin
conductors. After the top lift of the chimney shell has been completed, temporar
air terminals which may consist of reinforcing bars, should be installed at the to
to serve as a temporary protection until the lining and cap are completed an
permanent air terminals are installed.

ISSUE
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TCE FORM NO. 329 R4

TCE Consulting Engineers Limited

SPEC. NO.
TCE. 5607A-H-CCH400

SECTION:

ELECTRICAL AND I&C REQUIREMENTS


SHEET 12 OF 15

REINFORCED CONCRETE CHIMNEY

Chimney staircase / Ladder shall be electrically connected to the dow


conductors both at top and bottom. For this, the two lower pairs of insert
supporting the Staircase / ladder shall be adequately connected to the groundin
system and the top pair of inserts shall be connected to the circumferentia
conductor connecting the down conductor. All intermediate breaks in the ladde
should be electrically bonded to form a continuous support from top to bottom.
Each down conductor shall be provided with a testing point around 1500 mm
above ground level but inaccessible in order to avoid interference. Test link sha
be enclosed in 200X200X100 GI box fabricated out of 16 SWG sheet steel. A
bolt-nuts and washers in the test link shall be electroplated.
Incoming and outgoing portion of the lightning down conductor from the test lin
shall be galvanised to length of atleast 500mm.
All connections, clamps, anchors, etc., of the lightning protection system shall b
made of GI and shall conform IS-2309. All electrical connections or joints, unles
otherwise specified, shall be clamped or bolted by high-pressure contact to form
a connection of adequate current carrying capacity and mechanical strength
Soldered connections shall not be permitted.
Air terminals, connections, conductors, clamps, fixtures, anchors, etc., expose
within 25000 mm of the top of the chimney shall have a continuous lead coverin
of a sheath of commercially pure lead not less than 2mm in thickness extruded
the ends being covered by soldering or puddling. Where lead covering i
specified, after the joints have been made, they shall be again covered wit
solder or lead either by wiping or casting.
3.0

INSPECTION TESTING AND COMMISSIONING

3.1

After completion of erection / installation, such piece of equipment shall b


thoroughly inspected in presence of the owner for correctness and completenes
of erection and acceptability
A checklist shall be furnished for owner/consultants approval wherein all detail
to be checked and necessary instruction shall be listed. The inspection an
checking shall strictly follow the checklist.
On completion of the inspection two copies of the checklist dully filled in shall b
handed over to the owner.
The checklist shall be jointly signed by the Bidder and the owner. Suc
endorsement, however shall not relive the Bidder of his obligation under th
contract.
The Bidder shall provide all tools, materials, labour and supervisory personne
for carrying out field tests on equipment and materials under his scope of work.
The tests shall be conducted in presence of the owner and according to hi
directions.
All temporary arrangements, rigging and connections required for the tests sha
be provided by the Bidder.
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TCE FORM NO. 329 R4

TCE Consulting Engineers Limited

SPEC. NO.

SECTION:

ELECTRICAL AND I&C REQUIREMENTS

TCE. 5607A-H-CCH400

SHEET 13 OF 15

REINFORCED CONCRETE CHIMNEY

The Bidder shall record the test results on approved proforma and furnish six (6
copies of the results to the owner for approval within a week of the date of test
completed.
On successful inspection and testing the equipment shall be commissioned an
put on service in a manner mutually agreed upon.
3.2

RECTIFICATION

3.3

The Bidder shall carry out all rectifications, repairs or adjustment work foun
necessary during testing, commissioning at his own cost
TAKING OVER

3.4

On commissioning and on carrying out necessary rectification work, the owne


shall take over the installation either wholly or in parts, as the case may be.
DEFECTS FOUND AFTER TAKING OVER
If any defects of design, workmanship and materials are observed within on
year from the date of completion of work as certified by the Engineer, it shall b
corrected by the Bidder, entirely at his risk and cost. If the work of repairs o
replacement is carried out by the owner, actual cost shall be recovered from th
Bidder.

4.0

LIST OF SPECIFICATION DRAWINGS


Sl No

Description

Drg. No

RC Chimney Earthing
Lightning Protection Layout

RC Chimney Lighting Layout

and TCE 5312A-816-GL-3071


TCE 5312A-815-GL-3070

ANNEXURE -1
LIST OF SPARES FOR 3 YEARS OF OPERATION & MAINTENANCE
1

Photo electric device

1 set

Junction boxes

4 nos of each type

Termination boxes

4 nos of each type

Aviation lamps(LED type Medium


intensity & Low intensity)

3 nos

MCB/SFU

3 nos of each type

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TCE FORM NO. 329 R4

TCE Consulting Engineers Limited

SPEC. NO.
TCE. 5607A-H-CCH400

SECTION:

ELECTRICAL AND I&C REQUIREMENTS


SHEET 14 OF 15

REINFORCED CONCRETE CHIMNEY

Flasher unit complete with electronic


cards etc

1 set of each type

70W HPSV light fittings

10 nos

ANNEXURE II
The installation of electrical system shall be in strict accordance with the latest
editions of relevant Indian Standards, Codes of Practice and Regulations
existing in the locality where the system is installed. In particular, the following
standards shall be applicable:
LIST OF APPLICABLE CODES FOR ELECTRICAL EQUIPMENT
1

Protection against lightning

IS-2309

Earthing

IS-3043

Aviation warning lighting

IS-4998

Dust proof electric light fittings

IS-4012

Switches

IS-13947

Indian Electricity Rules

ANNEXURE III
PREFERRED MAKES OF EQUIPMENT
Distribution panel

S&S/MDS/HAVELLS/INDO-ASIAN

Switch socket outlet/power


receptacle

ANCHOR/ELLORA/ESSEN/CGL/
ALSTOM/ BEST & CROMPTON/

Cables

CCI/ASIAN CABLES /UNIVERSAL/ FORT


GLOSTER/ NICCO/ FINOLEX /
POLYCAB/ KEI / PARAMOUNT/
INDUSTRIAL CABLES/ CRYSTAL
CABLES

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TCE FORM NO. 329 R4

TCE Consulting Engineers Limited

SPEC. NO.
TCE. 5607A-H-CCH400

SECTION:

ELECTRICAL AND I&C REQUIREMENTS


SHEET 15 OF 15

REINFORCED CONCRETE CHIMNEY

Aviation obstruction luminaire

PHILIPS/AVAIDS TECHNOVATORS PVT


LTD/ WIPRO/BINAY/ALTUS / KANMUR

Photo electric light detector

ADVANCE/ELECTRONICS/ VIJAY FIRE


PROTECTION SYSTEM/ PHILIPS/ TATA
HONEYWELL

Light fittings

PHILIPS / CGL/ BAJAJ / GE/ WIPRO

MCBs

MDS/STANDARD/ INDO KOPP/S&S/


INDO ASIAN/HAVELLS

Contactor
SIEMENS/ L & T/TM
O/L relay
SIEMENS/ L & T/TM
Motor
BHEL/ CGL /KEC/ SIEMENS/
ABB/ALSTOM/BBE
Note :
Similar items shall be of one make only.
For items not indicated above, the Bidder shall obtain approval from the
purchaser.

