flapkbZ foHkkx] mRrj izns'k - Irrigation and Water Resources ...

flapkbZflapkbZflapkbZflapkbZ foHkkxfoHkkxfoHkkxfoHkkx]]]] mRrjmRrjmRrjmRrj izns'kizns'kizns'kizns'k jkexjkexjkexjkexaaaaxkxkxkxk laxBu] dkuiqjlaxBu] dkuiqjlaxBu] dkuiqjlaxBu] dkuiqj

STANDARD PRE-QUALIFICATION BIDDING

DOCUMENT

INFORMATION & INSTRUCTIONS

dkuiqj dkuiqj dkuiqj dkuiqj iz[k.Miz[k.Miz[k.Miz[k.M f}rh; e.Myf}rh; e.Myf}rh; e.Myf}rh; e.My fupyhfupyhfupyhfupyh xaxkxaxkxaxkxaxk ugjugjugjugj flapkbZflapkbZflapkbZflapkbZ dk;Zdk;Zdk;Zdk;Z dkuiqjdkuiqjdkuiqjdkuiqj dkuiqjdkuiqjdkuiqjdkuiqj

dk;kZy; vf/k’kklhdk;kZy; vf/k’kklhdk;kZy; vf/k’kklhdk;kZy; vf/k’kklh vfHk;UrkvfHk;UrkvfHk;UrkvfHk;Urk dkuiqjdkuiqjdkuiqjdkuiqj iz[k.M] fupyhiz[k.M] fupyhiz[k.M] fupyhiz[k.M] fupyh xaxkxaxkxaxkxaxk ugj] dkuiqjugj] dkuiqjugj] dkuiqjugj] dkuiqj

vYidkyhuvYidkyhuvYidkyhuvYidkyhu fufonkfufonkfufonkfufonk lwpuk la[;k% 0lwpuk la[;k% 0lwpuk la[;k% 0lwpuk la[;k% 05555@bZ0bZ0@ 2017&18@bZ0bZ0@ 2017&18@bZ0bZ0@ 2017&18@bZ0bZ0@ 2017&18

egkefge jkT;iky mRrj izns’k dh vksj ls fuEufyf[kr dk;ksZ gsrq vku ykbu fufonk

http://etender.up.nic.in ds ek/;e ls VsfDudy fcM ,oa Qkbusafl;y fcM flapkbZ foHkkx] mRrj izns’k]

esa oxhZd`r Js.kh esa iathd`r Bsdsnkjksa ls fnukad% 17&12&2017 dks le; vijkUg 17%00 cts

rd vkeaf=r dh tkrh gSA ftldh VsfDudy fcM fnukad% 18&12&2017 dks iwokZUg 11%00 cts

lfefr ds le{k vkWuykbu [kksyh tk;sxh VsfDudy fcM es DokfyQkbM gksus okys fufonknkrkvks dh

Qkbusafl;y fcM fnukad% 19&12&2017 dks vijkUg 15%00 cts dk;kZy; vf/k’kklh vfHk;Urk]

dkuiqj iz[k.M fupyh xaxk ugj] dkuiqj esa fufonk lfefr ds le{k vkWu ykbu [kksyh tk;sxhA

fufonk izi= fnukad% 11&12&2017 dks iwokZUg 10%00 cts ls 17&12&2017 vijkUg 17%00

cts rd MkmuyksM+@viyksM dh tk ldrh gSA dk;kZy; cUn@vodk’k dh n’kk es ;g fufonk vxys

dk;Z fnol es mlh le; Mkyh ,oa [kksyh tk;sxhA

ykV ykV ykV ykV la0la0la0la0

dk;Z dk fooj.kdk;Z dk fooj.kdk;Z dk fooj.kdk;Z dk fooj.k

dk;Z dh dk;Z dh dk;Z dh dk;Z dh vuqekfur vuqekfur vuqekfur vuqekfur ykxr ykxr ykxr ykxr

¼yk[k :0 ¼yk[k :0 ¼yk[k :0 ¼yk[k :0 esa½esa½esa½esa½

/kjksgj /kjksgj /kjksgj /kjksgj jkf’k jkf’k jkf’k jkf’k ¼yk[k ¼yk[k ¼yk[k ¼yk[k :0 esa½:0 esa½:0 esa½:0 esa½

dk;Z dks dk;Z dks dk;Z dks dk;Z dks iw.kZ djus iw.kZ djus iw.kZ djus iw.kZ djus dh vof/kdh vof/kdh vof/kdh vof/k

fufonk fufonk fufonk fufonk izi= ewY; izi= ewY; izi= ewY; izi= ewY; e; e; e; e; GST

18%

iathd`r iathd`r iathd`r iathd`r Js.khJs.khJs.khJs.kh

1 2 3 4 5 6 7

1

tuin dkuiqj uxj ds vUrxzr dkuiqj 'kk[kk ds fd0eh0 188-366 nkWa;s rV ij ubZ vfYidk ds fuekZ.k gsrq gsM jsxqyVj ds fuekZ.k dk dk;Z

32.60 3.26 60 fnol554 $ 99 =

649-00

ßlhÞ vFkok mPp

2

tuin dkuiqj uxj ds vUrxzr dkuiqj 'kk[kk ds fd0eh0 188-366 nkWa;s rV ls ubZ vfYidk ds fuekZ.k dk dk;Z

21.80 2.18 90 fnol554 $ 99 =

649-00

ßlhÞ vFkok mPp

fu;e ,oa ‘krZs%fu;e ,oa ‘krZs%fu;e ,oa ‘krZs%fu;e ,oa ‘krZs%

1- fuekZ.k dk;Z dks le;c} :Ik ls iw.kZ fd;k tkuk vfuok;Z gSA dk;ksZ dh izxfr ,oa xq.koRrk flapkbZ foHkkx ds ekud ds vuq:i u gksus ij v/kksgLrk{kjh dks ek= ,d uksfVl nsdj vuqcU/k dks fujLr djrs gsrq ‘ks”k dk;Z dks fdlh vU; laLFkk@Bsdsknkj ls dk;Z dks iwjk djkus dk iw.kZ vf/kdkj gksxkA blds fy;s Bsdsnkj dk dksbZ nkok ekU; ugh gksxkA

2- TokbaV osapj dh fufonk fdlh Hkh n’kk esa LOkhdkj ugh dh tk;sxhA 3- fufonknkrk dk flapkbZ foHkkx es fu/kkZfjr Js.kh dk iathdj.k izek.k i= fufonk izi= ds lkFk

layXu djkuk vfuok;Z gSA 4- izR;sd fufonknkrk dks :0 100@&ukWu&twfMf’k;y LVSEi isij ij ,d :Ik;s dk jlhnh fVdV

yxk dj vuqcU/k fy[kuk gksxk fd njs 90 fnol rd ekU; gksxhA bl ls igys fufonk@vkQj okil ysus ij /kjksgj /kujkf’k tCr dj yh tk;sxhA fu;ekuqlkj ns; okf.kT;dj] vk;dj] LVSEiM;wVh] jk;YVh] izpfyr VSDl nsuh gksxhA vuqcU/k ds le; fu;ekuqlkj LVSEi M~;wVh rFkk tekur dh ‘ks”k /kujkf’k Hkh tek djuh gksxhA

5- dk;ZLFky dh vko’;drkuqlkjdk;ZLFky dh vko’;drkuqlkjdk;ZLFky dh vko’;drkuqlkjdk;ZLFky dh vko’;drkuqlkj dk;Z dh ek=k ?kVdk;Z dh ek=k ?kVdk;Z dh ek=k ?kVdk;Z dh ek=k ?kV&c<+ &c<+ &c<+ &c<+ ldrhldrhldrhldrh gS] ftldsgS] ftldsgS] ftldsgS] ftlds fy, fufonkfy, fufonkfy, fufonkfy, fufonk njksanjksanjksanjksa eeeessss dksbZdksbZdksbZdksbZ ifjorZuifjorZuifjorZuifjorZu ughaughaughaugha fd;kfd;kfd;kfd;k tk;sxkAtk;sxkAtk;sxkAtk;sxkA

6- fufonknkrk dks mijksDrkuqlkj fufonk ds fofHkUu pj.kksa dh frfFk;kW rFkk le;kof/k@LFky dh iw.kZ tkudkjh fufonk Mkyus ls iwoZ Lo;a izkIr djuh gksxhA dksbZ Hkh tkudkjh lEcfU/kr dk;kZy; ls dk;Z fnolksa esa izkIr dh tk ldrh gSA

7- fufonknkrk }kjk fufonk Mkyrs le; izfdz;k dh iw.kZ tkudkjh vFkok vU; fdlh dkj.k ls ‘krksZ dks iw.kZ u djus@ckf/kr gks tkus ds dkj.k fufonk u iM+us ij foHkkx dh dksbZ ftEesnkjh ugh gksxhA

8- bl fufonk dks iw.kZ ;k vkaf’kd :Ik ls fujLr djus dk vf/kdkj fcuk dkj.k crk;s v/kksgLrk{kjh ds ikl lqjf{kr jgsxkA

9- ;g laKku eas vkus ij fd fdlh fufonknkrk }kjk fdlh vU; lEHkkfor fufonknkrk dks bl fufonk izfdz;k esa Hkkx ysus ,oa fufonk Mkyus ls jksdk x;k gks ;k /kedh nh xbZ gks rks ,sls

Bsdsnkj ds lkFk ;fn vuqcU/k gks Hkh x;k gks] rks mlds lkFk fd;k x;k vuqcU/k fujLr djus dk iw.kZ vf/kdkj v/kksgLrk{kjh dk gksxkA

10- dksbZ fufonknkrk tks jkT; ljdkj }kjk dkyh lwph esa ntZ gks bl fufonk izfdz;k esa Hkkx ugha ys ldsxkA

11- jkT;ckj dkSfUly esa iathd`r dksbZ Hkh vf/koDrk fufonk izfdz;k esa Hkkx ugha ys ldsxsaA 12- ‘kklukns’k la[;k% 31@1862@16&27&lh&3&8Vh0] fnukad% 14&12&2016 ds vuqlkj

fufonknkrk@Bsdsnkj ,d dk;Z dh ,d gh fufonk dj ldsxk ;k Mky ldsxkA ‘krZ;qDr fufonk Lohdkj ugha dh tk;sxhA

13- ;g dksbZ fufonknkrk fu/kkZfjr fof/k ,oa izfdz;k ds fo:} vuqcU/k djus gsrq l{ke izkf/kdjh ij ncko@vlE;d vlj Mkyrk gS rks iz’uxr fufonknkrk ds U;wure fufonk dh fLFkfr esa Hkh mldh fufonk fujLr dh tk ldrh gSA

14- fof'k”V ifjfLFkfr;ksa esa fufonk [kksyus dh frfFk@le; esa ;fn dksbZ ifjorZu gksrk gS rks bldh lwpuk uksfVl cksMZ ds ek/;e ls miyC/k djk nh tk;sxhA

15- vqucU/k xfBr gksus ds Ik’pkr Hkh ;fn ;g rF; laKku esa vkrk gS fd fdlh Hkh Lrj dk mYya?ku fd;k x;k gS rks ,sls vuqcU/k dks l{ke vf/kdkjh }kjk ldkj.k vkns’k iz[;kfir dj fujLr fd;k tk;sxkA

16- ;g fufonk @fcM lwpuk mRrj izns’k ljdkj dh osolkbV http://etender.up.nic.in lwpuk foHkkx dh

osclkbV http://information.up.nic.in rFkk flapkbZ foHkkx dh osclkbV http://irrigation.up.nic.in ij Hkh miyC/k gSA

17- fufonk ds lkFk flapkbZ foHkkx dh fu/kkZfjr Js.kh esa iathdj.k izek.k i= (IDT-1), (IDT-2), (IDT-3) o vU; izi=@vfHkys[k dh LdSUM dkih izh&DykfyfQds’ku@VSDuhdy fcM ds lkFk viyksM fd;k tkuk vfuok;Z gksxkA

18- ‘kklukns’k la[;k% 622] fnukad% 08&06&2012 ds vUrxZr Bsdnkj vFkok QeZ dks 10 izfr’kr U;wure rd 0-50 izfr’kr] izfr 1 izfr’kr de nj ij rFkk 10 izfr’kr ls vf/kd U;wure nj ij 1-00 izfr’kr izfr ,d izfr’kr de nj ij vfrfjDr ijQkjesal /kjksgj /kujkf’k ns; gksxhA

19- /kjksgj /kujkf’k jk”Vªh;d`r@f’kM;wYMcSad ds }kjk fuxZr ,u0,l0lh0@,Q0Mh0vkj0 ds :i esa tks fd vf/k’kklh vfHk;Urk] dkuiqj iz[k.M] fupyh xaxk ugj] dkuiqj ds in uke ls ca/kd gksxh] tek djuk vfuok;Z gksxk ftldh LdSUM dkih bZ&Vs.Mj iksVZy ij viyksM djuk vfuok;Z gksxkA cSad xkjUVh ,oa Mkd ?kj dh iklcqd /kjksgj /kujkf’k ds :i es ekU; ugha gksxhA

20- fufonknkrk@fcMj }kjk fufonk Mkyrs le; izfdz;k dh iw.kZ tkudkjh@Vsªfuax vFkok fdlh vU; dkj.k ls ‘krksZ dks iw.kZ u dj ikus@ckf/kr gks tkus ds dkj.k fufonk u iM+us ij foHkkx dh dksbZ ftEesnkjh ugh gksxhA

21- fufonk izi= dh /kujkf’k e; th0,l0Vh0 lfgr cSad Mªk¶V ds :i es gh Lohdkj dh tk;sxh] tks vf/k’kklh vfHk;Urk] dkuiqj iz[k.M] fupyh xaxk ugj] dkuiqj ds uke ns; gksxk rFkk bls fnukad% 17-12-2017 vijkUg 17%00 cts rd v/kksgLrk{kjh ds dk;kZy; es miyC/k djkuk vfuok;Z gksxk rFkk ftldh LdSUM dkih bZ&Vs.Mj iksVZy ij viyksM djuk Hkh vfuok;Z gksxkA

22- vk;dj@th0,l0Vh0@lsl o vU; dVkSrh Bsdsnkjks ds fcyksa ls fu;ekuqlkj dh tk;sxhA 23- fufonk Lohdkj gksus ds mijkUr fufonknkrk dks Je foHkkx es iathdj.k dk izek.ki= vuqcU/k

xfBr gksus ls iwoZ izLrqr djuk vfuok;Z gksxk] vU;Fkk dh fLFkfr esa Hkqxrku djuk lEHko ugh gksxkA Hkqxrku ds iwoZ dk;ksZ@dk;Z ij Jfedks dk iath;u izLrqr djuk vfuok;Z gksxkA

24- ‘kklukns’k l[a;k% 52@1439@17&27&fla0&3&07 fofo/k@17] fnukad% 09&10&2017 ds vuqikyu es bZ&Vs.Mfjax ds le; fufonknkrkvksa }kjk fu/kkZfjr izi= ds vfrfjDr ewy vfHkys[kks dh LdSudkih o izfrHkwfr izek.ki= v/kksLrk{kjh ds uke ca/kd djkus dk izkIr VªkUtSD’ku uEcj dks Hkh fufonk ds le; osclkbV ij Mkyh tk;sxh rFkk fufonk Lohdkj gksus ij ewy vfHkys[k O;fDrxr :i ls [k.M dks fufonknkrk }kjk izLrqr fd;s tk;sxsaA fufonk Lohdkj gksus ds mijkUr fufonknkrk }kjk izfrHkwfr /kujkf’k ewy :i esa izLrqr ugh fd;s tkus ij fufonknkrk ds fo:) okn nk;j dj dkuwuh dk;Zokgh dh tk;sxh rFkk mldk jftLVsª’ku fujLr dj dkyh lwph es Mkyus dh Hkh dk;Zokgh dh tk;sxhA

Additional Conditions to be made part of the General Conditions of Contract:

25- If any person whosoever is found actively associated with Mafia & Unsocial elements or engaged in organized

crime or is a Mafia Mafioso is disqualified from bidding.

26- Even if it comes to knowledge after award of a contract that the contractor is associated with Mafia and unsocial

elements or engaged in organized crime or is a Mafia of Mafioso, the contract will be cancelled after serving a

show cause notice & if the contractor is found repeating the same, then the proceeding of black listing him shall

also be initiated.

27- If it is found that contractor or bidder has threatened the other bidder of prevented them from bidding the

tender/contract will be cancelled.

28- Any advocate registered in state bar council will not be authorized for bidding, if it comes in knowledge that

contractor is a state or bar council registered advocate the contract will be cancelled after having been satisfied of

these fact.

uksV%uksV%uksV%uksV% fufonkfufonkfufonkfufonk lslslsls lEcfU/krlEcfU/krlEcfU/krlEcfU/kr vU; ‘krsZvU; ‘krsZvU; ‘krsZvU; ‘krsZ fufonkfufonkfufonkfufonk izi= ds lkFkizi= ds lkFkizi= ds lkFkizi= ds lkFk layXulayXulayXulayXu gSaAgSaAgSaAgSaA

vf/k’kklhvf/k’kklhvf/k’kklhvf/k’kklh vfHk;UrkvfHk;UrkvfHk;UrkvfHk;Urk

dkuiqjdkuiqjdkuiqjdkuiqj iz[k.M] fupyhiz[k.M] fupyhiz[k.M] fupyhiz[k.M] fupyh xaxxaxxaxxax ugugugugjjjj dkuiqjdkuiqjdkuiqjdkuiqj

COMPETITIVE BIDDING

1. GENERAL

Letter of transmittal and for pre-qualification are attached.

Applications are invited for complete work as detailed in the brief note of this document.

The tender document in the prescribed form duly completed and signed shall be super scribed

“Pre-qualification document for Reconstruction of Service Road of Irrigation colony, Kanpur.

The cost incurred by applicants in preparing this application, in providing clarifications or

attending discussion, conference in connection with this document will be borne by the

application and the Employer will in no case be responsible or liable for these costs, regardless of

the conduct or outcome of the pre-qualification process.

2. DEFINITION

In this document the following words and expression have the meaning hereby assigned to

them.

EMPLOYER: Means the Governor of Uttar Pradesh acting through the EXECUTIVE

ENGINEER LOWER GANGA CANAL KANPUR.

APPLICACNT: Means the individual, proprietary firm, firm in partnership, limited company, or a

corporation eligible to tender.

3. METHOD OF APPLYING

If the application is made by individual it should be signed by the individual above his full

type written or printed Name and current Address.

3.01 If the application is made by a proprietary firm, it shall be signed by the proprietor above

his full type written or printed name and the full name of his firms with its current address.

3.02 If the application is made by a firm in partnership, it shall be signed by all the partners of

the firm above their full typewritten of printed names and current address, or alternatively by a

partner holding power of attorney shall accompany with the application.

3.03 If the application is made by a limited company or a corporation it shall be signed by a

duly authorized person holding power of attorney for signing the application in which case

certified copy of the power of attorney shall accompany the application. Such limited company or

corporation may be required to furnish satisfactory evidence of its existence before the pre-

qualification application is filled.

4. FINAL DECISION MAKING AUTHORITY

The employer reserves the right to accept or reject any or all application without assigning

any reason. For this action any claim from the firm/contractor will not be entertained.

5. PARTICULARS PROVISIONAL

The particulars of the proposed work given in Chapter-I are provisional and must be

considered only advance information to assistant applicant.

6. SITE VISIT

6.01 The applicant is advised to visit and examine the site of works and its surroundings &

obtain for himself on his own responsibility all information that may be necessary for preparing

the pre-qualification application. The cost of visiting the site shall be at applicant’s own expense.

6.02 The applicant and any of his personal or agents will be granted permission by the

Employer to enter upon his premises and lands for the purpose of such inspection, but only upon

the express condition that the applicant, his personal and agent from and against all liabilities in

respect thereof and will be responsible for personal injury (whether fatal or otherwise), loss of or

damage to property and any other loss, damage, costs and expenses however caused, which but

for the exercise of such permission would not have arisen.

7. ELIGIBILITY AND MINIMUM CRITERIA FOR PRE-QUALIFICATION

7.01 This invitation to Pre-qualification is open to all eligible applicants registered in Uttar

Pradesh Irrigation Department in Class C as mentioned in lots detail.

7.02. To eligible for Pre-qualification, application shall provide evidence satisfactory to the

employer of their eligibility under sub clause 7.01 above, and of their capability and adequacy of

resources to carry out the contract effectively. To this end, all application submitted shall include

the following information.

a) Letter of Transmittal.

b) Copies of original documents defining the construction or legal status, structure of

organization, place of registration and principle place of business of the company or

corporation or firm or partnership in Form “A”.

c) Reports on the financial standing of the applicant such as profit and loss statements,

balance sheets and auditor’s report for the past three years.

d) Details of experience and past performance for the applicant in the construction Irrigation

Projects which included (silt clearance works (lot no. 1 to 40) and Brick works, & RCC

work (lot 41) etc) in past three years in Form “B” and details of current work in hand and

other contractual commitments in Form “C).

e) Major items of constructional plant proposed for use in carrying out the contract in the

format prescribed in Form “D”.

f) The qualification and experience of key personnel proposed for administration and

execution of the contract, both on and off site, in the format prescribed in Form “E-1 &E-

2”.

g) Any other relevant additional information on Form “F”.

h) Litigation History should be given on Form “G” (Information regarding any current

litigation in which the applicant is involved. The applicant should provide accurate

information on any litigation or arbitration resulting from contacts complete or under

execution by him over the last five years.

7.03. For the purpose of this particular contract, applicants should meet the following qualifying

criteria as minimum.

a) The applicant must be well established contractor of Class C and above registered in UP

Irrigation Department in construction of civil engineering works (comprising of Canal

Lining works, etc).

b) The applicant must give evidence of having adequate experience in mobilizing equipment

and personal of large contracts and in the deployment of heavy equipment and in using

modern technology in construction/ canal lining works, etc.

c) To qualify, applicant must have achieved as a minimum of the following performance.

PARTICULARS OF WORK

EMPLOYER : Executive Engineer, Kanpur Division,

Lower Ganga Canal, Kanpur, Irrigation

Department (Uttar Pradesh)

dz0 dz0 dz0 dz0 la0la0la0la0

dk;Z dk ukedk;Z dk ukedk;Z dk ukedk;Z dk uke dk;Z iw.kZ djus dk;Z iw.kZ djus dk;Z iw.kZ djus dk;Z iw.kZ djus dh vof/kdh vof/kdh vof/kdh vof/k

1

tuin dkuiqj uxj ds vUrxZr dkuiqj 'kk[kk ds fd0eh0 188-366 nkWa;s rV ij ubZ vfYidk ds fuekZ.k gsrq gsM jsxqyVj ds fuekZ.k dk dk;ZA

60 fnol

2 tuin dkuiqj uxj ds vUrxZr dkuiqj 'kk[kk ds fd0eh0 188-366 nkWa;s rV ls ubZ vfYidk ds fuekZ.k dk dk;Z

90 fnol

QUALIFICATION CRITERIA

S.NO. DESCRIPTION OF

REQUIREMENTS

QUALIFICATION CRITERIA

1 2 3

1 TURNOVER Average annual financial turnover during the last 3

years, ending 31st

March of the previous year,

should be at least 30% of the estimated cost

2 EXPERIENCE i) Experience of having successfully completed

similar work during last 7 years ending last

day of month previous to the one in which

application are invited should be either of the

following.

a. Three similar completed works costing not

less than amount equal to 40% of the

estimated cost.

or

b. Two similar completed works costing not


estimated cost.

or

c. One Similar completed works costing not


Note:

(I) In case of work executed in the past as joint ventures the certificate enclosed in support of

qualification criteria should indicate their share holding in those joint ventures. Copies

of that J.V. agreement forming part of those contract agreements should be enclosed

with the pre-qualification documents.

(II) All applicants are requested to provide above mentioned information which is required for

prequalification should have been strictly based on true fact. All information must

have been issued from the organizational where the applicants performed their civil

engineering work, not less than the rank of Executive Engineer.

(III) Pre-qualification application supported by prescribed forms attached, should be signed

by firms/ contractors and will be uploaded till up to date 17.12.2017 at 17:00 pm.

(8.0) PRICE BIDS

After evaluation of pre-qualification applications, a list of qualified tenders will be

prepared. Therefore, only those applicants who pre qualify for work will be able to upload

price bids. Employer will upload the successful applicants list that who has been pre-qualified

for submitting price bids. The applicants are cautioned not to submit the price bids until

specifically asked to do so after-qualification

DECLARATION TO BE FURNISHED

I/We here by declare that the information furnished by me/ us is true statement of facts.

Date ______________ (Name & Designation and Title of Person Signing)

estimated cost.

3 ACHIVEMENTS IN CONSTRUCTION

OF WORK, ETC.

Bidder must submit certificates of the

Experience acquired from the previous

employer not below the rank of Executive

Engineer to support his eligibility to execute

the similar work under consideration.

LETTER OF TRANSMITTAL

(TO BE FILLED IN BY THE APPLICANT)

For Pre-Qualification

To,

The Executive Engineer

Kanpur Division lower ganga canal, Kanpur,

Irrigation Department, Uttar Pradesh.

Subject: Application for Pre-qualification of contractors for

1- Construction of Head Regulator for new minor from right bank of

Kanpur branch at km. 188.366 in Distt. Kanpur nagar.

2- Construction of new minor from right bank of Kanpur branch at km.

188.366 in Distt. Kanpur nagar.

Sir,

Reference to your advertisement no.______________________ Dated_________

I/We are interested in getting ourselves Pre-qualified for the aforesaid work in district Kanpur

Nagar (UP).

Enclosed herewith please find the questionnaire duly filled in along with the document

stipulated in Pre-qualification document and to be prescribed by the Irrigation Department,

Uttar Pradesh from the time to time in this respect.

List of Documents Enclosed:

i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

Yours Faithfully

Name_________________________

Designation____________________

(For and on behalf of Contractor)

FORM- “A”

QUESTIONANAIRE FOR QUALIFICATION

S.NO

.

QUESTION REPLIES BY THE

FIRM/CONTRACTOR

1 Name of Firm

2 Nationality of Firm

3 Registered Office Address

Telephone/ Fax No.

4 Head Office Address

Telephone/ Fax No.

5 Former Name of Company (If any)

6 Branch Office Address

7 Status of Organisation

Individual

Partnership

8 Year when established

And where

9 The firm is a

a) Member of a group of

companies (If yes, give name,

address, connection and

descriptions of the other

companies)

b) Subsidiary of large organization

(If yes, give particulars)

10 Has your firm works as a

a) Joint Venture

b) Prime contractor

c) Sub-contractor (If yes, please

give name & address of prime

contractor and details of

contractor)

11 Have you executed works in the

following areas in last three years?

a) Construction of Head Regulator of

Canal and Canal. (Please furnish

details and particular of such wok

in the relevant format).

b) Attach a note as per format

highlighting the detail of works

indicating degree of mechanization

adopted, major equipments used

and time schedule adhered to in

respect of each of the major works

pertaining to Construction of Head

Regulator of Canal and Canal.

12 What best describes your firm?

a) Engineer & Contractors

b) Consulting Engineers &

Contractors.

c) Contractors.

d) If other, please specify.

13 Quantity of Concrete executed per year

in last three years in any work under

Central/ State Govt. or in P.S.U. of

India. Give details with attested

certificate from official not less than

the rank of Executive Engineer of the

department concerned.

14 Are you registered with any other Govt.

Deptt./ Public Sector undertaking (If

yes, give details).

15 Are you working anywhere on turnkey

basis (If yes, give details).

16 What type of work your usually sublet

(If yes, give details).

17 For what countries/ states/ cities have

you performed such work (Give

reference).

18 For the Bureaus of Deptt. have you

performed such work (Give reference)

19 Have you ever failed to complete any

work awarded to you (If so, give

particulars).

a) In how many project have you

asked for arbitration (If so, give

details).

b) How many cases were settled in

your favour (Give details).

20 In how many projects were you saddled

with penalties for delay?

21 In what other line or business are you

engaged?

22 Do you have material testing laboratory

and mobile laboratories (Give details).

23 Were you ever debarred for tendering

by any Govt. Deptt./ Public Sector

Undertaking of India or any other

country (Give details).

24 For how many years have you been in

business under your present business

name?

25 What were your working fields when

your organization was established?

Whether any new work area were

added in your organization and when?

26 In what field do you claim

specialization?

27 What are your sources of finance?

(Please give details, bank reference in

the prescribed format).

28 Have your company ever been declared

Bankrupt? (If yes, please give details).

29 What is the maximum value of project/

work that you have handled so far?

(Give details).

30 Give the last five years account with

auditors’ reports, balance-sheets, profit

and loss account.

31 Do you intend to associate any other

organization for the works, for which

you are applying? (If so, please give

full particulars and deed executed with

that organization separately under each

head of questionnaire and forms).

32 Whether the firm/ contractor have

criminal record? A certificate on this

regard from the District Magistrate is to

be attached.

33 Give details of successfully completed

works in last five years including cost

& actual time of completion.

I/We hereby declare that the above information furnished by me/us is a true statement of

facts.

Signature of Contractor/ Firm

FORM- “B”

WORK OF SIMILAR TYPE AND MAGNITURE TO WORK UNDER

CONSIDERATION

WORK SUBSTANTIALLY COMPLETED BY THE CONTRACTOR/

FIRM

NOTE: Attested copies of certificates should be enclosed as proof of information entered.

S.

NO.

NAME

OF

WORK

PLACE &

COUNTRY

TENDERED

COST

PERIOD OF

COMPLETION

AS PROVIDED

IN THE

ORIGINAL

AGREEMENT

TIME IN

WHICH

COMPLETED

COST OF

WORK ON

COMPLETION

PRINCIPAL

FEATURES

CLAIMS BY

THE

APPLICANT

1 2 3 4 5 6 7 8 9


FORM- “C”

WORK TENDER FOR AND WORK TO BE COMPLETED AS ON THE

DATE OF SUBMISSION OF APPLICATION

NOTE: Attested copies of certificates should be enclosed as proof of information entered.


FORM- “D”

S.

NO

NAME OF

WORK

PLACE &

COUNTRY

WORK IN HANDS ESTIMATED

COST

WORK TENDERED FOR REMARK

TENDERED

COST

COST OF

REMAINING

WORK TO

BE

EXECUTED

ANTICIPATED

DATE OF

COMPLETION

DATE

WHEN

DECISION

IS

EXPECTED

STIPULATED

DATE AND

PERIOD OF

COMPLETIO

N

1 2 3 4 5 6 7 8 9 10

List of minimum essential T&P in workable condition to be available with the contractor for

1. Construction of new minor from right bank of Kanpur branch at km. 188.366 in Distt.

Kanpur nagar.

2. Construction of Head Regulator for new minor from right bank of Kanpur branch at km.

188.366 in Distt. Kanpur nagar..

Note- Only those machinery/ equipment should be listed whose invoices of in Contractor’s/

Firm’s name attested copy of the invoices/proof of possession should be attached.

S.

No.

Name of T&P in

Workable

Condition

Minimum

Essential

Quantity

(in Nos)

Make/Capacity/Year

of Manufacture

Total Useful

Life of New

T&P (in

Hrs)

Past Use

(in Hrs)

1 2 3 4 5 6

1 Excavator 2

2 Loaders 1

3 Survey Instrument

(Auto Level/ Total

Station)

2 Sets

4 Concrete Mixer

(Only for Lot No.