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TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC. NO.
TCE. 5607A-H-CCH-400

SECTION: D8
SHEET 1 OF 7

TITLE

SUPPLY AND FABRICATION OF STRUCTURAL


STEEL
1.0

SCOPE

1.1

This specification covers the general requirements for supply where specified,
fabrication and delivery at site of structural steel.

1.2

This specification also covers fabrication and painting of structures.

2.0.

APPLICABLE CODES & SPECIFICATIONS


The following specifications, standards and codes are made as a guide line
and a part of this specification. All standards, specifications and codes of
practices referred to herein shall be the latest editions including all applicable
official amendments and revisions.
In case of discrepancy between this specification and other documents
referred to herein, this specification shall govern.
a) MATERIALS
i)

IS : 2062

Steel for General Structural Purposes

ii)

IS : 2074

Ready Mixed Paint, Air drying, Red Oxide Zinc


Chrome and Priming

iii)

IS : 5369

General Requirements for Plain Washers and


Lock Washers

iv)

IS : 5372

Taper Washers for Channels

v)

IS: 5374

Taper Washer for I Beams

vi)

IS : 6639

Hexagonal bolts for steel structures

b)

CODES OF PRACTICE

i)

IS : 800

Code of Practice for General Construction in


Steel

ii)

IS : 816

Code of Practice for use of Metal Arc Welding


for General construction in Mild Steel

iii)

IS : 818

iv)

IS : 822

Code of Procedure for Inspection of Welds

v)

IS : 1477

Code of Practice for Painting of


Ferrous Metals in Buildings

vi)

IS : 3016

Code of Practice for fire precaution in welding

Code of Practice for safety and health


requirement in electric and gas welding and
cutting operations

(Parts 1 & 2)

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TCE CONSULTING ENGINEERS LIMITED

SPEC. NO.
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SECTION: D8
SHEET 2 OF 7

TITLE

SUPPLY AND FABRICATION OF STRUCTURAL


STEEL
and cutting operations
vii)

IS : 3600

Methods for testing fusion welded joints and


weld metal in steel

viii)

IS : 7215

Tolerances for Fabrication of Steel Structures

ix)

IS : 7318

Approval test for welders when welding


procedure Approval is not required Part IFusion welding of steel

3.0

SUPPLIED MATERIALS

3.1

Materials supplied by Owner free of cost basis should be collected from Stock
Yard / Works Material Yard / authorised Dealer as instructed

3.1.1

While executing the Work the Contractor shall indicate the quantity of steel
required, sufficiently in advance.

3.1.2

All other materials required to complete the work shall be supplied by the
contractor.

3.1.3

All the charges for taking delivery, loading, unloading, stacking, transporting
and storage shall be borne by the contractor.

3.1.4

The Contractor shall be responsible for timely collection of materials from any
location as specified, in full / part in quantity requires to complete the job
within agreed schedule.

3.1.5

The materials to be supplied Free of Cost by the Employer as mentioned


above to the contractor, for execution of this would always remain the
property of the Employer throughout the duration of the order and therefore
should not be used by the contractor for any purpose other than the scope
specified under the order. It will be responsibility of the contractor to keep
these materials in safe custody, during the execution of the order against any
loss, pilferage etc.

3.1.6

On completion of work contractor shall submit reconcillation statement and


surplus materials shall be returned by the contractor to the Employer, at the
places as may be directed by the Employer/Engineer. Sortage return of
surplus excess materials issued by the Employer will be charged to the
contractor @ 1.25 times of the prevailing market rate on the date of enquiry.
The market rate as decided by owner will be final & binding on the contract.

4.0

DRAWINGS PREPARED BY THE OWNER

4.1

Design drawings will be furnished to the VENDOR/CONTRACTOR and all


drawings so furnished shall form a part of this specification. These design
drawings prepared by the ENGINEER will show all the, levels,forces on
members where shall necessary, size and orientation of each member,
location/size of openings, to enable the VENDOR/CONTRACTOR carry out
fabrication and erection.
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SPEC. NO.
TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED

SECTION: D8
SHEET 3 OF 7

TITLE

SUPPLY AND FABRICATION OF STRUCTURAL


STEEL
4.2

The ENGINEER reserves 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 updated requirements.
Revisions to drawings and any new drawings made to include additional work
by the VENDOR/CONTRACTOR shall be considered a part of this
specification and contract.

4.3

Should the VENDOR/CONTRACTOR during the execution of his work find


discrepancies in the information furnished by the ENGINEER, he shall refer
such discrepancies to the ENGINEER before proceeding with such work.

5.0

FABRICATION

5.1

General
All workmanship and finish shall be of the best quality and shall conform to
the best approved method of fabrication. All materials shall be finished
straight and shall be machined/ground smooth true and square where so
specified. All holes
and edges shall be free of burrs. Shearing and
chipping shall be neatly and accurately done and all portions of work
exposed to view shall be neatly finished . Unless otherwise directed/
approved, reference may be made to relevant IS codes for providing
standard fabrication tolerance. Material at the shops shall be kept clean and
protected from weather.

5.2

Connections

5.2.1

Shop/field connections shall be as per approved design drawings.

5.2.2

In case of bolted connections, taper washers or flat washers or spring


washers shall be used with bolts as necessary. The length of the bolt shall
be such that atleast one thread of the bolt projects beyond the nut, except in
case of high strength friction grip bolts where this projection shall be atleast
three times the pitch of the thread.

5.2.3

In all cases where bearing is critical, the unthreaded portion of bolt shall
bear on the members assembled. A washer of adequate thickness may be
provided to exclude the threads from the bearing thickness, if a longer grip
bolt has to be used for this purpose.

5.2.4

Fastners of all grades, consumables etc. shall be supplied/brought to site


10% in excess of the requirement in each category and size.

5.3

Straightening
All materials, shall be straight and, if necessary, before being worked shall
be straightened and/or flattened by pressure and shall be free from twists.
Heating or forging shall not be resorted to without the prior approval of the
ENGINEER in writing.
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SPEC. NO.
TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED

SECTION: D8
SHEET 4 OF 7

TITLE

SUPPLY AND FABRICATION OF STRUCTURAL


STEEL
5.4

Cutting, punching, drilling, welding and fabrication tolerances shall be


generally as per relevant IS codes.

5.5

Welding

5.5.1

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).

5.5.2

While fabricating 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 members. Wherever weld reinforcement interferes with
proper fit-up between components to be assembled for welding, these
welds shall be ground flush prior to assembly.

5.5.3

Approval of the welding procedure by the ENGINEER shall not relieve the
CONTRACTOR of his responsibility for correct and sound welding without
undue distortion in the finished structure.

5.5.4

No welding shall be done when the surface of the members is wet nor
during periods of high wind.

5.5.5

Each layer of a multiple layer weld except root and surfaces 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
overpeening.

5.5.6

No welding shall be done on base metal at a temperature below -5 Deg.C.


Base metal shall be preheated to the temperature as per relevant IS codes.

5.5.7

Electrodes other than low-hydrogen electrodes shall not be permitted to use


for higher thicknesses as per standard practice.

5.5.8

Inspection of Welds
All welds shall be inspected for flaws by any of the methods described under
clause 8 "Inspection". The choice of the method adopted shall be
determined by the PURCHASER/ENGINEER.

5.5.9

The correction of defective welds shall be carried out as directed by the


ENGINEER without damaging the parent metal. When a crack in the weld is
removed, magnetic particle inspection or any other equally positive means
as prescribed by the ENGINEER shall be used to ensure that the whole of
the crack and material upto 25 mm beyond each end of the crack has been
removed. Cost of all such tests and operations incidental to correction shall
be to the VENDOR/CONTRACTOR's account.

5.6

Tolerances
The dimensional and weight tolerances for rolled shapes shall be in
accordance with IS:1852 for indigenous steel. The tolerances for fabrication
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SPEC. NO.
TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED

SECTION: D8
SHEET 5 OF 7

TITLE

SUPPLY AND FABRICATION OF STRUCTURAL


STEEL
of structural steel shall be as per IS:7215.
6.0

INSPECTION

6.1.1

The VENDOR/CONTRACTOR shall give due notice to the


PURCHASER/ENGINEER 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 PURCHASER's/ENGINEER's
approval/inspection. The fact that certain material has been accepted at the
VENDOR/CONTRACTOR's shop shall not invalidate final rejection at site by
the PURCHASER/ENGINEER 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
PURCHASER may make because of defective or unsatisfactory materials
and/or workmanship. Vendor shall have to extend all facilities to Engineer to
inspect the material at any stage during execution.

6.1.2

No materials shall be painted or despatched to site without inspection and


approval by the PURCHASER/ ENGINEER unless such inspection is
waived in writing by the ENGINEER.

6.1.3

The VENDOR/CONTRACTOR shall provide all the testing and inspection


services and facilities for shop work except where otherwise specified.

6.1.4

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

6.2

Tests on Welds

6.3

Dimensions, Workmanship & Cleanliness


Members shall be inspected at all stages of fabrication and assembly to
verify that dimensions, tolerances, alignment, surface finish and painting
are in accordance with the requirements shown in the
VENDOR/CONTRACTOR's approved fabrication drawings and the
ENGINEER's drawings.

6.4

Test Failure
In the event of failure of any member to satisfy inspection or test
requirement, the CONTRACTOR shall notify the ENGINEER or his
authorised representative. The VENDOR/CONTRACTOR must obtain
permission from the ENGINEER before repair is undertaken. The quality
control procedures to be followed to ensure satisfactory repair shall be
subject to approval by the ENGINEER.

6.5

The ENGINEER has the right to specify additional testing as he deems


necessary, and the additional cost of such testing shall be borne by the
PURCHASER, only in case of successful testing.
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SPEC. NO.
TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED

SECTION: D8
SHEET 6 OF 7

TITLE

SUPPLY AND FABRICATION OF STRUCTURAL


STEEL
6.6

The VENDOR/CONTRACTOR shall maintain records of all inspection and


testing which shall be made available to the ENGINEER or his authorised
representative.

7.0

MARKING OF MEMBERS

7.1

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.

7.2

All erection marks shall be on the outer surface of all sections and near
one end, but clear of bolt holes. The marking shall be so stamped that
they are easily discernible when sorting out members. The stamped
marking shall be encircled boldly by a distinguishable paint to facilitate
easy location.

7.3

Erection marks on like pieces shall be in identical locations. Members


having lengths of 7.0 m or more shall have the erection mark at both ends.

8.0

ERRORS
Any error in shop fabrication which prevents proper assembling and fitting
up of parts in the field by moderate use of drift pins or moderate amount of
reaming will be classified by the ENGINEER as defective workmanship. In
case ENGINEER rejects such material or defective workmanship, the same
shall be replaced by the materials and workmanship conforming to the
ENGINEER's requirements by VENDOR/CONTRACTOR free of cost at site.

9.0

PAINTING

9.1

All fabricated steel material, except those galvanised shall receive


protective paint coating as specified.

10.0

METHOD OF MEASUREMENT

10.1

For the purpose of payment, the weight of the actual completed structures
shall be calculated from the approved drawings for different items of work.
The VENDOR/CONTRACTOR shall submit to the PURCHASER relevant
material list containing weight of each item.

10.2

No allowances will be permitted for bolts, nuts, washers, studs, screws etc,
galvanizing, welding or for rolling margins. One tonne for the purpose of
payment shall mean ONE METRIC TONNE i.e. 1000 Kg.

10.3

The weight of a member made out of standard rolled section such as


beams, channels, angles, etc. shall be based on the standard IS:808 without
deductions for holes, notches, bevel cuts, etc. Where a component consists
of a cut joist or channels, the full weight of the rolled section shall be
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SPEC. NO.
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TCE CONSULTING ENGINEERS LIMITED

SECTION: D8
SHEET 7 OF 7

TITLE

SUPPLY AND FABRICATION OF STRUCTURAL


STEEL
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 the components.
Deductions shall be made in the weight of gussets/plates for cuts and
notches of 900 sq. cm. or larger.
10.4

For gussets/plates used in trusses, bracings, columns, beams, etc, the


area shall be that of the minimum circumscribing rectangle except as
stated in 10.3 above.

10.5

The weight of any built-up members shall be based on the weight of each
component.

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Spec No.
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1.0

TCE CONSULTING ENGINEERS LIMITED


ERECTION/DISMANTLING OF
STRUCTURAL STEEL

Section : D9
SHEET 1 OF 7

SCOPE
This specification covers the general requirements for erection/dismantling of
structural steel. It covers the supply and delivery of all necessary materials,
labour, scaffolding, tools, tackles, cranes, equipment and everything that is
necessary for the satisfactory completion of the job on schedule. Special
Technical Requirements covers the specific requirements for the project. The
two parts are complementary and are to be read together for a correct
interpretation of the provisions of this specification. Where requirements of the
two sections conflict, those of Special Technical Requirements shall govern.

2.0

SITE OPERATIONS

2.1

An experienced and qualified engineer shall be in full time charge of the job.