1)

1

Note: Other Machinery if any available with the Contractor/Firm may also be listed.


FORM- “E- 1”

KEY PERSONAL

DESIGNATION NAME OF

I. NOMINATE

II. ALTERNATE

SUMMARY OF

QUALIFICATION

EXPERIENCE AND

PRESENT OCCUPATION

Headquarters

Partner/Director including

other dey staff (Give

designation)

Site Office

Site Superintendent

Deputy Superintendent

Supervising Engineers

Construction Other Key Staff

The applicant shall list the key personal in this schedule together with their qualification,

experience and position held (including first nominee and the second choice alternate). He

will employ in headquarters and from site office to direct and execute the work.


FORM- “E- 2”

DETAILS OF PERSONAL WITH THE CONTRACTOR/ FIRM FOR

THE WORKS

NAME OF CONTRACTOR/ FIRM ____________________________________________

S.NO. DESIGNATION NAME QUALIFICATION

& DATE OF

APPOINTMENT

PROFESSIONAL

EXPERIENCE

AND DETAIL

OF WORKS

CARRIED OUT

REMARK

1 2 3 4 5 6

1 Project Manager 1

2 Site Engineer 1

S.NO. DESIGNATION WITH CONTRACTOR/

FIRM

THAT COULD BE

MADE AVAILABLE

FOR WORK

1 2 3 4

1 Number of Skilled

Employees.

2 Number of Unskilled

Employees.


FORM- “F”

A. Please add any further information which the applicant considers relevant in

regard to his capabilities:

B. Please give brief note indicating why the applicant considers himself eligible

for Pre-qualification for the work:


FORM- “G”

LITIGATION HISTORY

(OF LAST FIVE YEARS)

flapkbZ foHkkx] mRrj izns'kflapkbZ foHkkx] mRrj izns'kflapkbZ foHkkx] mRrj izns'kflapkbZ foHkkx] mRrj izns'k jkexaxk laxBu] dkuiqjjkexaxk laxBu] dkuiqjjkexaxk laxBu] dkuiqjjkexaxk laxBu] dkuiqj

.

STANDARD PRE-QUALIFICATION

BIDDING DOCUMENT

LOT No. ……..

INFORMATION & INSTRUCTIONS

dk;kZy; vf/k’kklh vfHk;Urkdk;kZy; vf/k’kklh vfHk;Urkdk;kZy; vf/k’kklh vfHk;Urkdk;kZy; vf/k’kklh vfHk;Urk

dkuiqj iz[k.M] fupyh xaxk ugj] dkuiqj iz[k.M] fupyh xaxk ugj] dkuiqj iz[k.M] fupyh xaxk ugj] dkuiqj iz[k.M] fupyh xaxk ugj] dkuiqjdkuiqjdkuiqjdkuiqj INDEX

Agreement No.: ………………………….……………..…. Dated …………………..………

Name of Work : ……………………………………………….…………...………………….

…………………………………………………………………...…………..

Name of Contractor : …………………………………………………………………………...…..

Sr. Contents From To

Page Page

1. Tender Notice

2. Certificate of Divisional Accountant

3. Agreement Form

4. Rs. 100.00 Stamp

5. Contractor’s Warranty

6. Contractor’s Bond

7. Declaration

8. Certificate regarding relatives

9. Conditions of Contract- I.D. from No 111

10. I. D. Form No. 112

11. Schedule “B”

12. Bill of Quantity

13. Special Conditions of contract

14. General condition of contract

15. Letter for Work Acceptance

16. Latter for Date of Start

17. IDT-1, IDT-2, & IDT-3

18. Stamp Paper With Rs. ………………

dk;kZy; vf/k’kklhvfHk;Urkdk;kZy; vf/k’kklhvfHk;Urkdk;kZy; vf/k’kklhvfHk;Urkdk;kZy; vf/k’kklhvfHk;Urk dkuiqjiz[k.M] fupyhxaxkugj] dkuiqjdkuiqjiz[k.M] fupyhxaxkugj] dkuiqjdkuiqjiz[k.M] fupyhxaxkugj] dkuiqjdkuiqjiz[k.M] fupyhxaxkugj] dkuiqj

vYidkyhufufonklwpuk la[;k% 0vYidkyhufufonklwpuk la[;k% 0vYidkyhufufonklwpuk la[;k% 0vYidkyhufufonklwpuk la[;k% 05555@bZ0bZ0@ 2017&18@bZ0bZ0@ 2017&18@bZ0bZ0@ 2017&18@bZ0bZ0@ 2017&18

egkefgejkT;ikymRrj izns’k dh vksj ls fuEufyf[kr dk;ksZ gsrq vku ykbu fufonk

http://etender.up.nic.in ds ek/;e ls VsfDudy fcM ,oa Qkbusafl;y fcM flapkbZ foHkkx] mRrj izns’k]

esa oxhZd`r Js.kh esa iathd`r Bsdsnkjksa ls fnukad% 17&12&2017 dks le; vijkUg 17%00 cts

rd vkeaf=r dh tkrh gSA ftldh VsfDudy fcM fnukad% 18&12&2017 dks iwokZUg 11%00 cts

lfefr ds le{k vkWuykbu [kksyh tk;sxh VsfDudy fcM es DokfyQkbM gksus okys fufonknkrkvks dh

Qkbusafl;y fcM fnukad% 19&12&2017 dks vijkUg 15%00 cts dk;kZy; vf/k’kklh vfHk;Urk]

dkuiqj iz[k.M fupyh xaxk ugj] dkuiqj esa fufonk lfefr ds le{k vkWu ykbu [kksyh tk;sxhA

fufonk izi= fnukad% 11&12&2017 dks iwokZUg 10%00 cts ls 17&12&2017 vijkUg 17%00

cts rdMkmuyksM+@viyksM dh tk ldrh gSA dk;kZy; cUn@vodk’k dh n’kkes ;g

fufonkvxysdk;Zfnolesmlh le; Mkyh ,oa [kksyhtk;sxhA

ykV ykV ykV ykV

la0la0la0la0dk;Z dk fooj.kdk;Z dk fooj.kdk;Z dk fooj.kdk;Z dk fooj.k

dk;Z dh dk;Z dh dk;Z dh dk;Z dh

vuqekfur vuqekfur vuqekfur vuqekfur

ykxr ykxr ykxr ykxr

¼yk[k :0 ¼yk[k :0 ¼yk[k :0 ¼yk[k :0

esa½esa½esa½esa½

/ kjk sgj /kjk sgj /kjk sgj /kjk sgj

jkf’k jkf’k jkf’k jkf’k

¼yk[k ¼yk[k ¼yk[k ¼yk[k

:0 :0 :0 :0

esa½esa½esa½esa½

dk;Z dks dk;Z dks dk;Z dks dk;Z dks

iw.k Z iw.k Z iw.k Z iw.k Z

djus djus djus djus

dh dh dh dh

vof/kvof/kvof/kvof/k

fufonk fufonk fufonk fufonk

izi= izi= izi= izi=

ewY; ewY; ewY; ewY;

e; e; e; e; GST

18%

iathdr̀ iathdr̀ iathdr̀ iathdr̀

Js.khJs.khJs.khJs.kh

1 2 3 4 5 6 7

1

tuin dkuiqj uxj ds vUrxZr dkuiqj

'kk[kk ds fd0eh0 188-366 nkWa;s rV ij

ubZ vfYidk ds fuekZ.k gsrq gsM jsxqyVj ds

fuekZ.k dk dk;Z

32.60 3.2660

fnol

554 $

99 =

649-00

ßlhÞ

vFkok mPp

2

tuin dkuiqj uxj ds vUrxZr dkuiqj

'kk[kk ds fd0eh0 188-366 nkWa;s rV ls

ubZ vfYidk ds fuekZ.k dk dk;Z

21.80 2.1890

fnol

554 $

99 =

649-00

ßlhÞ

vFkok mPp

fu;e ,oa ‘krZs%fu;e ,oa ‘krZs%fu;e ,oa ‘krZs%fu;e ,oa ‘krZs%

29- fuekZ.k dk;Z dksle;c} :Iklsiw.kZfd;ktkukvfuok;ZgSAdk;ksZ dh izxfr,oaxq.koRrkflapkbZfoHkkx ds ekud ds vuq:i u gksusijv/kksgLrk{kjh dks ek= ,d uksfVlnsdjvuqcU/k dksfujLrdjrsgsrq ‘ks”kdk;ZdksfdlhvU; laLFkk@Bsdsknkjlsdk;Zdksiwjkdjkusdkiw.kZvf/kdkjgksxkAbldsfy;sBsdsnkjdkdksbZ nkok ekU; ugh gksxkA

30- TokbaV osapjdhfufonkfdlhHkhn’kkesaLOkhdkj ugh dh tk;sxhA 31- fufonknkrkdkflapkbZfoHkkxesfu/kkZfjr Js.kh dkiathdj.kizek.k i= fufonkizi= ds

lkFklayXudjkukvfuok;ZgSA 32- izR;sdfufonknkrkdks :0 100@&ukWu&twfMf’k;yLVSEiisijij ,d :Ik;sdkjlhnhfVdVyxkdjvuqcU/k

fy[kukgksxkfdnjs 90 fnolrdekU; gksxhAbllsigysfufonk@vkQjokilysusij /kjksgj /kujkf’ktCrdjyhtk;sxhAfu;ekuqlkj ns; okf.kT;dj] vk;dj] LVSEiM;wVh] jk;YVh] izpfyrVSDlnsuhgksxhAvuqcU/k ds le; fu;ekuqlkjLVSEi M~;wVhrFkktekur dh ‘ks”k /kujkf’kHkhtekdjuhgksxhA

33- dk;ZLFky dh vko’;drkuqlkjdk;Z dh ek=k ?kVdk;ZLFky dh vko’;drkuqlkjdk;Z dh ek=k ?kVdk;ZLFky dh vko’;drkuqlkjdk;Z dh ek=k ?kVdk;ZLFky dh vko’;drkuqlkjdk;Z dh ek=k ?kV&c<+ &c<+ &c<+ &c<+ ldrhgS] ftldsfy, ldrhgS] ftldsfy, ldrhgS] ftldsfy, ldrhgS] ftldsfy, fufonknjksaesdksbZifjorZuughafd;fufonknjksaesdksbZifjorZuughafd;fufonknjksaesdksbZifjorZuughafd;fufonknjksaesdksbZifjorZuughafd;ktk;sxkAktk;sxkAktk;sxkAktk;sxkA

34- fufonknkrkdksmijksDrkuqlkjfufonk ds fofHkUupj.kksa dh frfFk;kWrFkkle;kof/k@LFky dh iw.kZtkudkjhfufonkMkyuslsiwoZLo;aizkIrdjuhgksxhAdksbZHkhtkudkjhlEcfU/krdk;kZy; lsdk;ZfnolksaesaizkIr dh tkldrhgSA

35- fufonknkrk }kjkfufonkMkyrs le; izfdz;k dh iw.kZtkudkjhvFkokvU; fdlhdkj.kls ‘krksZdksiw.kZ u djus@ckf/krgkstkus ds dkj.kfufonk u iM+usijfoHkkxdhdksbZftEesnkjh ugh gksxhA

36- blfufonkdksiw.kZ ;k vkaf’kd :IklsfujLrdjusdkvf/kdkjfcukdkj.kcrk;s v/kksgLrk{kjh ds ikllqjf{krjgsxkA

37- ;g laKkueasvkusijfdfdlhfufonknkrk }kjkfdlhvU; lEHkkforfufonknkrkdksblfufonkizfdz;kesaHkkxysus ,oafufonkMkyuslsjksdkx;kgks ;k /kedhnhxbZgksrks ,slsBsdsnkj ds lkFk ;fnvuqcU/k gksHkhx;kgks] rksmldslkFkfd;kx;kvuqcU/k fujLrdjusdkiw.kZvf/kdkj v/kksgLrk{kjhdkgksxkA

38- dksbZfufonknkrktksjkT; ljdkj }kjkdkyhlwphesantZgksblfufonkizfdz;kesaHkkxughaysldsxkA

39- jkT;ckjdkSfUlyesaiathd`rdksbZHkhvf/koDrkfufonkizfdz;kesaHkkxughaysldsxsaA 40- ‘kklukns’k la[;k% 31@1862@16&27&lh&3&8Vh0] fnukad% 14&12&2016 ds

vuqlkjfufonknkrk@Bsdsnkj,d dk;Z dh ,d ghfufonkdjldsxk ;k MkyldsxkA‘krZ;qDrfufonkLohdkjugha dh tk;sxhA

41- ;g dksbZfufonknkrkfu/kkZfjrfof/k ,oaizfdz;k ds fo:} vuqcU/k djusgsrq l{keizkf/kdjhijncko@vlE;dvljMkyrkgSrksiz’uxrfufonknkrk ds U;wurefufonkdhfLFkfresaHkhmldhfufonkfujLr dh tkldrhgSA

42- fof'k”VifjfLFkfr;ksaesafufonk [kksyus dh frfFk@le; esa ;fndksbZifjorZugksrkgSrksbldhlwpukuksfVlcksMZ ds ek/;e lsmiyC/k djknhtk;sxhA

43- vqucU/k xfBrgksus ds Ik’pkrHkh ;fn ;g rF; laKkuesavkrkgSfdfdlhHkhLrjdkmYya?kufd;kx;kgSrks ,slsvuqcU/k dks l{kevf/kdkjh }kjkldkj.kvkns’kiz[;kfirdjfujLrfd;ktk;sxkA

44- ;g fufonk @fcMlwpukmRrjizns’kljdkj dh osolkbVhttp://etender.up.nic.in lwpukfoHkkxdh

osclkbVhttp://information.up.nic.in rFkkflapkbZfoHkkxdhosclkbVhttp://irrigation.up.nic.in ijHkhmiyC/k gSA

45- fufonk ds lkFkflapkbZfoHkkx dh fu/kkZfjr Js.kh esaiathdj.kizek.k i= (IDT-1), (IDT-2), (IDT-3) o vU; izi=@vfHkys[k dh LdSUMdkihizh&DykfyfQds’ku@VSDuhdyfcM ds lkFkviyksMfd;ktkukvfuok;ZgksxkA

46- ‘kklukns’k la[;k% 622] fnukad% 08&06&2012 ds vUrxZrBsdnkjvFkokQeZdks 10 izfr’krU;wurerd 0-50 izfr’kr] izfr 1 izfr’kr de njijrFkk 10 izfr’krlsvf/kdU;wurenjij 1-00 izfr’krizfr ,d izfr’kr de njijvfrfjDrijQkjesal /kjksgj /kujkf’k ns; gksxhA

47- /kjksgj /kujkf’kjk”Vªh;d`r@f’kM;wYMcSad ds }kjkfuxZr ,u0,l0lh0@,Q0Mh0vkj0 ds :i esatks fdvf/k’kklhvfHk;Urk] dkuiqjiz[k.M] fupyhxaxkugj] dkuiqj ds in ukelsca/kdgksxh] tekdjukvfuok;ZgksxkftldhLdSUMdkihbZ&Vs.MjiksVZyijviyksMdjukvfuok;ZgksxkAcSadxkjUVh ,oaMkd ?kj dh iklcqd /kjksgj /kujkf’k ds :i esekU; ughagksxhA

48- fufonknkrk@fcMj }kjkfufonkMkyrs le; izfdz;k dh iw.kZtkudkjh@VsªfuaxvFkokfdlhvU; dkj.kls ‘krksZdksiw.kZ u djikus@ckf/krgkstkus ds dkj.kfufonk u iM+usijfoHkkxdhdksbZftEesnkjh ugh gksxhA