2.2

CONTRACTOR shall complete all preliminary works at site well before the
arrival of structural steel, such as establishment of electrical and water
connections, derricks, cranes, all tools and tackles, welding sets, staging, etc.
as well as experienced erection and supervisory personnel as part of this
contract and any other work that may be necessary so as to start erection
immediately after the arrival of the first batch of steel at site.

2.3

CONTRACTOR shall furnish at his own expense, the necessary noninflammable staging and hoisting materials or equipment required for the
erection work and shall remove and take them away after completion of the
job. CONTRACTOR shall also provide necessary passageways, fences, safety
belts, helmets, lights and other fittings to the
satisfaction
of
OWNER/ENGINEER and to meet the rules of local authorities and for
protection to his men and materials. A licensed electrician shall be kept on the
job for the entire duration of the work to maintain CONTRACTOR's electrical
equipment and connections.

2.4

CONTRACTOR shall protect all existing plant, structures, piping, conduits,


equipment and facilities against damage during erection. Any damage caused
by CONTRACTOR shall be rectified entirely at CONTRACTOR's cost,to the
satisfaction of OWNER/ENGINEER. If work has to be carried out adjacent to
existing switch yards or electrical installations which are live, CONTRACTOR
must ensure suitable safety precautions in consultation with ENGINEER.

2.5

If a portion of the work of the project area cannot be made available to


CONTRACTOR for his activities due to operations being carried out by other
agencies, he shall suitably modify his sequence of operations so as to
continue work without interruption. CONTRACTOR shall work in coordination
with other agencies working on the project site and plan his work suitably so as
not to hinder the progress of construction at site.

3.0

ACCEPTANCE OF STEEL, ITS HANDLING & STORAGE

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Spec No.
TCE-5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED


ERECTION/DISMANTLING OF
STRUCTURAL STEEL

Section : D9
SHEET 2 OF 7

3.1

No dragging of steel shall be permitted. All shall be stored 300mm above


ground on suitable packing to avoid damage. It shall be stored in the order
required for erection, with erection marks visible. All storage areas shall be
prepared and maintained by CONTRACTOR. Steel shall not be stored in the
vicinity of areas where excavation or grading will be done and, if so stored
temporarily, this shall be removed by CONTRACTOR well before such
excavation and/or grading commences to a safe distance to avoid burial under
debris.

3.2

Scratched or abraded steel shall be given a coat of red oxide zinc chromate
primer confirming to IS:2074, 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.

4.0

ANCHOR BOLTS & FOUNDATIONS

4.1

CONTRACTOR shall carefully check the location and layout of anchor bolts
embedded in foundations constructed , to ensure that the structures can be
properly erected as shown on the drawings, Any discrepancy in the anchor
bolts/foundation shall be reported to ENGINEER well in advance for any
correcting measures.

4.2

Levelling of column bases to the required elevation may be done either by


providing shims or three nuts on the upper threaded portion of the anchor bolt.
All shim stock required for keeping the specified thickness of grout and in
connection with erection of structures on foundations shall be of good M.S.
plates and shall be supplied by CONTRACTOR at his cost.

4.3

A certain amount of cleaning of foundations and preparing the area is


considered normal and shall be carried out by CONTRACTOR at not extra
cost.

4.3

All grouting under column base plates or beam bearing plates will be carried
out by CONTRACTOR, unless the grouting is specifically excluded from the
CONTRACTORS scope.

4.4

Even though foundation bolts are placed in position by other agency, minor
modifications and adjustments, if necessary, shall be carried out by the
CONTRACTOR for erection purposes without any additional cost to OWNER

4.5

The final adjustment of the foundation bolts and their grouting are included in
the scope of this contract

5.0

ASSEMBLY & CONNECTIONS

5.1

Field connection shall be by means of black MS bolts conforming to IS or by


means of welding as would be indicated in design drawings.

5.2

All assembling shall be carried on a level platform.

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Spec No.
TCE-5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED


ERECTION/DISMANTLING OF
STRUCTURAL STEEL

Section : D9
SHEET 3 OF 7

5.3

Drifts shall be used only for drawing the work to proper position and must not
be used to such an extent as to damage the holes. Size of drifts larger than the
nominal diameter of hole shall not be used. Any damaged holes or burrs must
be rectified to the satisfaction of ENGINEER.

5.4

Corrections of minor misfits and reasonable amount of reaming and cutting of


excess stock from rivets shall be considered as a part of erection. Any error in
the shop, which prevents proper fit on a moderate amount of reaming and
slight chipping or cutting, shall be immediately reported to ENGINEER.

6.0

ERECTION

6.1

All structural steel shall be erected as shown on the drawings. Proper size
steel cable slings, etc., shall be used for hoisting. Guys shall not be anchored
to existing structures, foundations, etc. unless so permitted by ENGINEER in
writing. Care shall be taken to see that ropes in use are always in good
condition.

6.2

Any item requiring/if felt necessary to strenghten to prevent buckling/damage


should be welded before dismantling /erection and the same has to be cut off
and repainted locally at no extra cost.

6.3

Structural steel frames shall be erected plumb and true. Frames shall be lifted
at such points that they are not liable to buckle and deform. Frames/Trusses
shall be lifted only at node points. In the case of trusses, roof girders, all of the
purlins and wind bracing shall be placed simultaneously and the columns shall
be erected truly plumb on screed bars over the pedestals. All steel columns
and beams shall be checked for plumb and level individually before and after
connections are made. Temporary bracings shall 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.

6.4

As erection/dismantling of structure progresses, the work shall be securely


bolted to take care of all dead load, wind, seismic and erection stresses.

6.5

No riveting or welding or final bolting shall be done until the structure has been
properly aligned and approved by ENGINEER. No cutting, heating or enlarging
of the holes shall be carried out without the prior written approval of
ENGINEER.
Final alignment by the CONTRACTOR with help of surveying instrument shall
be submitted at no extra cost.

6.6

7.0

INSPECTION

7.1

ENGINEER/OWNER or their authorised representatives shall have free


access to all parts of the job during erection/dismantling and all work shall be
subjected to their approval. In case of faulty erection/dismantling , all rework
required will be at CONTRACTOR's cost. No paint shall be applied to field
welds or bolts until these have been approved by ENGINEER.

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TCE CONSULTING ENGINEERS LIMITED


ERECTION/DISMANTLING OF
STRUCTURAL STEEL

TCE-5607A-H-CCH-400

8.0

Section : D9
SHEET 4 OF 7

TOLERANCES
Tolerances mentioned below shall be achieved after the entire structure or part
thereof is in line, level and plumb. The tolerances specified below do not apply
to steel structures where the deviations from true position are intimately linked
with and directly influence technological process. In such cases, the tolerances
on erected steel structures shall be as per recommendations of process
technologists/suppliers which will be indicated in the drawings.

8.1

Columns

8.1.1

Deviation of column axes at foundation top level with respect to true axes :

8.1.2

8.1.3

(a)

In longitudinal direction

5 mm

(b)

In lateral direction

5 mm

Deviation in the level of bearing


surface of columns at foundation
top with respect to true level

5 mm

Out of plumbness (verticality) of column axis from true vertical axis, as


measured at column top :
(a)

For columns upto and including


metres in height

: 1/1000 of column height in


mm or 15mm whichever is
less

(b)

For columns exceeding 15


metres in height

1/1000 of column height in


mm or 20 mm whichever
is less

8.1.4

Deviation in straightness in longitudinal


and transverse planes of column at any
point along the height

8.1.5

Difference in erected position of adjacent :


pairs of columns along length or across
width of building prior to connecting
trusses/beams with respect to true distance

10 mm

8.1.6

Deviation in any bearing or seating level


with respect to true level

5 mm

8.1.7

Deviation in differences in bearing levels


of a member on adjacent pair of columns
both across and along the building

10 mm

8.2

Trusses And Beams

8.2.1 Shift at the centre of span of top chord

15

: 1/1000 of column height in


mm or 10 mm whichever
is less

: 1/250 of height of truss in


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TCE-5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED


ERECTION/DISMANTLING OF
STRUCTURAL STEEL

member with respect to the vertical plane


passing through the centre of bottom chord

Section : D9
SHEET 5 OF 7

mm or 15 mm whichever
is less

8.2.2

Lateral shift of top chord of truss at the


centre of span from the vertical plane
passing through the centre of supports
of the truss

: 1/1500 of span of truss in


mm or 15 mm whichever
is less

8.2.3

Lateral shift in location of truss from its


true vertical position

: 10 mm

8.2.4

Lateral shift in location of purlin true


position

: 5 mm

8.2.5

Deviation in difference of bearing


levels of trusses or beams from
the true difference

: i) 20 mm for trusses
ii) For beams :
Depth < 1800mm : 6mm
Depth > 1800mm : 10 mm

8.2.6

Deviation in sag in chords and diagonals


of truss between node points

: 1/1500 of length in mm or
10mm whichever is smaller

8.2.7

Deviation in sweep of trusses, beams etc.


in the horizontal plane

: 1/1000 of span in mm subject


to a maximum of 10 mm

8.2.8

Deviation in diagonal length in any


horizontal cross section from the true
diagonal length

: 1/500 of diagonal
length in mm

9.0

SHEETING
Sheetingwork including cutting, welding, placing & fixing in position at all
heights above ground level, 10/75 G.C. Sheets 20/22G, ridging ,flashing with
20G G.P. Sheet bent to shape as shown in drawing including supply and fixing
of galvanised steel bolt and other accessories. For all items, only net area,
lengths as laid excluding laps will be considered for measurement and
payment.

10.0

PAINTING

10.1

After steel has been erected, all bare and abraded spots, field welds, bolt
heads and nuts shall be spot painted with red oxide zinc chromate primer as
per IS:2074. Before paint is applied, the surface shall be dry and free from
dust, dirt, scale and grease. All surfaces inaccessible after erection shall
receive two coats of the approved paint before erection. Paint damaged
portions shall also be painted with one coat (25 micron) of primer and two
coats (2 x 25 microns) of finished paint.

11.0

METHOD OF MEASUREMENT

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Spec No.
TCE-5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED


ERECTION/DISMANTLING OF
STRUCTURAL STEEL

Section : D9
SHEET 6 OF 7

11.1

For the purpose of payment, the weight of the actual, completed structures
shall be calculated from the approved drawings for different items of work.
CONTRACTOR shall submit to OWNER relevant material list containing
weight of each item.

11.2

No allowance will be permitted for weights of welds, bolts,washers,screws etc.


in calculating the weight of the completed structure. No allowances will be
permitted for galvanizing, welding or for rolling margins. One tonne for the
purpose of payment shall mean ONE METRIC TONNE i.e. 1000 Kg.

11.3

The weight of a member made out of standard rolled sections such as beams,
channels, angles, etc. shall be based on the weight of the member given in IS
808, without deducting for holes, notches, bevel cuts, etc. Where a component
consists of a cut joist or channel, the full weight of the rolled section shall be
considered only if more than half the depth of the section is used. Otherwise
only half the section unit weight shall be taken. Deductions shall be made in
the weight of gussets/plates including chequered plates for skew cuts, notches
and openings of 900 sq.cm. or larger.

11.4

For gussets/plates used in trusses, bracings, columns, beams etc. the area
shall be that of the minimum circumscribing rectangle, except as stated in
clause 14.3 above.

11.5

The weight of any built-up member shall be separated into the weight of each
component.

11.6

No additional payment shall be made for supply or use of Erection bolts. If


erection bolts are removed after erection is complete, holes shall be plug
welded and ground smooth. No extra payment shall be made for such plug
welding.

11.7

For modification to existing structures, only new tonnage of steel required for
modification shall be considered for payment.

12.0

CLEAN UP OF WORK SITE

12.1

During erection/ dismantling, the CONTRACTOR shall without any additional


payment, at all times keep the working and storage areas used by him, free
from accumulation of waste materials or rubbish. Before completion of
erection/dismantling work, he shall remove or dispose of in a satisfactory
manner all temporary structures, waste and debris and leave the premises in a
condition satisfactory to OWNER/ENGINEER.

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SPEC NO.

SECTION : D10

TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

PAINTING OF STRUCTURAL STEEL

SHEET 1 of 8

1.0

SCOPE

1.1

This specification covers the general requirements for painting structural


steel work involving the supply and delivery of all necessary materials,
labour, scaffolding, tools and equipment. This document covers the aspects
of surface treatment, application of primer paint and finish painting.

2.0

APPLICABLE CODES AND SPECIFICATIONS


The following Standard Specifications and Codes of Practice are made a
part of this Specification. All standards and codes referred to herein shall be
the latest editions including all applicable official amendments and revisions.
In case of discrepancy between this specification and those referred to
herein, this specification shall govern.
i) IS:102
Priming.

Ready Mixed paint, Brushing, Red Lead, Non-setting,

ii) IS:110

Ready Mixed paint, brushing, grey filler for enamels for use
over primers.

iii) IS:117
for

Ready Mixed paint, Brushing, Finishing, Exterior Semigloss


general purposes, to Indian Standard colours.

iv) IS:158

Ready Mixed paint, Brushing, Bituminous, Black, Lead free,


Acid,alkali and heat resisting.

v) IS:159

Ready Mixed paint, Brushing, Acid resisting.

vi) IS:341

Black Japan, Types A, B and C

vii) IS:1477

Codes of Practice for painting of ferrous metals in buildings.