49- fufonkizi= dh /kujkf’k e; th0,l0Vh0 lfgrcSadMªk¶V ds :i esghLohdkj dh tk;sxh] tksvf/k’kklhvfHk;Urk] dkuiqjiz[k.M] fupyhxaxkugj] dkuiqj ds uke ns; gksxk rFkk bls fnukad% 17-12-2017 vijkUg 17%00 ctsrd v/kksgLrk{kjh ds dk;kZy; esmiyC/k djkukvfuok;ZgksxkrFkkftldhLdSUMdkihbZ&Vs.MjiksVZyijviyksMdjukHkhvfuok;ZgksxkA

50- vk;dj@th0,l0Vh0@lsl o vU; dVkSrhBsdsnkjks ds fcyksalsfu;ekuqlkj dh tk;sxhA 51- fufonkLohdkjgksus ds mijkUrfufonknkrkdks Je foHkkxesiathdj.kdk izek.ki= vuqcU/k

xfBrgksuslsiwoZizLrqrdjukvfuok;Zgksxk] vU;Fkk dh fLFkfr esa Hkqxrku djuk lEHko ugh gksxkAHkqxrku ds iwoZdk;ksZ@dk;ZijJfedksdkiath;uizLrqrdjukvfuok;ZgksxkA

52- ‘kklukns’k l[a;k% 52@1439@17&27&fla0&3&07 fofo/k@17] fnukad% 09&10&2017 ds vuqikyuesbZ&Vs.Mfjax ds le; fufonknkrkvksa }kjkfu/kkZfjrizi= ds vfrfjDrewyvfHkys[kks dh LdSudkih o izfrHkwfr izek.ki= v/kksLrk{kjh ds ukeca/kddjkusdkizkIrVªkUtSD’kuuEcjdks Hkhfufonk ds le; osclkbVijMkyhtk;sxhrFkkfufonkLohdkjgksusijewyvfHkys[k O;fDrxr :i ls [k.Mdksfufonknkrk }kjkizLrqrfd;stk;sxsaAfufonkLohdkjgksus ds mijkUrfufonknkrk }kjkizfrHkwfr /kujkf’kewy :i esaizLrqr ugh fd;stkusijfufonknkrk ds fo:) oknnk;jdjdkuwuhdk;Zokgh dh tk;sxhrFkkmldkjftLVsª’kufujLrdjdkyhlwphesMkyusdhHkhdk;Zokgh dh tk;sxhA

Additional Conditions to be made part of the General Conditions of Contract:

53- If any person whosoever is found actively associated with Mafia & Unsocial elements or engaged in organized

crime or is a Mafia Mafioso is disqualified from bidding.

54- Even if it comes to knowledge after award of a contract that the contractor is associated with Mafia and unsocial

elements or engaged in organized crime or is a Mafia of Mafioso, the contract will be cancelled after serving a

show cause notice & if the contractor is found repeating the same, then the proceeding of black listing him shall

also be initiated.

55- If it is found that contractor or bidder has threatened the other bidder of prevented them from bidding the

tender/contract will be cancelled.

56- Any advocate registered in state bar council will not be authorized for bidding, if it comes in knowledge that

contractor is a state or bar council registered advocate the contract will be cancelled after having been satisfied of

these fact.

uksV%uksV%uksV%uksV% fufonklslfufonklslfufonklslfufonklslEcfU/krvU; ‘krsZfufonkizi= ds lkFklayXugSaAEcfU/krvU; ‘krsZfufonkizi= ds lkFklayXugSaAEcfU/krvU; ‘krsZfufonkizi= ds lkFklayXugSaAEcfU/krvU; ‘krsZfufonkizi= ds lkFklayXugSaA

vf/k’kklhvfHk;Urkvf/k’kklhvfHk;Urkvf/k’kklhvfHk;Urkvf/k’kklhvfHk;Urk dkuiqjiz[k.M] fupyhxaxugjdkuiqjiz[k.M] fupyhxaxugjdkuiqjiz[k.M] fupyhxaxugjdkuiqjiz[k.M] fupyhxaxugj

dkuiqjdkuiqjdkuiqjdkuiqj

CERTIFICATE OF DIVISIONAL ACCOUNTANT

Certified that the contract documents of this agreement No. ……………………………

Dated ………………. in favour of Sri…………………………………. contract

for…………………………………………………………………………………………………….

containing pages from 1 to ………… have been checked by me in respect of financial aspects and

there is no financial irregularity.

Divisional Account Officer

Kanpur Division, Lower Ganga Canal,

Kanpur

(TO BE GIVEN ON STAMP PAPER OF RS. 100/- AND WITH REVENUE STAMP OF RS, 1.00 ONLY)

AGREEEMENT

Tender invited by Executive Engineer, Kanpur Division, Lower Ganga Canal, Kanpur Tender for: ………………………………………………………………………………………………………………… …………………………………………………………………………………….……………….. in Tender Notice No ................................................................................ Name of tenderer ...............................................................................................................................................

In Consideration of the Governor of Uttar Pradesh having treated the tenderer to be an eligible

person whose tender may be considered, the tenderer hereby agrees to the conditions that the proposal in

response to the above invitation shall not be withdrawn within three months from the date of opening of

the tender, also to the condition that if there after the tenderer does withdraw his proposal within the said

period the earnest money deposited by him may be forfeited to the Government of Uttar Pradesh at the

discretion of the later.

And the tenderer hereby also agrees that if subsequent to the submission of this tender the tenderer

amends, alters or modifies the contents of his tender which are not acceptable to the department, then the

tenderer shall for the purposes of the aforesaid condition be deemed to have withdrawn his proposal.

Signed this ...............................

Witness :

1.

2.

Contractor’s Signature

With full address

CONTRACTOR’S WARRANTY

The Executive Engineer, Kanpur Division, Lower Ganga Canal, Kanpur having invited tenders for

execution of the various work required for

………………………………….……………...………………………..……………………………………

…………………………………..here-in-after referred to as “The contractor” being desirous of tendering

for works for which the above mentioned tenders have been invited and having carefully studied all the

contract document, Specification etc. accompanying the tender papers and the local site conditions.

DO HEREBY WARRANTY THAT:

1. The Contractor is familiar with all the requirements of the contract. 2. The Contractor has investigated the site and satisfied himself regarding the character of the work

and local conditions that may affect the work or its performance. 3. The Contractor is satisfied that the work can be performed and completed as required in the

contract. 4. The Contractor accepts all risks directly or indirectly connected with the performance of the

contract. 5. The contractor has no collusion with other contractors, with any of the men of the Engineer-in-

charge or with any other person in the preparation of the bid. 6. The Contractor has not been influenced by any statement or promise of the Government or

Engineer-in-charge but only by the Contract documents. 7. The Contractor is financially solvent. 8. The Contractor is experienced and competent to perform the contract to the satisfaction of the

Engineer-in-charge. 9. The statements submitted with the bids are true. 10. The Contractor is familiar with all general and special laws, Acts, ordinances rules and

Regulations of the Municipal, District and Central Government that may affect the work, its

performance or personnel.

Signature of Tenderer

CONTRACT BOND

The Agreement made this ……… day of ……………… year ……….. between the Governor of Uttar

Pradesh (hereinafter called the Government) represented the Executive Engineer, Kanpur Division Lower Ganga

Canal Kanpur. On the one part and Shri/Ms ……………………..……………………………

……………………………………(Hereinafter called the contractor) on the other part.

WHEREAS the Governor of Uttar Pradesh is undertake the construction of folloing works for

………………………………………………………………………… on District ………………………….

Uttar Pradesh (hereinafter called the Work) ………………………………………………………………….

. .

AND WHEREAS the contractor has agreed to undertake the construction and execution of the said work as per

conditions of contract. Technical provision and dia wing hereafter. NOW THERFORE. It is agreed between the

parties as follows:-

ARTICLE I :- SCOPE OF WORK: The contractor shall perform faithfully everything require to be

performed and shall furnish all the labor, Material tools and equipment required to

perform and complete in a workman like manner all the work covered by the contract

documents in strict accordance with the drawings and conditions of contract, technical

provisions including annexure and list of corrections and amendment to drawings and

conditions of contract and technical provisions which are part of this contract, and in strict

compliance which the contract documents shall do everything required by this contract and

the other documents constructing a part thereof.

ARTICLE II :- PAYMENTS: The Government will have sufficient funds in Indian currency for the

execution of the work and will pay the contractor in Indian currency for the satisfactory

performance of this contractor and in accordance with the provisions embodied in the

documents made a part of this contract.

ARTICLE III :- TIME OF COMPLETION: The work to be performed under this contract shall be

commenced by the contractor within 02 days of the date of receipt of notice with the work

and shall be diligently prosecuted and completed ready for handing over to the Engineer in

charge before ……………… month from the date of notice to commence work.

ARTICLE IV :- COMPONENT PARTS OF THE CONTRACT: This consists contract of the following

component part all of which are as fully a part of this contract as it here in setout verbatim

or if not attached as if here to attached.

Part I – (a) Contractors warranty.

(b) Schedule of quantites and bids.

Part II – Condition of contract

Part III – Technical provisions & specifications.

Part IV –(Drawing) As stated technical specifications and provisions

Witness :------

Signed by Contractor

1- ………………………………………………..

2- ………………………………………………..

Witness :------

Signed by ………………………….

For and on behalf of the

Governor of Uttar Pradesh

1- ………………………………………………..

2- ………………………………………………..

DECLARATION

I/We...................................................................................................................

Hereby declare that no work shall be taken in hand by me/us or my/our/authorized agent

unless a proper agreement is drawn in my/our names by the Executive Engineer

K.D.L.G.C. Kanpur In case of default on my/our part I/We fully understand that my/our

security deposit shall be forfeited to the Government and I/We shall have no grunds to

represent for the same.

Signature.of Executive Engineer Contractor’s Signature

With full address

Further I/We ....................................................................................................

here by declare that no office bearer is/are related to me/us in ------

(a) ....................................................................................

(b) Irrigation Department, Uttar Pradesh

If so, his name, designation, address and relationship is given below-----

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

(2) ......................................................................................

(3) ......................................................................................

(4) ......................................................................................

(5) ......................................................................................

Signature Executive Engineer Contractor’s Signature

With full address

CERTIFICATE REGARDING RELATIVES

To,

The Executive Engineer Kanpur Division Lower Ganga Canal

Kanpur Sir,

It is hereby certified that except the persons noted below none other is employed in Irrigation Department, Uttar Pradesh. Sr. Name Designation Place of Posting

……………………………………… Contractor …………………………. Full Address………………………..

……………………………………… ………………………………………

Note : Following come under the definition of relatives – Father, mother, Sister, Brother, Brother in law,

Son, Daughter in law, Mother in law, first cousins of self or wife. The list is illustrative and not exhaustive.

Contractor E.E

I.D. Form _No. 111

CONDITIONS OF CONTRACT

CLAUSE 1:-The person or persons whose tender is accepted (here in aftercalled the “contractor”) shall within one week after his or their tender has been accepted, deposit with the Government of Uttar Pradesh (here in after called the “Government”) either in cash or in securities as provided in paragraphs 614 and 615 of the Financial Hand book Volume VI, such sum as will with the earnest money deposited with the tender amount to Rupees...................and where any security so deposited is not payable to bearer, the contractor shall endorse or transfer it to the said Government in such a manner that the sum represented by it can be realized without the

consent or assistance of the contractor. The contractor shall also permit Government at the time of making any payment to him for work done under the contract to deduct ………………. Of all money so payable on account of security deposit until such deduction along with the sum already deposited as earnest money to be adjusted in the last deduction will amount to 10% of the agreement cost.

If the security is furnished in the form of guarantee bonds, the

contractor undertakes to renew or to furnish fresh guarantee to cover the period of time extension, if any, and failure on his part to do so shall be construed as a breach of this contract and without prejudice to any other remedy provided in these conditions the Engineer-in-charge shall have the right to withhold payment and deduct the entire security amount from any money becoming

payable to the contractor. The amount of the security money shall, if not with

held on account of breach of contract be refunded after 6 months of the date of completion of work or after payment of final bill which ever is later subject to the condition that in case of building work the first rainy season comprising of June, July, August & September is fully covered within the period of 6 months

mentioned above. The amount of security money may if not with-held on account of breach of contract, be refunded after the expiry of the first rainy season comprising of the months mentioned above or after the payment of the final bill which ever is later.

Provided that in case the payment of the final bill is not made within six month of the completion of the work, 75% of the amount of security money can be refunded with the prior approval of the authority next higher to the person accepting the contract on behalf on the Government.

Further Deposit

Deduction from

Payment as security deposit

Contractor E.E

All compensation or other sums of money payable by the contractor to Government under the terms of his contract may be deducted from or realized by the sale of a sufficient part of his security deposit, or from the interest arising there from or from any sums which may be due or may become due to contractor by Government or on any account whatsoever and in the event of his security deposit being reduced by reason of any such deduction or sale as aforesaid, the contractor shall within 10 days there after, make good in cash or Government securities (endorsed or transferred as aforesaid) any sum or sums which may have been deducted from or raised by sale of his security deposit or any part thereof.

Without prejudice to any other remedy provided by law, the Government may recover all dues hereunder from the contractor as the arrears of land revenue (G.O. No. A-2-2242/x 83-17 (5) 71.dated 23.12.83). Explanation :-

For the purpose of this clause if the work under this contract includes construction, reconstruction or repair of any structure having roof over it, the whole work will be classed as building work. CLAUSE - 1 (A)

If not appropriated by the Government under the provision of this contract, the security money or such balance thereof as may be left over after making the deductions will be refunded to contractor after the …………… Engineer has satisfied himself that all the terms of this contract have been duly and faithfully carried out by the contractor, but not before the expiry of the period of six months after the completion of the work.

Provided that in case the ………………. Engineer is satisfied even before the expiry of period of six months that all the terms of this contract have been duly and faithfully carried out by the contractor the security money or such balance as aforesaid may to refunded to the contractor with the previous sanction of the head of the Department as provided in rule 23 appendix XIX of F.H.B. Vol V Part I CLAUSE - 2 (A):- Time is the essence of the contract. The contractor shall commence and shall complete the work covered by the tender, on the date fixed by the ………. Engineer for the commencement and completion of such work and shall in the interval between those dates, keep the work up to the schedule of quantities and dates shown in the progress statement to be signed

by the contractor and attached to the tender. If the work falls in arrear of the progress statement either in quantity or in time, then for every day that the work is so in arrears the contractor shall be liable to pay as compensation an amount equal to 1% or such smaller amount as the ………….. Engineer

(Whose decision in writing shall be final) may decide, on the estimated cost of whole work. Provided always that the entire amount of compensation to be paid under the provision of this clause, shall not exceed ten percent of the estimated cost of the work as shown in the tender.

(G.O. No. 5645 A N/XXIII-1B-550/62 dt. 1967.)

CLAUSE 2 (B) To be used instead of (2A) when the latter is from the nature of the work impracticable Contractor E.E

Compensation

for delay

CLAUSE 2 (C):- Time is the essence of the contract. The contractor shall commence and shall complete the work within the period specified in the tender such period shall be reckoned from the date on which the order to commence the work is given to the contractor. The contractor shall at time during such period proceed with work with due diligence and he shall pay as compensation an amount equal to one percent or such smaller as the ……………… Engineer (whose decision in writing shall be final) may decideon the amount of estimated cost of the whole work as shown in the

tender for every day that the work remains uncommented, or unfinished after

the proper, date and further in order to ensure good progress during the

execution of the work. The contractor shall be bound in all cases in which the

time allowed for any work exceeds one month, to complete one fourth of the value or the quantity (as the …………... Engineer may determine) of the whole

of the work before one fourth of the whole time allowed under the contract has

elapsed, one half of the value or quantity (as the ………….. Engineer may

determine) of the work before one half of such time has elapsed and three-fourth of value or quantity (as the ……… Engineer may determine) of the

work before three fourth of such time has elapsed. If the contractor fails to comply with this conditions he shall be liable to pay as compensation an

amount equal to one percent or such smaller amount as the ………….. Engineer (whose decision in writing shall be final) may decide on the said

estimated cost of the whole work for everyday that the quantity of work

remains incomplete. Provided always that the entire amount of compensation to be paid under the provisions of this clause shall not exceed ten percent of the

estimated cost of the work as shown in the tender.