Part I - Pretreatment
Part II - Painting

viii)IS:2074

Ready Mixed paints, Red Oxide Zinc chrome priming.

ix) IS:2339

Aluminium paint for general purposes, in Dual container

x) IS:2932

Specification for enamel, synthetic, exterior, type 1,


(a) undercoating (b) finishing

xi) IS:2933

Specification for enamel, exterior, type 2,


(a) undercoating, (b) finishing
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TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

PAINTING OF STRUCTURAL STEEL

SECTION : D10

SHEET 2 of 8

xii) IS:5905

Sprayed aluminium and zinc coatings on Iron and Steel.

xiii)IS:6005

Code of practice for phosphating of Iron and Steel.

xiv)IS:9862

Specification for ready mixed paint, brushing, bituminous,


black, lead free, acid, alkali, water & chlorine resisting.

xv) IS:13183

Aluminium paint, Heat resistant.

xvi)SIS-05-5900 Swedish Standard


3.0

SURFACE TREATMENT

3.1

All the surfaces of steel work to be painted shall be thoroughly cleaned of all
loose mill scale, rust, grease, dirt and other foreign matter. The type of
surface treatment shall be as specified in the respective item of work. The
workmanship shall generally conform to the requirements of IS 1477-Part I.

3.2

Oil and grease removal shall be carried out either by solvent cleaning or by
using alkali type degreasing agents. To remove grease material the surface
shall be cleaned with solvents containing emulsifier. After cleaning, the
surface shall be washed with water. When the surface has cement pelts or
salts, the cleaning shall be done with strong alkalies. After cleaning, water
rinsing and subsequent passivation by dilute chromic acid rinsing shall be
carried out to ensure that no traces of alkali is left on the surface. The
procedure for cleaning by above mentioned methods shall be as per
manufacturers instructions.

3.3

Derusting and descaling of steel shall be carried out either manually,


mechanically or chemically.

3.3.1

Manual Or Hand Tool Cleaning


Loose mill scale, loose rust and loose paint shall be removed by wire
brushing, scrapping, chipping and rubbing with abrasive paper or steel wool.
This method shall not be employed when the surface has firmly adhering
mill scale. After hand tool cleaning, the surface shall be rubbed with sand
paper so as to ensure that no loose material exists and the surfaces shall be
dusted off.

3.3.2

Mechanical Cleaning

3.3.2.1 Power Tool Cleaning

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SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

PAINTING OF STRUCTURAL STEEL

SECTION : D10

SHEET 3 of 8

This shall be carried out by employing power operated wire brushes. Power
tool cleaning shall be resorted to only if sand/shot blasting is not
possible/permissible and high quality of surface preparation is required.
The surface prior to such cleaning shall be cleaned of dust, grease etc. and
heavier layers of rust shall be removed by chipping.
The powertool cleaning shall remove loose mill scale and rust by adopting
very thorough scrapping, grinding and machine brushing. After the surfaces
are cleaned by compressed air, it shall have a pronounced metallic sheen.
3.3.2.2 Flame Cleaning
Hard mill scale and rust shall be removed through Oxy- acetylene flame. The
work shall be carried out by trained workmen to ensure that only mill scale is
removed without affecting the parent steel. The work shall be carried out
carefully on welded surfaces so that the strength of weld is not affected due
to heating.
3.3.3

Sand Blasting And Shot Blasting

3.3.3.1 Sand/shot blasting shall be resorted to only after removal of grease, oil and
other contaminants. The work shall be carried out by impinging under
pressure of air, a jet of sharp sand or granulated steel (steel grits) on to the
metal surface. The process shall ensure complete removal of rust and firmly
adhering mill scale. Special care shall be taken on weld areas to remove flux
and spatter. Blasting shall ensure an even colour of the surface and the
surface shall have silver grey colour. Precautions shall be taken when sand
or shot blasting of light gauge steel surfaces to ensure that buckling does not
occur to continuous impingement of sand or steel shots under high velocity.
3.3.3.2 Sand/shot blasting shall be adopted for structures which are exposed to
corrosive conditions for which superior paint protection is to be adopted. The
finished surfaces shall conform to the requirements of Sa 2 or Sa 3 as per
Swedish Standard SIS-05-5900 as specified in the item of work.
3.3.3.3 As Sandblasting causes dust nuisance necessary clearance shall be
obtained by the CONTRACTOR from Competent authorities prior to
commencing Sand blasting.
3.4

Chemical Cleaning (Pickling)

3.4.1

The cleaning shall be done by pickling in sulphuric, hydrochloric or


phosphoric acids. Pickling shall be carried out in accordance with detailed
procedure as given in IS 6005.

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SPEC NO.

TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

PAINTING OF STRUCTURAL STEEL

SECTION : D10

SHEET 4 of 8

3.4.2

Washing after pickling shall remove all traces of the acids. All work pieces
shall be thoroughly inspected and in particular the inaccessible corners.

4.0

MATERIALS

4.1

Primer Paint

4.1.1

Anti-corrosive primers shall be either lead based or lead free types. Red lead
primer shall conform to IS 102 and red oxide zinc chrome primer shall
conform to IS 2074.

4.2

Finish Paint

4.2.1

Synthetic enamel painting for undercoat and finish coat shall conform to IS
2932/IS 2933.

4.2.2

Acid, alkali and heat resistant bituminous paint shall conform to IS 158.

4.2.3

Acid, alkali, water and chlorine resisting bituminous paint shall conform to IS
9862.

4.2.4

Heat resistant aluminium paint shall conform to IS 13183.

4.2.5

Epoxy primer and epoxy paint shall be of the type as specified in the item of
work from an approved manufacturer.

4.2.6

Chlorinated rubber based paint shall be of the manufacture as specified or


any equivalent approved manufacture.

4.3

All the materials shall be of the best quality from an approved manufacturer.
CONTRACTOR shall obtain prior approval of the ENGINEER for the brand of
manufacture and the colour/shade prior to procurement for usage in the
works.

4.4

Primer and finish paints shall be compatible with each other to avoid
cracking and wrinkling. As such it is recommended that the primer and finish
paint shall be from the same manufacturer.

4.5

The colour and shade shall conform to IS Standards referred to in Appendix


'D' of IS 1477-Part II. To facilitate choosing the correct shade/number from
the alternatives available, CONTRACTOR shall adopt trial painting in small
patches in consultation with and as directed by the ENGINEER.

4.6

All paint delivered to the fabrication shop/site shall be ready mixed, in


original sealed containers, as packed by the manufacturer. Thinner shall not
be permitted for usage unless specifically directed by the ENGINEER.
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TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

PAINTING OF STRUCTURAL STEEL

SECTION : D10

SHEET 5 of 8

4.7

Paints shall be stirred thoroughly to keep the pigment in suspension.

4.8

CONTRACTOR shall at his own cost arrange for testing of paints as per
relevant Indian Standards in standard laboratory whenever OWNER wants
the tests to be carried out for each batch of paints. Test results shall be
submitted to the OWNER for obtaining approval.

4.9

Surfaces inaccessible after assembly and after erection shall receive 2 coats
of the above paint prior to assembly.

4.10

Colour code shall be as desired by the OWNER and will be indicated during
execution.

4.11

Welds and adjacent parent metals shall not be applied with primer and/or
painting prior to deslagging, inspection and approval

5.0

WORKMANSHIP

5.1

The type and the number of coats of the primer paint and finish paint shall be
as specified in the respective items of work.

5.2

Painting shall be carried out only on thoroughly dry surfaces.

5.3

No painting shall be done in frosty/foggy weather or when the humidity is


high enough to cause condensation on the surface to be painted. Paint shall
not be applied when the temperature of the surface to be painted is at 5C or
lower.

5.4

Primers shall adhere to the surface firmly and offer a key to the subsequent
coats.

5.5

The application of paint film shall serve the twin purpose of protecting the
steel from corrosion and giving the decorative appearance. A paint which
gives the steel adequate protection over a long period together with good
appearance shall therefore be adopted.

5.6

Workmanship shall generally conform to requirements specified in IS:1477Part II.

5.7

It is essential to ensure that immediately after preparation of the surfaces,


the first coat of primer paint shall be applied by brushing and working it well
to ensure a continuous film without "holidays". After the first coat becomes
hard dry a second coat of primer shall be applied by brushing to obtain a film
free from holidays.

5.8

Structural steel surfaces shall be given the first coat of primer at shop and
the second coat after it is erected in position. Further, any abraded surfaces
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TCE CONSULTING ENGINEERS LIMITED

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PAINTING OF STRUCTURAL STEEL

SECTION : D10

SHEET 6 of 8

of the first coat during transport from shop to site and during erection shall be
provided with a touch-up coat of the primer.
Shop coat of primer, touch up coat before erection, touch up coat after
erection and second coat of primer after erection shall be of red oxide zinc
chromate primer as per IS.2074. Paint shall be applied by brush.
5.9

The dry film thickness of each coat of primer shall be not less than 25
microns.

5.10

Application of finishing paints shall be carried out within the shortest possible
time interval after primer since the primer coats are too thin to give adequate
corrosion protection to the steel surface over a long duration.

5.11

Filler coats shall be applied to fill dents and to obtain a smooth finish
wherever necessary. Only factory prepared filler suitable for steel work shall
be used. Fillers prepared by whiting and linseed oil by craftsmen at site shall
never be used as such fillers may be unbalanced and incompatible with
primer and finishing coats. Application of filler shall be done with good `putty
knife' and necessary skill. Filler applied shall be just sufficient to fill the
depression or unevenness and it shall be restricted to the minimum. It shall
be applied in thin layers. In filling depression or unevenness, due as many
coats as are necessary may be applied allowing each layer to dry hard. The
hardened coat shall be cut down by wet rubbing before the subsequent coat
is applied. Where necessary, filler coats shall be applied over the undercoats
also.

5.12

Painting shall be carried out either by brushing or by spraying.


CONTRACTOR shall procure the appropriate quality of paint for this purpose
as recommended by the manufacturer.

5.13

After the second coat of primer is hard dry, the entire surface shall be wet
rubbed cutting down to a smooth uniform surface. When the surface
becomes dry, the undercoat of paint of optimum thickness shall be applied
by brushing/spraying with minimum of brush marks. The coat shall be
allowed to hard-dry. The under coat shall then be wet rubbed cutting down to
a smooth finish, taking adequate care to ensure that at no place the
undercoat is completely removed. The surface shall then be allowed to dry.

5.14

The first finishing coat of paint shall be applied by brushing or by spraying


and allowed to hard-dry. The gloss from the entire surface shall then be
gently removed and the surface dusted off. The second finishing coat shall
then be applied by brushing or by spraying.

5.15

At least 24 hours shall elapse between the application of successive coats.


Each coat shall vary slightly in shade and this shall be got approved by the
ENGINEER.
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TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

PAINTING OF STRUCTURAL STEEL

SECTION : D10

SHEET 7 of 8

5.16

Minimum dry film thickness of each coat of finish paint of synthetic enamel
shall be 25 microns. Minimum dry film thickness of other finish paints shall be
as specified in the respective item of work.

5.17

The thickness of film shall be measured by an Elcometer to be supplied by


the CONTRACTOR. The CONTRACTOR shall calibrate the Elcometer
frequently for differentsettings. Necessary calibrating accessories should be
kept ready for calibration/testing of Elcometer at any time.

5.18

Epoxy primer and epoxy paint shall be applied within the specified pot life all
as per recommendations of the manufacturer.

5.19

Surfaces inaccessible after assembly shall receive two coats of primer prior
to assembly.

5.20

Surfaces inaccessible after erection, including top surfaces of floor beams


supporting grating or chequered plate shall receive one additional coat of
finish paint over and above the number of coats specified prior to erection.

5.21

Portion of steel members embedded/to be encased in concrete shall not be


painted. Joints to be site welded shall have no shop paint for atleast 50mm
from the welding zone. Similarly, the steel surfaces shall not be painted in
areas where connection is by use of friction grip bolts. On completion of the
joint, the surfaces shall receive the painting as specified.

5.22

Maintenance painting of steel structures will become necessary if the


painting already carried out shows signs of chalking, hairline cracking, deep
checking, fine checking, peeling, blistering and rusting. The breakdown of a
paint film is progressive from the top finish paint to the primer coat and the
object of maintenance painting is to renovate periodically to effectively check
the breakdown and protect the steel surfaces from corrosion. It is essential
that same quality of paint as specified earlier need be adopted to ensure
compatibility. The general workmanship for maintenance painting shall
conform as per Clause. 7 of IS 1477-Part II.

5.23

CONTRACTOR shall provide suitable protection as necessary to prevent


paint finishes from splashing on equipment, floors, walls etc.

6.0

MEASUREMENT

6.1

Method of measurement for payment for painting shall be in sq.metres,


correct to two places of decimals, if so specified, in the respective item of
work.

6.2

Painting work shall not be measured separately, if primer painting and/or


primer and finish painting is already included in the scope of the item of
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TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

PAINTING OF STRUCTURAL STEEL

SECTION : D10

SHEET 8 of 8

work of fabrication and erection of structural steel since the rate per tonne of
steel is deemed to include for painting as specified.
6.3

In cases where primer and/or finish painting work as specified is carried out
on erected structural steel executed by a different agency, the method of
measurement for painting shall be on the basis of tonnage of the steel
erected. For this purpose, the tonnage of erected steel as certified for
payment to the different agency shall be considered as the basis and no
measurement will be carried out separately.

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SPEC.NO.