CLAUSE 3 (1) In any case in which under any clause or clauses of this contract the

contractor shall have rendered himself liable to pay compensation amounting to the whole of his security deposit (whether paid in one sum or deducted by installments) the ………….. Engineer shall have power to adopt such of the following courses as he may deem best. (a) He may rescind the contract by giving the contractor …….days’ notice of rescission signed by the ………….. Engineer and may then take the whole of the contractor’s security deposit for the use of Government as compensation for the loss caused by the contractor’s default. (b) He may, after giving contractor ……days’ notice in writing of his intention to do so, measure up the work done by the contractor & then employ and pay labourers and supply or procure materials and carry out all or any part of the work himself on behalf of Government debiting the contractor with the actual cost and crediting him at the contract rates with the value of the work so done, and may postpone till completion of the work, so taken over assessment

of the compensation to be paid by the contractor. If any work is so taken over by the ………… Engineer the certificate in writing of the Executive Engineer or of the sub division officer as to its cost and value shall be final and conclusive against the contract. (G.O. No. 5645-A N/XXIII-1B-550/62 dt. 1967.)

Compensation

for delay Action by which whole security

deposit is forfeited

Contractor E.E

(c) He may after giving the contractor……. days’ notice in writing of his intention to do so measure up the work done by contractor, take the work out of his hands and give a contract for its completion to another contractor and may postpone till the completion of the work, the assessment of the compensation to be paid by the original contractor. If the ………..…. Engineer

elects to give the completion of work to another contractor, the original contractor shall pay any expenses which may be incurred in excess of the sum which would have been paid to him if the whole work had been carried out by him and a certificate in writing of the Executive Engineer or of the Sub Divisional Officer shall be final and conclusive as against the original contractor as to the amount of any such expenses. (2) If the ………….. Engineer does not desire to do so the work, the contractor shall not be entitled to compensation for any loss sustained by him by reason of his having purchased or procured any materials, or entered into any engagements or made any advances on account of with a view to the execution of the work or the performance of this contract, and shall not be entitled to recover or be paid or be given credit for any sum for any work therefore actually performed by him under the contract unless and until the Executive Engineer or the Sub-Divisional Officer acting under his order shall have

certified in writing the performance of such work and the value thereof. The contractor shall only be entitled to be paid the value as so certified. (3) If upon any occasion the …….…….. Engineer abstains from exercising the power given to him by this clause such abstention shall not prevent him from exercising of such power upon a subsequent occasion if the contractor again makes default nor shall such abstention absolve the contractor from liability to pay compensation for any default which he may have made.

CLAUSE 4: If the ………….…. Engineer exercises any of the power given to him by clause 3 he may if he so desires take possession of all or any tools,

plants, materials and stores in or upon the work or the site there of and belonging to contractor or procured by him and intended to be used for the execution of work or any part thereof, and pay or allow the contractor for the same at the contract rates or in the case these not being applicable, at current market rates to be certified by the ……..…… Engineer, whose certificate

thereof shall be final, and it the ……..…….. Engineer does not desire to do so,

the …………… Engineer may by notice in writing to the contractor or his clerk of the work, foreman or other authorized agent require him to remove such tools and plants, materials or stores from the premises (within a time to be

specified in such notice), and if the contractor fails to comply with any such requisition the ………. Engineer may remove them at the contractor’s expense and at his risk in all respects by auction or private sales and the certificate of the Executive Engineer as to expenses of any such removal and the amount of the proceeds and expenses of any such sale shall be final and conclusive

against the contractor. CLAUSE 5:- If the contractor desires an extension of the time for completion of the work on grounds of any unavoidable hindrance to its execution having arisen, he shall apply in writing to the …………… Engineer within 30 days the existence of such hindrance first becomes known to him, and the ……………..

Engineer shall, if in his opinion reasonable grounds are shown thereof,

Contractor

Contractor remains liable to pay

compensation if action not taken under clause 3

Power to take possession of or require removal of or sell contractor’s plant

E.E

authorize to extend this time limit up to a period of 6 months or 50% of the

time limit provided as time for completion whichever is less and thereafter, Extension of time

…………… Engineer shall, if in his opinion (which shall be final) reasonable grounds are shown thereof authorize extensions as may, in his opinion, be necessary or proper. CLAUSE 6:- On completion of the work the contractor shall send a registered

notice to the ………… Engineer (her-In-after called Engineer-in-Charge) giving Final certificate

the date of completion and shall also send a copy of such notice to the ……….. Engineer and shall request the Engineer-in-Charge to give him a certificate of completion. No such certificate shall be given nor shall the work be considered to be complete until the contractor has removed from the premises on which the

work has been executed all scaffolding, surplus materials and rubbish, and cleaned all wood-work, doors, windows, walls, floors or other parts of any building in, upon or about which the work has been executed or of which he may have had possession for the purpose of the execution thereof, and if contractor fails to do so, on or before the date fixed for completion of the work,

the Engineer-in-Charge may to do so, and may sell such scaffolding and material as have not been removed by the contractor and the contractor shall forthwith pay all expenses so incurred and shall have no claim in respect of any such scaffolding, surplus materials as aforesaid except for any sum actually

realized by the sale thereof. On completion the work shall be measured by the

Engineer-in-Charge, whose measurements shall be binding and conclusive against the contractor.

CLAUSE 7:- In the case of work estimated to cost more than rupees one

thousand, the contractor shall, on submitting the bill thereof to be entitled to

receive a monthly payment proportionate to the part thereof then approved for such purpose by the Engineer-in-Charge, whose certificate of approval and

passing of the sum so payable shall be final and conclusive against the contractor, but any such payment, will only be made as advance to be credited

to Government in the final settlement of accounts with the contractor and not as payment for work completed to Government in the final settlement of accounts

with the contractor and not as payment for work completed and passed and the making of any such payment shall not either preclude the Executive Engineer or

Sub-Divisional officer from requiring to remove or reconstruct or re-erect any

work on the ground that such work is bad, unsound, imperfect or unskilled or prevent Government from enforcing any claim against the contractor on account

of any default by him or conclude, determine or affect in any way the powers of the Engineer-in-Charge under these conditions or any of them as to the final

settlement and adjustment of the accounts or otherwise or in any other way vary

or affect the contractor. The Engineer-in-Charge’s certificate of the

measurement and of the total amount payable for the work shall be final and binding on all parties.

Payment on intermediate certificate to be regarded as advances

Contractor E.E

CLAUSE 8:- If the contractor abandons, or is unable to complete the work, the …………… Engineer may certify in writing the value of the work done by the contractor towards the completion of the contract. Such a certificate shall be final and conclusive against the contractor and he will not be paid more than the value of such work as so certified irrespective of the contract rates. CLAUSE 9:- When the estimate on which a tender in made includes lump sum in respect of parts of the work the contractor shall be entitled to payment in respect of the items of the work involved, or the part of work in question at the same rate as are payable under this contract for other such item of work unless the or work in question is not in the opinion of the Engineer-in-Charge, capable of measurement in which case the Engineer-in-Charge, may pay such lump sum as he may determine to be the value thereof and the certificate in writing of the Engineer-in-Charge shall be final and conclusive against contractor as to the basis upon which payment is to be made in such cases and as to the amount to be paid. CLAUSE 10:- Every month on or before a date to be fixed by the Engineer-in-Charge the contractor shall, if so required, submit a bill for all the works

executed by him during the previous month and the Engineer-in-Charge shall

take or cause to be taken all measurement necessary for checking the contractor’s bill and adjusting his claim as speedily as possible. If the contractor does not submit his bill within the time so fixed the Engineer-in-Charge may after giving the contractor …… day notice in writing, measure or depute

someone to measure such work in the presence of the contractor whose signature on the list of measurement shall be sufficient authority to the Engineer-in-charge to draw up a bill based on such measurement and any bill so drawn up shall be binding on the contractor. If the contractor fails to attend when such measurement are taken, such measurements shall be binding on him,

and if he attends but refuses to sign the list of measurements the matter shall be referred to the immediate superior of the Engineer-in-Charge whose decision shall be binding on the contractor. CLAUSE 11:- The contractor shall submit all bills on the printed form which will be supplied to him at the office of the Engineer-in-Charge and all items in such bills shall be charged at the rates specified in the tender or in the case of any extra work ordered in pursuance of these condition and not mentioned or provided for in the tender at the rates here in after provided for such work. CLAUSE 12:- If the specification or estimate of the work provides the use of any special description or materials to be supplied from the Engineer-in-charge’s store or if it is required that the contractor shall use certain stores to be provided by the Engineer-in-charge (such materials and stores and the prices to be charged thereof as herein after mentioned being so far as practicable and for the convenience of the contractor specified in the schedule hereto annexed but not so as in any way to control of the meaning or effect of this contract), the contractor shall be supplied with such material and stores as may from time to time be required by him for the purpose of the contract but only for such purpose and he shall pay for the same at the rates specified in the said schedule or if no rate is so specified at cost price as defined in clause 13

thereof.

Inability to complete the work

Lump sum in estimates

Bills to be submitted monthly

Bills to be printed form

Stores supplied by the Government

Contractor E.E

All materials so supplied to the contractor will become the property of the contractor but shall not on any account be removed from the site of the work until the work is certified to be completed by the Executive Engineer except with the written permission of the Executive Engineer and shall at all times be open to inspection by the Engineer-in-charge. The Executive Engineer, shall however have the option to take over any such material, if unused at time of the completion or termination of the contract at the specified issue rate or the current market rate, whichever is less.

CLAUSE 12(A):- In case where the contractor is himself to supply the materials he must obtain the articles required for the construction of the work from the firms with which the Director of Industries had made arrangement while in the case of materials for supply for which no such arrangements have been made by the Director of Industries but in respect of which officers have in consultation with consuming department prescribed such specification and/or test the material supplied by the contractor must confirm to such specification and/or test.

CLAUSE 12 (B):- Provided always that contractor shall not be entitled to any compensation for damages caused or loss sustained by him to for late supply of materials or store by the Engineer-in-charge for the reasons beyond his control.

CLAUSE 13:- All articles required by the contractor for the construction of the work and which the contractor is to supply himself, shall be obtained by the contractor from the firms with which the director of industries has made arrangements and if for the supply of any articles no such arrangements have been made any such articles supplied by the contractor shall confirm to such specifications and/or tests, if any as may be prescribed by the Director of Industries in consultations with the consuming department.

CLAUSE 14:- The contractor shall obtain from the stores or the Engineer-in-charge. all such imported stores or materials as may be required in any considerable quantity for the work or any part thereof or for making up articles required thereof or in connection there with. The value of such stores and

articles as may be supplied to the contractor by the Engineer-in-charge will be debited to the contractor in his account at the rates shown in the schedule

attached to contract and if they are not entered in the schedule they will be debited at the cost price. which for the purpose of the contract shall include the cost of carriage and all other expenses what so ever which have been incurred

in obtaining delivery of the same at the stores aforesaid. The Executive Engineer may issue materials to the contractor from existing stock if he is asked for in excess of those entered in the schedule. In such cases the price charged will be stock rate or market rate whichever is greater.

Stores imported from Europe to be obtained from Government

Contractor E.E

CLAUSE 15:- The Contractor shall execute the whole and every part of the work in the most substantial and workman like manner and in every respect in strict accordance with the specification both as regards materials and otherwise. The contractor shall also conform exactly, fully and faithfully to the designs, drawing and instructions in writing relating to the works signed by the Engineer-in-charge and lodged in his office and the contractor shall be entitled to inspect the same during office hours and he may at his own expense have copies of the specifications and of all such designs, drawing and instructions as aforesaid made for his own use.

CLAUSE 16:- The Engineer-in-charge shall have powers to make such

alterations in or additions to the original specifications, drawings, designs and

instructions as may appear to him to be necessary or advisable during the progress of the work, and the contractor shall be bound to carry out the work in

accordance with any instructions which may be given to him in writing signed by the Engineer-in-charge and such alteration shall not invalidate the contract,

and any additional work which the contractor may be so directed to do shall be

carried out by the contractor on the same conditions in all respect on which he agreed to do the main work, and at the same rates as are specified in the tender

for the main work. The time for the completion of the work shall be extended in the proportion that the additional work bears to the original contract work

and the certificate of the Engineer-in-charge shall be conclusive as to such proportion. If the additional work includes any item for which no rate is

specified hereunder the contractor shall carry out the work at the rate entered in schedule of rates of the District. but if the schedule does not contain any rate

for such work, then the contractor shall not begin, such work until a rate in

respect of such work has been settled by mutual agreement between him and

the Engineer-in-charge with the approval of the officer accepting the contract

and if they are unable to agree upon a rate within two weeks from the date when the contractor received the order the Engineer-in-charge may by a notice

in writing cancel the order for such work and carry it out in such manner as he may think best. In the event of dispute the decision of the ……….……. Engineer shall be final and binding on the contractor.

CLAUSE 17:- The Executive Engineer acting on the written orders of his immediate superior, may at any time by notice in writing to the contractor either stop the work altogether or reduce or cut it down. If the work is stopped

altogether, contractor will only be paid for work done and expenses legitimately incurred by him on, or preparation for the execution of the work up to the date on which such notice is received by him. Such expenses shall be assessed by the Executive Engineer, whose decision shall be final and binding on the contractor. If the work is cut down the contractor will be paid for the work’s as so cut down but in neither case he will be paid any compensation whatever for the loss or profit which he might have made if he had been allowed to complete all the work included in the tender.

Work to be

executed in

accordance with

specifications

drawing order etc.

Alternation in specification and designs.

Do not invalidate contract.

Extension of time in consequence of alteration.Rate for additional works not in estimate or schedule of the rate of the district. No compensation

of alteration in or

restriction of work

to be carried out.

Contractor E.E

CLAUSE 18:- If the Engineer-in-charge is satisfied that the construction of any part of the work is faulty or that material used in the same are inferior to those for which the specification provides or that any materials or articles provided by the contractor are not in accordance with the contract, he may, not withstanding that such work, materials or articles may have been passed, certified or paid for, serve the contractor with notice in writing specifying the work, materials or articles of which he complains and requiring the contractor to remove such defects or to replace such materials or articles within a specified period of time.

If the contractor fails to comply, in all respects with the requirement of any such notice within ten days after the expiration of the period specified in that notice the Engineer in charge may himself remedy such defects or as the case may be replace such materials or articles and contractor shall pay all expenses incurred by the Engineer-in-charge in so doing and the certificate in writing of the Engineer -in-charge at to amount of any such expenses shall be final and binding upon the contractor. CLAUSE 18(A):- Government shall have the right to accept at reduced rate substandard or defective work, and to cause and order any audit and technical

examination of work and running and final bills of the contractor including all supporting vouchers, abstracts etc. to be made before or after the payment of the

final bills and if as a result of such acceptance of sub standard or defective work by audit and technical examination, any sum is found to have been over paid in respect of any work done by the contractor under the contract or any work claimed to have been done by him under the contract but found not to have been

actually executed the contractor shall be liable to refund the amount of the over payment and it shall be lawful for Government to recover the same from him in the manner prescribed in clause 11 above or any other manner legally permissible, and if it is found that the contractor was paid less than what was due to him under the contract in respect of any work executed by him under it,

the amount of such under payment may be duly paid by Government to the contractor.

Provided that the substandard or defective work accepted, if not considered to be seriously defective by the Engineer-in-charge, and the rate of the work accepted is suitably reduced by him to compensate the Government, such reduction will be binding on the contractor.

Action and

compensation

payable in case

of bad work.

CLAUSE 19:- All works under or in the course of execution or executed in pursuance of the contract shall at all-time be open for inspection and supervision by the Engineer-in-charge and his subordinates and the contractor shall at all times during the usual working hours and on any other occasion of which he shall have had reasonable notice, either himself be present to receive orders and instructions, or have responsible agent duly accredited in writing present for that purpose. Orders given to any such agent have the same effect as order given to the contractor himself. CLAUSE 19 (A):- No laborer below the age of 14 years shall be employed on the work. CLAUSE 19 (B):- The contractor shall pay to his labourer a fair wage. CLAUSE 19 (C):- The contractor before he commences the work shall (a) post in a conspicuous place on the work site a notice giving the rates of wages which have been certified as fair by the Executive Engineer and (b) send a copy of the notice to the Executive Engineer.

Work to be open to inspection Contractor or responsible agent to be present

Contractor E.E

CLAUSE 19 (D):- The Contractor shall be bound and shall be responsible

tocomply with the provisions of the labour laws in force in the state of Uttar Pradesh including the Minimum Wages Act, or any enactment in super session extension or modification there of which may he passed at any time or from time to time by a competent legislative body and may have effect in the State of Uttar Pradesh and the Rules and Regulations made there under or any

amendments or modifications thereof for the time being in force. All expenses in connection with the compliance of such laws and rules shall be borne by the contractor, and the contractor shall neither demand nor claim nor shall be entitled to any additional payment for the reason that he failed to take in to

account any such expenses in his tender or that any subsequent amendment in

such laws or rules have changed the basis on which he worked out such expenses while submitting his tender.

In every case in which by virtue of the provisions of labour laws in force in the State of Uttar Pradesh and the Rules and Regulation made there under, the Government is obliged to pay any sum in the execution of the work, Government will recover from the contractor the amount so paid, and without prejudice to the other right of the Government. The Government shall be at liberty to recover such amount or any part thereof by deducting it either from the security money deposited by the contractor or to his credit under clause 1 of these conditions or from any other sum due by government to the contractor whether under this contract or otherwise.

CLAUSE 19 (E) The contractor shall engage labour for the work through the nearest Employment Exchange.

CLAUSE 19 (F) The contractor will request Employment Exchange toprovide him labour on wages to be mentioned by him which shall not be less than the fair wages, for the locality of work to be fixed by the superintending Engineer in consultation with District Magistrate concerned. He will also specify the period of the supply of labour which shall not be less than a week from the date of contractor’s request for labour at the employment Exchange. If Employment Exchange fails to supply labour within the specified period the contractor will have option to engage labour from other sources.

CLAUSE 19 (G) The labor employed through Exchange will be kept at par with and shall have no preference over the labour engaged by the contractor privately as regards their transport, wages, accommodation, working hours and amenities. The contractor will have the option to dispense with the labour without any reference to the Exchange when such labor is not required for the work and when he is not satisfied with it, but he will give due information of the discharge of the labour to the Exchange. (G.O. No. 1381-1BD-50/XXIII-1B-81-B-123 W, dt. May 26, 1950 )

CLAUSE 20:- In order that the work may be measured and the correct

dimensions thereof taken, the contractor shall not cover up any part of the same

or otherwise place it beyond the reach of measurement until he has either

obtained the consent in writing of Engineer-in-charge or of his subordinate in

charge of the work or until he has given to the Engineer-in-charge or to such

subordinate five days’ notice in writing that the work is ready for

measurement. If the contractor covers up any work or places it beyond reach of

the

Notice to be given before work is covered up.

Contractor E.E

measurement without such consent and before the expiration of the period of such notice, the contractor shall either as he may elect strip such work at his own expense in order that it may be measured or shall forfeit the price of such work and of the materials used in its constructions.

CLAUSE 21:- All works to be executed under the contract shall be executed under the direction and subject to the approval in all respects to the Engineer-in-charge for the time being, who shall be entitled to direct at what points and in what manner they are to be commenced, and from time to time carried on.

CLAUSE 22:- Except where otherwise specified in the contract the decision of the …………….. Engineer for the time being shall be final conclusive and binding on all parties to the contract upon all questions relating to the meaning of the specifications, designs, drawings and instructions here in before

mentioned The decisions of such Engineer as to the quality of workmanship or materials used on the work or as to any other question, claim, right matter or thing what so ever in any way arising out of or relating to the contract, design, drawings, specifications, estimates instructions, order, or there conditions, or otherwise concerning the works or the execution or failure to execute the same whether arising during the progress of the work or after the completion or abandonment of the contract by the contractor, shall also be final conclusive and binding on the contractor.

CLAUSE 23.If the contractor or his work people or servant shall break, deface, injure or destroy any part of a building on or in which they may be working or any building, road, fence, enclosure, grassland or cultivated ground continuous to the premises on which the work or any part of it is being executed or if any damage shall happen to the work while in progress from any cause due to the negligence of responsibility (the decision the Executive Engineer shall be final) the contractor shall at his own expense make good

such damage, or in default the Engineer-in-charge may cause the same to be made good and the contractor shall, pay any expenses so incurred and the certificate of the Engineer-in-charge as to the amount of such expense shall be final and binding on the contractor.

CLAUSE 24:- The contractor shall supply at his own cost all materials (except such special materials if any as may in accordance with the contract be

supplied from the Engineer-in-charge’s stores) plant, tools, appliances,

implements, ladders, cordage tackle, scaffolding and temporary works requisite for the proper execution of the work whether, original, altered or substituted and whether included in the specifications or other documents, farming part of the contract or referred to in these conditions or not which may be necessary

for the purpose of satisfying or complying with the requirements of the Engineer-in-charge as to any matter as to which under these condition he is entitled to be satisfied or which he is entitled to require and shall pay for the carriage of all such things to and from the work. The contractor shall also supply without charge workmen with the means and materials necessary for

the purpose of setting out works and for counting,

Direction of work. Decision of Engineer-in-charge to be final.

Contractor liable for damage done and for imperfections for three months after certificate.

Contractor to

supply plant,

ladders, scaffolding

etc. and liable for

damages arising

from non-provision

for light, fencing

etc.

Contractor E.E.

weighing and assisting the measurement or examination of the work or materials at any time, if the contractor fails to do so the same may be provided by the Engineer-in-charge and the contractor shall pay the cost of same as certified by the Engineer-in-charge whose certificate shall be final. The contractor shall also provide all necessary fencing and lights required to protect

the public from accident and shall bear the expenses of defence of every suit, action or other proceeding at law that may be brought by any person for injury sustained owing to neglect of the above precautions and shall also pay any damages and costs which may be awarded in any such suit, action or proceeding to any such person or which may with the consent of the contractor be paid to compromise any claim by any such person.

CLAUSE 25:- The Contractor shall not employ female labour in the execution of the work or any part thereof within the limits of cantonment.

CLAUSE 26:- The contractor shall not assign or sub-let the contract without the written approval of the ………... Engineer and if the contractor does or attempts to do so or becomes insolvent or commences any insolvency

proceeding or makes attempts to make any composition with his creditors for or if he or any of his servants or agents either directly or indirectly, gives offers or promises any bribe, gratuity, gift, loan, perquisite, reward or advantage pecuniary or otherwise to any public officer or person in the employment of Government in any way relating to his office or employment or if any such

officer or person shall become in any way directly or indirectly interested in the contract without having first obtained the permission in writing of the Government, the …………… Engineer may there upon by notice in writing

rescind the contract and the security deposit of the contractor shall there upon stand forfeited and be absolutely at the disposal of Government and the same

consequence shall ensure as if the contract had been rescinded under clause 3 hereof, and in addition the contractor shall not to be entitled to recover or be paid for any work there for actually performed under the contract. CLAUSE 27:- Any sum payable by the contractor as compensation under any of these conditions shall be deemed to be reasonable compensation for the act or default in respect of which the same becomes payable without proof of the actual amount of damages or loss sustained.

CLAUSE 28:-In the case of a tender by partners the contractor shall state the name of the members of the firm and shall notify to the Engineer-in-charge any changes in the constitution of the firm as soon as such change occurs.

CLAUSE 29:-In the case of any class of work for which there is no such specification as is mentioned in rule 1 such work shall be carried out in accordance with the district specifications and if there is no district specification the work shall be carried out in all respect in accordance with instructions, and requirement of the Engineer-in-charge.

CLAUSE 30:- In these conditions unless there is something in the subject or context repugnant to such an interpretation, the expressions ‘works’ or ‘work’ mean the work to be done or executed under the contract whether such works in permanent or temporary and whether it is original, altered substituted or additional.

Female labour not to be employed.

Work not to be sub-let. Contract may be

rescinded and

security deposit

forfeited for

subletting, bribing

or if contractor

becomes insolvent. Sum payable by way of compensation to be considered as

reasonable compensation without reference to actual loss

Changes in constitution of firm

Action where no specification is given.

Definition of work

Contractor E.E

CLAUSE 31:- The additions and deductions on accounts of the percentage referred to at page 3 of the accepted tender will be calculated on the gross and not the net amounts of the bills for the work done. CLAUSE 32:- (i). In every case in which by virtue of the provisions of section12 sub section (1) of the workman’s compensation Act. 1932, Government is obliged to pay compensation to a workman employed by the

contractor or by any sub-contractor from him in the execution of the work. Government will recover from the contractor the amount of the compensation so paid, and without prejudice to the rights of Government under section 12 sub-section (2) of the of the said Act. Government shall be at liberty to recover

such amount or any other part thereof by deducting it either from the security money deposited by the contractor or to his credit under clause I of these conditions or from any other sum due by Government to the contractor whether under this contract or otherwise. (ii) Government shall not be bound to contest any claim made against it under section 12 sub section (1) of the said Act, except on the written request of the contractor and upon his giving to Government full security for all costs for which Government might become liable in consequence of contesting the claim. CLAUSE 33:- Not withstanding anything stipulated in the aforesaid clause, Government shall have power to retain any sum due to the contractor (S) and set off all claims against him whether arising out of the particular contract or out of any other transaction or contract held by him alone or in partnership with others. CLAUSE 34:- (1) If the contractor considers any record or ruling of the Engineer-in-charge or of his representative in respect of any of the provisions of this contract to be unfair or considers any work demanded by him to be

outside the requirements of the contract he shall immediately, ask upon such

record or ruling being made or such work being demanded, in writing for written instructions or decisions, on receipt whereof he shall proceed without any delay to confirm to the record or ruling or to perform work demanded and within 15 days after date of receipt of the written instructions or decision he

may file written protest to the Engineer-in-charge stating clearly and in detail the basis of his objections. Except for such protests or objections as are made on record in the manner herein specified and within the limit stated, ruling, instructions and/or decisions of the Engineer-in-charge shall be conclusive and

binding on contractor. Instructions and/or decisions of the Engineer-in-charge contained in letter transmitting drawings to the contractor shall be considered as written instructions or decision, subject to protest or objection as herein provided. CLAUSE 34 : (2) If the contractor is dissatisfied with the final decision of theEngineer-in-charge on the protest or objection made by the contractor in accordance with the procedure prescribed in clause 34 (A) (i) the contractor may within twenty eight (28) days after receiving notice of such decision give notice in writing to the Engineer-in-charge requesting that matter be submitted to arbitration and furnishing detailed particulars of the dispute or difference specifying clearly the point at issue. If the contractor fails to give such notice within the period 28 days as stipulated above the decision of the Engineer-in-charge shall be conclusive and binding on the contractor.

Contractors

percentages whether

applied to net or

gross amount of

bills (Strike out his

clause in the case of

an item contract.)

Compensation to workman

Contractor E.E

CLAUSE 34 : (3) Every dispute, difference or question which may at any time arise between the parties here to or any person claiming under them, touching or arising out or in respect of this deed or the subject matter thereof shall be referred to the arbitration of …………. Engineer or any person nominated by him. It will be no objection to any such appointment that an arbitrator so appointed is a Govt. servant who had to deal with the matters to which the contract relates and that in the course of his duties as Govt. servant had expressed views on all or any of the matters in dispute or difference. In the event of the arbitrator to whom the matter is originally referred, being transferred or vacating his office or being unable to act for any reason …………. Engineer shall either enter upon the reference himself or appoint another person to act as arbitrator. Such person shall be entitled to proceed with reference from the stage as it was left by his predecessor. No person other than a person appointed aforesaid should act as arbitrator and if for any reason that is not possible the matter is not to be referred to arbitration at all. It is a term of this contract that the party invoking the arbitration shall specify the dispute or disputes to be referred to arbitration together with the amount or amounts claimed in respect of each such dispute.

Subject as aforesaid the provisions of the arbitration, and concillation Act 1940 or any statutory modification or reenactment thereof and the rule made there under and for the time being in force shall apply to the arbitration proceedings.

The arbitrator may from time to time with the consent of the parties enlarge the time for making and publishing the award.

CLAUSE 34 (4):- If work under the contract has not been completed when a dispute is referred to arbitration, the work shall continue during the arbitration proceedings, and no payment due to the contractor within the provisions of the contract shall be withheld on account of arbitration proceeding unless authorized or required by the arbitrator.

CLAUSE 34 (5):- The cost of such arbitration shall be borne by the parties or party as decided by the arbitrator.

CLAUSE 35. Quantities are liable to variation on either sides without entitling the contractor to compensation on this account.

CLAUSE 36. Contractor shall himself make proper living accommodation, water and sanitary arrangements etc. for labour which ordinarily should be arranged though Employment Exchange will give preference to Ex-service man. He will have to remove any undesirable labour if ordered by the department.

CLAUSE 37.Claim not referred within 48 hours of occurrence are liable to be rejected.

CLAUSE 38.No extra payment shall be made to the contractor for makingprofiles and namunas in connection with the execution of work (As per G.O, N0 355-38 /66/-XXIII-1B-LT dated 22-6-1966). Contractor E.E

CLAUSE 39.During the course of construction if any necessity is caused due to any clause or claims of work, the contractor shall send a registered notice to the Engineer-in-charge within a fortnight of the origin of claims. If he fails to do so or if he postpones submissions of such claims till the completion of work he will be entitled to no compensation.

CLAUSE 40.The contractor shall not influence or direct labour borne on theMuster Roll, or by any other contractor by paying higher wages or providing extra facilities without the permission of the …………. Engineer and if he does so contrary to the above, will be responsible for the loss or damage caused or claimed by other parties and the decision of the ……… Engineer as to the amount of such damage shall be final and binding on both parties.

CLAUSE 41. This agreement is subject to the standard specifications. The clearance of site, shall be done by the contractor at his own expense.

CLAUSE 42:- 2.3% of the gross amount of any bill i.e. including cost of materials etc. shall be deducted towards income tax under section 194.c of Income Tax Act. XVI of 1972, subject to any amendment made in future.

CLAUSE 43 For Family Planning Purpose In Contract. The contractor agrees to persuade all his labour and other employees. including casual labour employed by him, to adopt family planning techniques (including Vasectomy and Tubectomy) in lines with policies and program announced by the State Government in so far as may be applicable and furnish monthly report to Engineer-in-charge. (As per G.O. No. 5032/76-22/C-3/1975/76, dated 8.9. 1976). Schedule showing (approximate) to Be Supplied from Public Works Stores for works contracted to be executed and the rates which they are to be charged for, vide clause 12 of Conditions :

Unit Rs. P.

Particulars

Rates at which the materials will be charged to

the ciontractor Place of delivery

Contractor E.E

ID- form _No.-112

IRRIGATION DEPARTMENT, UTTAR PRADESH

Division Kanpur Division, Lower Ganga Canal, Kanpur

Name of work :-

Name of contractor :-

GENERAL RULES AND DIRECTIONS FOR THE GUIDANCE

OFCONTRACTORS

1- All works proposed for execution by contract will be notified in a form of invitation to tender pasted on a board hung up in the office of and signed by the …………………. Engineer.