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TCE. 5607A-H-CCH-400

SECTION: F1
SHEET 1

OF 1

SCHEDULE OF DEVIATIONS FROM


TECHNICAL SPECIFICATIONS

All deviations from the Technical Specifications shall be filled in by the BIDDER
clause by clause in this schedule.
SECTION

SPECIFICATION NO.

CLAUSE NO.

DEVIATION

The BIDDER hereby certifies that the above mentioned are the only deviations from
the PURCHASERs Technical Specifications for this enquiry. The BIDDER further
confirms that in the event any other data and information presented in the BIDDERs
proposal and accompanying documents including drawings, catalogues, etc., are at
variance with the specific requirements laid out in the PURCHASERs Technical
Specifications, then the latter shall govern and shall be binding on the BIDDER for
the quoted price.

COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

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TCE FORM NO. 329 R4

SPEC.NO.

TCE CONSULTING ENGINEERS LIMITED


SCHEDULE OF DEVIATIONS FROM
GENERAL CONDITIONS

TCE. 5607A-H-CCH-400

SECTION: F2
SHEET 1 OF 1

All deviations from the General Conditions shall be filled in by the BIDDER clause by
clause in this schedule.
SECTION

SPECIFICATION NO.

CLAUSE NO.

DEVIATION

The BIDDER hereby certifies that the above mentioned are the only deviations from
the PURCHASERs General Conditions of Contract. The BIDDER further confirms
that in the event any other data and information presented in the BIDDERs proposal
and accompanying documents are at variance with the specific requirements laid out
in the PURCHASERs General Conditions of Contract, then the latter shall govern
and shall be binding on the BIDDER for the quoted price.

COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

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TCE CONSULTING ENGINEERS LIMITED

SPEC NO.

TCE. 5607A-H-CCH-400 TITLE

SECTION: F3
SHEET 1 OF 1

SCHEDULE OF PRICE IMPLICATIONS


ON ACCOUNT OF DEVIATIONS

The price implication on account of all deviations as listed out in the Schedule of
Deviations shall be indicated here below :
Sl.
No.

Section
No. of
Tender
Documen
t

Clause
No. of
Tender
Documen
t

Page
No.of
Tender
Document

Clause as
given in
Tender
Document

(1)

(2)

(3)

(4)

(5)

Deviation
as
proposed
by the
Tenderer in
Forms
(6)

Variation in Quoted
Price, if deviation not
acceptable to the
Owner ( mention
Plus or minus)
(7)

Note :
1.

The Bidder hereby certifies that the above mentioned are the only price
implications on account of deviations to the tender conditions.

2.

All price implications on account of deviations shall be given only in this


Schedule.

3.

Price implications on account of deviations furnished elsewhere shall be


summarily rejected and shall also be ignored.

4.

The Bidder also certifies that the price implications mentioned herein are
for deviations furnished in the Schedules of Deviations.

(SIGNATURE OF BIDDER)
COMPANY SEAL

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LTD.

SPEC.NO.

SECTION: F4

TITLE

TCE-5607A-H-CCH-400

SHEET 1 OF 1

SCHEDULE OF CEMENT REQUIREMENT

FOR QUARTER YEAR PERIOD


TAKING THE DATE OF AWARD OF
CONTRACT AS BASE
I
II
III
IV
V
VI
VII
VIII
IX
X

REQUIREMENT OF ORDINARY
PORTLAND CEMENT IN TONNES
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil

(Bidders signature)

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LTD.

SPEC.NO.

SECTION: F5

TITLE

TCE-5607A-H-CCH-400

(A)

SHEET 1 OF 2

SCHEDULE OF REINFORCEMENT

Requirement of Deformed Bars, in Tonnes

For quarter year period taking


the date of award of contract
as base
I
II
III
IV
V
VI
VII
VIII
IX
X

36

32

28

Diameters
25 20 16 12 10

Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil

(Bidders signature)

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LTD.

SPEC.NO.

SECTION: F5

TITLE

TCE-5607A-H-CCH-400

(B)

SHEET 2 OF 2

SCHEDULE OF REINFORCEMENT

Requirement of Mild Steel Bars in Tonnes

For quarter year period taking


the date of award of contract
as base
I
II
III
IV
V
VI
VII
VIII
IX
X

32

28

25

Diameters
20 16 12 10

(Bidders signature)

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

SPEC.NO.

TCE CONSULTING ENGINEERS LIMITED

TCE. 5607A-H-CCH-400

SECTION: F6
SHEET 1 OF 1

TITLE

SCHEDULE OF CONTRACTORS TECHNICAL


STAFF TO BE DEPLOYED ON THIS CONTRACT

No.

DESIGNATION

QUALIFICATION

PREVIOUS EXPERIENCE

SIGNATURE

DESIGNATION
SEAL OF COMPANY
DATE

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC NO.

SECTION: F7

SHEET 1 OF 1
TCE. 5607A-H-CCH-400

SCHEDULE OF EQUIPMENT

The BIDDER shall indicate hereunder the equipment he has in possession


and the equipment he proposes to bring to the site, in case the work is
awarded to him.
Sl.
No.

Type and description


of the Equipment

Numbers the
BIDDER has in
possession
3

Numbers he proposes
to bring on to site
4

BIDDER hereby confirms that the quantity and type of tools he will employ for
construction will not be less than those listed above, and agrees to bring more
equipment, if so warranted, in the opinion of the Engineer.

COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SPEC NO.

TCE. 5607A-H-CCH-400

SCHEDULE OF RATES FOR LABOUR

SECTION: F8

SHEET 1 OF 1

\BIDDER shall quote hereunder the all-inclusive price of labour assumed for
the purposes of this Contract.
Supplying Labour
--------------------i. Unskilled Labour male

Per day of Over time rate


8 hrs. Each per hour
------------------------------

ii. Unskilled Labour female


iii. Skilled Labour male
iv. Mason
v. Carpenter
vi. Painter
vii. Fitter (reinforcement)
viii. Fitter (Structural steel)
ix. Welder
x. Rigger
xi. Welders with welding equipment

Per hour

xii. Gas cutter with all equipment


ENGINEER/PURCHASER shall have the right to ask Contractor to supply
labour for any work at the rates quoted above.
COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LTD.

SPEC NO.

SECTION: F9

TCE-5607A-H-CCH-400

SHEET 1 OF 1

SCHEDULE OF BIDDERS EXPERIENCE

The BIDDER shall furnish hereunder a list of similar jobs executed by him to
whom a reference may be made by the PURCHASER in case the
PURCHASER considers such a reference necessary.
Sl.
No.

Name and
description
of work

Scheduled
completion
period

Actual
completio
n period

Valu
e of
work

Year of
start and
completion

Client

(1)

(2)

(3)

(4)

(5)

(6)

(7)

COMPANY SEAL

Persons to
whom ref.
may be
made
(8)

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

ISSUE
P0
FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4