This form will state the works to be carried out. as well as the date for submitting and opening tenders and the time allowed for carrying out the work, also the amount of earnest money to be deposited with the tender and amount of security deposit to be deposited by the successful tenderer and the percentage if any to be deducted from bills. This set of contract documents consisting of copies of drawing and details of the proposed work, specifications schedule of quantities of various items of work and a form of the printed conditions of contract together with the form of tender to be used, signed for the purpose of identification by the …………….…. Engineer and approved by the authority competent to make the contract shall be available for public inspection at the office of the …………………………. Engineer during the office hours. 2- In the event of the tender being submitted by a firm it must be signed separately by each member thereof, or in the event of the absence of any partner, it must be signed on his behalf by a person holding a power of attorney authorizing him to do so.

3- Receipt for payments made on account of work when executed by a firm must also besigned by the several partners, except where the contractors are described in their tender as a firm in which case the receipt must be signed in the name of the firm by one of the partners or by some other person having authority to give effectual receipt for the firm. 4- Any contractor who submits a tender shall fill up the prescribed form of tender striking outthe alternative offer on page 3 of the form not applicable to the case. Tenders which propose any alternation in the work specified in the form of notice inviting tender or in the time allotted for carrying out the work or which contain any other conditions of any sort or are not filled up in English or not accompanied by the deposit of earnest money notified will be liable to rejection. Tenders shall have the name of the work to which they refer written outside the envelope.

Contractor E.E

5- (1) The Superintending Engineer or his authorized assistant will open tender in thepresence of

any intending contractors who may be present at the time and will enter the amounts of several

tenders in a comparative statement in a suitable form. In the event of a tender being accepted, a

receipt for the earnest money forwarded herewith shall thereupon be given to the contractor who

shall there upon for purpose of identification sign copies of the specification and other documents

mentioned in rule-1. In the event of a tender being rejected, the earnest money forwarded with

such unaccepted tender shall thereupon be returned to the contractor making the same.

(2) When tenders are received by the Sub Divisional officer he will open and deal with them in the manner specified above and will submit them to the Executive Engineer for orders. The earnest money, if in currency notes shall be credited in the cash book and paid into the treasury, a receipts in account form No.3 being given to the party tendering. If earnest money is preferred in any of the securities, specified in rule 9, it shall be entered in the register of securities, account form 85 and 86, Earnest money received in currency notes shall be returned to unsuccessful tenderers as soon as their tenders are rejected the usual stamp receipt being taken. 6. The accepting authority shall have the right of rejecting all or any of the tenders. 7. The receipt of an accountant or a clerk for the earnest money paid by the contractor will not be considered as any acknowledgement of payment to the sub Divisional officer/Executive Engineer and the contractor shall be responsible for seeing that he produces a receipt signed by the ……………………….. Engineer.

8. The memorandum of work tendered for shall be filled in and completed in the office of the

………………………. Engineer before a tender from is issued.

9. The amount of earnest money should ordinarily be .. Rs.

(a) When the amount of the tender does not exceed Rs. 2,000 50 (b) When exceeding Rs.2,000 and not exceeding Rs. 5,000 100

(c) When exceeding Rs.5,000 and not exceeding Rs. 10,000 200 (d) For each additional Rs. 5,000 or portion of Rs. 5,000 100

a further sum of .......................................................................................

Such earnest money shall be deposited by the contractor in Government treasury or sub-

treasury laid down in paragraphs 340 [b] [i] 344 and 345 [b] of the financial Handbook volume v, part I Account Rules and the receipted treasury challan attached to the tender. Note - The Officer calling for tender may in special cases where it would be inconvenient for tenderers to deposit money in to the Government treasury relax the rule & permit contractors to deposit earnest money with him in cash or currency notes up to a limit of Rs. 100 instead of into a treasury. Such deposit should be treated as Public Works Department Deposit”

Contractor E.E

[a] If several sub. works are Included they should be detailed in separate list.

[b] Vide rule 9 on page 2.

TENDER FOR WORKS

I or we,

Hereby tender for the execution for the Governor of Uttar-Pradesh of the work specification in the under written memorandum within the time specified in each memorandum at the rate specified therein and in accordance, in all respects. with the specifications, designs, drawing and instructions, in writing referred to in rule 1 thereof and in clause to of the conditions of contract and with such materials as are provided for by and in all other respects in accordance with such condition so far as applicable.

[c] Strike out the alternative and attach Signature to it.

N.B - When tenders are to be submitted at a percentage above or below the rate in the sanctioned estimate the information in all the columns should be filled by the sub-Divisional Officer /Executive Engineer

(2) In the case of works when contractors are required to quote their own rate for the different items of works the column [f] should be left blank for tenderers to fill in

MEMORANDUM (a) General description.

(b) Estimated cost ………………… .Rs.

(c) Agreement cost …………………Rs.

(d) Earnest money ………………….Rs.

(e) Time allowed for the the work from date of written order to

commence.-

S. Item Approximate Unit Per Tendered rate No. Of number or

Work quantity Sanctioned rate (f) In Figure (f) In words

Rs P

Contractor E.E

I/We tender at......................................percent above/below the rates

entered above

or ...................................tenders at the above rates.

Should this tender be accepted........................hereby agreed

to abide by and fulfill all the terms and provisions of the conditions of contract annexed to the approved set of contract documents, or in default thereof to forfeit and pay to Governor of Uttar Pradesh or his successors in office the sums of money mentioned in the said

conditions.

the sum of Rs..................................is herewith forwarded in currency notes as earnest money the value of which shall be retained by Government an account of the security deposit specified in clause I of the conditions of contract.

Dated the............................day of ................................20

i..............................................ii...................................

Witness.......................................................

Address...................................................... Occupation................................................

i.................................... ii..........................

Date.............................Sub-Divisional officer................Sub

Division i................................. v...................................

Date...................................Executive Engineer......................

Division i......................................

v.....................................

Date..............................Superintending

Engineer......................Circle Irrigation works The

above tender is accepted by me on be behalf of the Governor of Uttar Pradesh.

Date...........................day of.............................20

I or we strike out the alternative and attach signature to it. Give particulars and numbers i- Signature of Witness to contractor’s signature

ii- Signature of contractor before submission of tender. Here enter recommended or not recommended v Signature.............and

v- Signature Signature and Official designation of the accepting authority

.

Contractor E.E

SCHEDULE “B”

SCHEDULE OF HIRING PLANT AND EQUIPMENT

1.01 The contractor shall arrange his own equipment for execution of the work under this contract. Signature of Tenderer Executive Engineer

Kanpur Division Lower Ganga ,Kanpur

SCHEDULE “C”

SCHEDULE OF CONSUMPTION OF MATERIALS ----------------------------------------------------------------------------------------------------------------- S. No. Item of Work Unit CONSUMPTION -----------------------------------------------------------------------------------------------------------------

1. Cement Concrete M-25 Grade CUM

2. Reinforcement Tonne. ----------------------------------------------------------------------------------------------------------------

The cost of materials consumed as specified in schedule “c” plus 2% for variation in

consumption shall be deducted at issue rates. If excess material is consumed than specified

above, the cost of such excess material shall be deducted at penal rates as mentioned in schedule

“D”.

In the event of actual quantity of material used in the work being less than calculated on

the basis of schedule “C” cost of quantity of material used less will be deducted at the issue rate

in schedule ‘D” and such balance material shall be returned to the Government stores by the

contractor. If such balance material is not returned by the contractor to Govt. stores, its cost at

penal rate as specified in schedule “D” shall be recovered.

VARRIATION OF CEMENT CONSUMPTION DUE TO MIX DESIGN

Actual consumption of cement shall depend on the mix design for the work. The excess

or less consumption than mentioned above in the table shall be adjusted as per consumption

prescribed for the mix design.

Signature of Tenderer Executive Engineer

Kanpur Division Lower Ganga , Kanpur

SHUEDULE “D”

MATERIAL TO BE SUPPLIED BY THE DEPARTMENT

The following material shall be supplied by the Department at the rate and store specified against each item. ---------------------------------------------------------------------------------------------------------------------

-

S. No. Material Unit Issue Penal

Site

of

rate Rs. rate Rs. store ---------------------------------------------------------------------------------------------------------------------

-

1. Cement Per bag 290.00 580.00

2.

Steel

reinforcemernt Tonne

---------------------------------------------------------------------------------------------------------------- (1) Empty Cement bags shall have to be returned back by the Contractor in good and

serviceable condition otherwise recovery @ Rs.2.00 per E.C. bag shall be made from the

contractor’s bills. (2) All material issued by the department to the contractor will remain the property of the

Government and shall not on any account be removed from the site of the work and shall

at all times be open for inspection and checking. The balance of Govt. material after

completion of the work shall be returned by the contractor to the department at site stores. (3) The above materials required for execution of works, will have to be accepted by the

contractor form Govt. stores and he will not be permitted to procure it himself, unless

authorized by the Engineer-in-charge. (4) If cement is issued to the contractor from any other place than …………………. store,

the difference in carriage rate shall either be paid to or recovered from him, whichever

the case may be, at the prevailing schedule of rate in the circle.

Signature of Tenderer Executive Engineer

Kanpur Division Lower Ganga , Kanpur

GENERAL CONDITIONS OF CONTRACT

1. DEFINITIONS

For the purpose of this contract, specifications comprising conditions of contract, technical provisions and annexure there to, including list of correction and amendments and drawings etc. the following words will have the meanings herein assigned to them.

2. GOVERNMENT Shall mean the Governor/Government of Uttar Pradesh, India or the person who has signed the agreement on behalf of Governor.

3. GOVERNOR Shall mean the Governor/Government of Uttar Pradesh, India

4. CHIEF ENGINEER Shall mean the Chief Engineer (Ram Ganga) irrigation Department U.P. Kanpur.

5. SUPERINTENDING ENGINEER Shall mean the Superintending Engineer II Circle Irrigation works, Kanpur.

6 ENGINEER-IN-CHARGE The Engineer-in-charge Shall mean the Executive Engineer Kanpur Division, Lower Ganga Canal,Kanpur or such other officer as may the authorized by him to act as Engineer-in-charge.

7. CONTRACTOR Shall mean the tenderer, whether firm, registered company, partnership or an individual whose tender has been accepted by the Government and shall include such tenderers, heir, legal representatives, successors and assignees.

8. WORK OR WORKS Shall be held to comprise not only works of construction but also all accessories there to, all matters and things pertaining to the work executed or to be carried out under the contract. Whether such work is permanent or temporary and whether it is original, altered, substituted or additional including clearance of site after the completion of construction.

9. WORK SITE Shall mean the location of the proposed works as detailed in the contract or any other place where works are to be executed under contract and such land, other than camp area of the contractor, in the vicinity of the work as may be notified by the Engineer-in-charge as the works site.

10. MONTH Shall mean the calendar month.

11. DAYS Shall mean the calendar days including Sundays & Holidays.

12. DEPARTMENT Shall mean the Irrigation Department, Uttar Pradesh.

13. WRITING Shall include any manuscripts, type written, cyclostyled or printed statements, under and over signature or seal, as the case may be.

14. SUB CONNTRACTOR Shall mean the person named by the contractor for any part of the work or any person to whom any part of the contract has been sublet by the contractor with the representatives, successors and assignees of such person

15. PARA OR PARAGRAPH

Shall include clause also.

“Contract” or “Contract document” shall mean the agreement and its component parts. Contractor E.E.

16. OPERATION OF AGREEMENT The Engineer-in-Charge shall operate the contract and give necessary instructions and orders to the contractor from time to time. The Engineer-in-charge may delegate any of his powers to his authorized representatives. The contractor will correspond only with the Engineer in charge or his authorized representatives regarding the execution of this contract.

17. SPECIFICATIONS Shall mean collectively all the terms and stipulations contained in the conditions of contract, technical provisions and annexure there to including list of corrections and amendments and drawings.

18. DRAWINGS Shall mean collectively all the general drawing as well as all detailed drawings, supplemented drawings, reproductions, which show the locations, character and details of the work to be done and are issued by the Engineer-in-charge from time to time during the period of construction.

19 TONNE OR METRIC TONNE Shall mean 1,000 Kg. (One thousand Kilogram). Metric system shall be followed in all interpretation and execution of works under contract. Any conversion found necessary shall be in accordance with the figures given in Indian standard conversion table [I.S. 786-1956] and subsequent revision of this standard.

20. ELEVATION OR REDUCED LEVEL Where ever figures are shown after the words “elevation”, “Reduced level” or any abbreviations thereof, or any figure representing Elevations or Reduced levels are given, they shall mean the height in meters above the mean sea level unless otherwise specified.

21. WORDS Words in the singular number shall include the plural number and vice versa where the contract so requires.

22. PLANT Plant and equipment or machinery shall mean and include plant, equipment, machinery, tools and other implements of all description necessary for the execution of the work in a work man like manner.

23. RATES/TENDERED RATES/UNIT PRICES Shall mean the unit rates as entered in the “Schedule of Quantities and bids” by the contractor and accepted by the Government or by the authorized representative of the Government.

24. ORDER TO COMMENCE WORK The order to commence work shall be given only after receipt of the initial security deposit and signing of the agreement and if the contractor starts the work earlier or incurs any liabilities, he shall do so at his own responsibility and risk and no payment what so ever will be made till the initial security in the form specified has been deposited and agreement signed.

25. QUANTITIES AND TENDERED RATES unit of rates as shown in the bill of quantities should be carefully noted as rate once given by the contractor shall remain unaltered and no change on any account shall be entertained after the tender have been opened. The quantities of various items of works given in the schedules of bids are approximate and liable to variations. The tenderers shall not be entitled to any claim or compensation due to variation in quality or omission of any item of work.

Contractor E.E.

26. CONTRACT After acceptance of the tender and deposition of the initial security by the contractor, the formal agreement shall be entered into between the contractor and the Government and the contract will become operative. After the tender has been accepted, all orders or instructions to the contractor shall be given by the Engineer-in-charge or his authorized representative on behalf or the Government.

27. SITE INVESTIGATION : It is understood and agreed that the contractor has satisfied himself as to the nature and location of the works, approach to site, the general and local conditions including those having bearing upon transportation, disposal, handling and storage of materials, availability of labour, water etc. or similar physical conditions at the work site. Sub soil

water hydrology the configuration, and condition of ground, the character quality and quantity of the surface and the sub-surface material to be uncounted, the character of equipment and facilities needed preliminary to and during the execution of the work and all other matter which may in any way affect the work or the cost there of, under this

contract. Any default or failures by the contractor to acquaint himself with all the information concerning these condition will not relive him from responsibility for the execution of the contract nor be made basis of any claim.

28. LINES AND GRADES During the execution of works, the contractor shall lay all lines and grades etc. required for the proper execution of the works. The Engineer-in-Charge may exercise check on such lines and grades for his satisfaction but the responsibility regarding their accuracy will rest entirely with the contractor. The contractor shall provide all facilities and

assistance as may be required by the Engineer-in-charge for checking the lines and grades etc. The lines, grades and bench marks shall be preserved carefully by the contractor until they have served their purpose. Work shall be suspended at such points and for such reasonable times as may be required for checking as above. No compensation or extension of time will be granted to the contractor for required assistance in checking of

lines and grades etc. or for loss of time on account of such suspension of work or otherwise or account of requirement of this clause/paragraph.

29. BENCH MARKS AND SURVEY STAKES Bench marks and survey stakes shall be preserved by the contractor, and in the event of their destruction or removal by him or his employees, these will be replaced by the Engineer-in-charge at the contractor’s expenses.

30. CLAIMS No claims shall be entertained unless submitted in writing within 48 hours of the occurrence necessitating demand of claim to the Engineer-in-charge and copy thereof to the Superintending Engineer, whose decision in all such matters shall be final and binding on the contractor. No claim for interest or damage will be entertained by the Government with respect to any dispute, difference or misunderstanding between the Engineer-in-charge and contractor on the part of the Engineer-in-charge in making periodical and final payment or in any other respect what-so-ever.No claim shall be entertained for damage to work and or material by natural calamities what-so-ever occurring prior to the final measurements and taking over the work by the Engineer-in-charge.

Contractor E.E.

31. DEATH BANKRUPTCY OF CONTRACTOR If the contractor dies or commits any act of bankruptcy or being a corporation, commences to wind up, except for reconstruction purpose or carries on its business under

a receiver the executors, successors or other representatives in law of the state the contractor or any such receiver, liquidator or any person in whom the contract may

become vested shall forthwith give notice thereof in writing to the Engineer-in-charge

and shall for one month during which he shall take all reasonable steps to prevent

stoppage of work have the option to carry out the contract subject to his or their providing

guarantee as may be required by the Engineer-in-charge but not exceed the value of work at the time remaining unexecuted. In the event of stoppage of work. The period of the

option under this clause shall be fourteen days only provided that, should the above option not be exercised the contract may be terminated by the Government by giving

notice in writing to the contractor and the Engineer-in-charge may exercise the same power which he could exercise and will have same rights which he would have under

clause 3 of I.D. Form - 111 if the work had been taken out of the contractor’s hand. 32. RISKS

The Contractor shall be the insurer of the Government’s agents and employees against any and all of the following risks. Whether they arise out of the acts of commission or omission of the contract or of third persons excepting only those risks which result from affirmative, willful acts done by the Engineer-in-charge subsequent to the submission of the contractor’s proposals. (a) The risks of loss or damage to the work prior to the issue of the certificate of final completion. In the even of any such loss or damages the contractor shall promptly repair replace and make goods the work without cost to the Government. (b) The risk of loss or injuries (including death) and damage directly or indirectly to Government their agents and their employees and to their property, arising out of or in connection with performance of the work. the contractor shall indemnify government and the government’s agents and employees for all such injuries’ damages’ and losses resulting there from.

33. ACCESS TO CONTRACTOR’S BOOK Whenever it is considered necessary by the Engineer-in-charge to ascertain the actual cost of the execution of any particular extra items of work or supply of the plant or materials on which advance is to be made or of items or claims, he shall direct the contractor to produce the relevant document such as pay rolls, records of personnel, invoices of materials and any or all the data relevant to the item are necessary to determine its cost etc. and the contractor shall, when so required, furnish all information relating to the aforesaid items in the mode and manner that may be specified by the Engineer-in-charge.

34. CONTRACT DOCUMENTS AND MATTERS TO BE TREATED AS

CONFINDETIAL All documents, correspondence, decisions and other matter concerning the contract shall be considered as of confidential and restricted nature by the contractor and he shall not divulge or allow access thereto of any kind to any unauthorized person.

35. LOCATION The work under consideration is located on

36. CONSTRUCTION PROGRAMME Within Ten (10) calendar days after the date of receipt of notice to proceed with the work, the contractor shall furnish to the Engineer-in-charge a complete construction program showing in detail his proposed program of operations which shall provide for orderly performance of the work. The construction program shall be in such form and in such details as to properly show the sequence of the work under each item of the schedule of quantities and bids. If found necessary during the progress of work, the contractor shall immediately advice the Engineer-in-charge of any proposed change and any additions there to in his construction program, for the approval of the Engineer-in-charge.

ContractorE.E.

. 37. ROADS IN WORK AREAS

The existing pubic kutchcha or pucca roads in work area will be available for use by the contractor subject to the conditions imposed by the Engineer-in-charge. The contractor shall construct and maintain additional roads in the work area as required at his own cost.

38 NOTICE AND INSTRUCTIONS The contractor shall furnish the postal address of his office. Any notice or instruction to be given to the contractor under the terms of contract shall be deemed to have been served if it has been delivered to his authorized agent or representative at site or sent by registered letter to site office or to the address or the firm last provided by the contractor.

39 CONSTRUCTION FACILITY TO OTHER CONTRACTOR AND GOVERNMENT EMPLOYEES: The government may undertake or award other contract for additional work at or in the

vicinity of the work site and the contractor shall fully cooperate with such other contractors and governments employees and carefully fit in his own work to such additional work in accordance with the direction of the Engineer-in-charge. The

contractor shall not commit or permit any act which will interfere with the performance of work by any other contractor or by government employees. The contractor shall permit without charges the Government and such other contractors to use the road bridges, lighting installations and any other facilities constructed or acquired by the contractor for use in the performance of work under this contract as are available without entailing any

material increase in cost to the contractor for maintenance or operation of such facilities.

40. CONTRACTOR NOT TO DISPOSE OFF SOIL ETC. The contractor shall not dispose off or remove except for the purpose to fulfillment of this contract, sand, stone, clay, ballast, earth, trees and shrubs or other material and equipment obtained in the excavation made or lying on the site of the work and all such materials and produce shall remain the property of the Government. Government may upon request from the contractor or if so stipulated in the conditions of contract, allow the contractor to use any of the above material for the work either free of cost or after payment as may be specifically mentioned or considered necessary during the execution of work.

41. JURISDICTIONS The contractor shall be governed by the laws of India or Uttar Pradesh for the time being in force and be subject to the jurisdictions of the High Court of judicature at Allahabad.

42. EMERGENCY In an emergency affecting the safety of life or of the work or of any adjoining property thereof, the contractor shall immediately inform the Engineer-in-charge of such emergency and of what-so-ever measures are proposed to be taken and the conditions that warrant such action. In case sufficient time is not available to obtain approval from the Engineer-in-charge of the measures required to be taken to meet the emergency, the contractor is permitted to act, at his discretion, to prevent such loss or injury. The measures that the contractor shall adopt to prevent such loss or injury shall, however, not cause any damage to any other work.

In case the contractor takes action to meet an emergency at his own discretion,

without obtaining approval of the Engineer-in-charge, he shall be bound to justify the soundness of the action taken by him. In case the action taken by the contractor is not found justifiable, the contractor shall be entirely responsible for the consequences thereof and shall make good any damage or loss at his own cost. Any compensation claimed by

the contractor on account of such emergency work shall be determined by the Engineer-in-charge and granted in case the details furnished for this are found satisfactory. The provision of this clause shall not in any way limit the provisions of any other clause, nor relieve the contractor of any responsibility what-so-ever under any other clause.

ContractorE.E.

43. ERRORS, OMISSIONS AND DISCREPANCIES If the contractor discovers any error, omission or discrepancy in the contract or drawing or technical provisions or in the work undertaken and being performed by him, he shall immediately notify the same in writing to the Engineer-in-charge and the latter shall

promptly verify and set right the same. The contractor shall not take advantage of errors or omission as full instructions shall be available it to the contractor, should any error or omissions be discovered even after detection of such error or omission and prior to the correction thereof, the contractor proceeds with any work affected thereby he shall do so

at his own risk and the work so done shall not be considered as work done under the contract and in performance thereof unless and until approved and accepted by the

Engineer-in-charge. However payment for extra work done as a result of errors or omissions which could not be detected even after reasonable care shall be made to the contractor to the extent of quantities of work executed before the error/omissions were

discovered and brought to notice.

(b) The drawings and technical provisions are to be considered as explanatory of each other and should any thing appear in the former but is not described in the later, no advantage shall be taken by the contractor of any such omission. In case of disagreement between technical provisions and drawings, the technical provisions shall govern the contract. Should any discrepancies appear or should any misunderstanding as to the meaning and interpretation of the technical provisions or drawings or as to the dimension or the quality of the materials for the proper execution of work or as to the measurements or quality and

valuation of the work executed, arise under this contract or in respect of extra item, the same shall be explained by the Engineer-in-charge and his decision shall be final.

44. ACCIDENT PREVENTION: The contractor shall at all times exercise reasonable and proper precaution for the safety

of the people on the works and shall comply with the provisions of current safety laws and relevant building and construction codes of the State and Central Government and

relevant manual of C.W.C. [Central Water Commission] as may be applicable. He shall

also provide all necessary fencing and lights required to protect public from accidents. All machinery and equipment and other source of physical hazard shall be guarded in

accordance with the regulations or laws of the state Government and Government of India. The contractor shall be responsible for all risk to the lives and property of people

from whatsoever cause, arising out of or in connection with the execution of the works during their progress although all reasonable and proper precaution may have been taken

by the contractor. The contractor shall be deemed to have indemnified and under taken to

save from harm the Government against all action suits, claims, demands and cost etc.

arising in connection with injuries suffered prior to the issue of the final certificate of

completion. In case the Government (either along or jointly with contractor) shall be called upon by a court of law to make good any such loss damage or to pay

compensation, (including that payable under provision of the workman’s compensation

Act.) to any person or persons sustaining damage as aforesaid by reason of any act of any

negligence or omission on the part of the contract, the amount which the government may be required to pay in respect thereof and the amount of any costs or charges (including

legal cost and charges in connection with legal proceedings) which the Government may incur in reference there to, shall be chargeable from the contractor.

(b) Monthly reports of all accidents shall promptly the submitted by the contractor to the

Engineer-in-charge giving such details as may be prescribed for that purpose.

ContractorE.E.

45. CAMP SITE: The contractor shall provide, maintain and operate under competent direction camp and facilities convenient to the works sufficient for the housing and accommodation of all his employees including labor. He shall also provide facilities for community latrines, bath room, kitchens dining halls etc., and recreation facilities labors. The location, operation

and maintenance of such camps, and facilities shall be subjected to the approval of Engineer-in-charge. No camp construction of any kind other than that of the most temporary nature, shall be undertaken. unless drawing and specification have been approved by the Engineer-in-charge. The contractor shall perform such grading surfacing and maintenance of the streets in camp sites as in the openion of the Engineer-in-charge

may be required to provide for safe and satisfactory use by the public and shall construct

suitable side works to serve all parts of the camp site. The government will assume rures pone for damage to or interference with contractor due to any operations under the contractor due to flooding by the construction of the work or otherwise.

46. CONTRACTOR’S OFFICE The contractor shall have office near the work site where notice or directions and instruction from the Engineer-in-charge may be served. A clerk or some authorized person shall receive such notice on behalf of the contractor at this office.. The name of such authorized person shall be intimated in writing to the Engineer-in-charge.

47. WATER SUPPLY AND FIRE PROTECTION: (a) The contractor’s camp site shall be provided with adequate water supply of pure water for

domestic purpose. The water for this purpose shall be treated so as to give potable water for drinking. The contractor shall also make arrangement of adequate water for fire protection.

(b) The camp site and its premises shall be maintained in clean and hygienic condition by the contractor to the satisfaction of the Engineer-in-charge. All garbage and refuse shall be collected regularly and shall be disposed off by burial or other satisfactory means.

(c) Should the Engineer-in-charge at any time consider the arrangement made by the contractor to be unsatisfactory he will give a notice to the contractor to make necessary improvements within a week (in case of epidemics this period will be 24 hours). If the contractor fails to improve the arrangements within the specified time the Engineer-in-charge may make the necessary improvement and recover the cost thereof from the contractor’s dues.

48. REMOVAL OF CAMP: After the completion of the work covered by this contract and

before final payment is made, the contractor shall remove from the camp site located on

land owned or controlled by the Government all building and all other construction above

the ground surface except building not owned by the contractor. He shall neatly fill with

earth all cellars basements and other excavated areas and shall leave the site in a clean

and tidy condition. Should the contractor refuse or fail to remove the building and other

construction as herein provided within a period of 30 days after the completion and

handing over of the work covered by this contract, the building and other improvement

shall become the property of government and at option of government all or any part

thereof shall be demolished as herein, provided and in such an event the cost of such

removal will be deducted from the final payment due to the contractor. However with the

written permission of the Engineer-in-charge, building and other construction shall then

become the property of the Government and the contractor shall have no claim what so

ever over it. 49. PAYMENT FOR CAMPCONSTRUCTION :

No payment will be made to the contractor for construction operation and maintenance of camp and other camp facilities and the entire cost of such work shall be deemed to have been included in the tendered rate for the various item of work in the schedule of bids.

ContractorE.E.

50. MEDICAL AID : The camp area shall be provided by the contractor with adequate medical facilities on scale commensurate with camp requirements. Facilities for first aid shall be arranged by the contractor at the work site.

51. EMPLOYMENT OF LABORER BROUGHT BY OTHER CONTRACTORS If the contractor takes away any labor brought and employed by other contractor for the government working on the project he shall be liable to pay compensation equal to the profit the original contractor would have made if the labor would have continued with him and he will also have to return the labor thus employed. The decision of the Engineer-in-Charge shall be final and binding on the contractor.

52. RIGHT TO OBJECT TO PERSONEL EMPLOYED The Engineer-in-charge shall have the right to object to the employment or presence of any representative or other persons, labor employed by the contractor on the work for incompetence, negligence, misconduct or being considered undesirable in the interest of work and on receipt of such objection in writing from the Engineer-in-Charge the contractor shall be bound to remove such person or persons as may have been pointed out in the written objection raised by the Engineer-in-charge.

(b) The contractor shall not be entitled to any compensation for any damage of loss that may be caused by removal of the person as aforesaid.

53. MEASUREMENT TO BE PROVISIONAL AND SUBJECT TO

CORRECTIONS Every Measurement for payment on account of work materials or other things shall be regarded as only provisional and approximate and shall be regarded as being advance payments and shall respectively be subject to revision and settlement by the Engineer-in-Charge and in the event of his concluding that under circumstances the measurements of work executed returns of materials provided and used or the estimate of value previously

made did not truly represent the quality and quantity of works executed and materials provided and used, the Engineer-in-charge shall have the power from time to time and at any time up to the time of the refund of the security deposit to correct the total results by recording measurements a fresh or by such other means as after communication with the contractor or his duly authorized agent the Engineer-in-Charge may deem to be just and

such correction shall be accepted by the contractor. 54. MAINTENANCE AFTER COMPLETION (a) The contractor shall remain liable to remedy all defects that may develop in the work

arising from faulty materials or workmanship for a period of six month from the date of completion.

(b) If it becomes necessary for the contractor to remedy and defect in the work under this Para the liability of the contractor shall remain for the part of the work required until the expiration of six month from the date of completion.

55. WORKS SUBJECTED TO INSPECTION_ BY TECHNICAL AUDIT CELL

All the works during the progress and after the completion shall be subject to inspection by Technical Audit Cell, Irrigation Department, (U.P). Any defects of materials or workmanship pointed out by the Technical Examiner and established as such shall be rectified by the contractor at his own cost. Any recoveries or reduction in rates, considered necessary by the Technical Examiner shall be realized from the contractor even if the work has been accepted by the Engineer-in-charge from subsequent bills or securities of the contractor, or contractor’s dues available with the Irrigation department in other Divisions.

56. QUALITY CONTROL : All the materials supplied by the contractor should be as per relevant latest Indian standard specification. All samples required for testing the quality of material or works shall be given by the contractor free of cost. Labour required for sampling and testing of the material at site shall be provided by the contractor free of cost.

ContractorE.E.

57. PLANTS, EQUIPMENTS AND CONSTRUCION POWER (a) Plant and equipment required for construction of work shall be arranged by the contractor

at his own cost. (b) The contractor shall himself make arrangements for supply of electricity required by him

for lighting purpose or running of machines. Any expenditure in this regard shall be borne by the contractor himself. He may, however, be provided power connection from the power arranged at site to the extent approved by the Engineer-in-charge on the terms and conditions fixed by him. The necessary Lt lines will be laid by the contractor himself at this own expenses and he will also make his own arrangements for supply from the departmental distribution board and will arrange for installation of metering equipment also. He will pay the charge at UPSEB’S relevant rate for the units of power consumed by him. All equipments, materials and work in connection with the electrical installation shall conform to the specification and rules acceptable to the U.P.State Electricity Board as well as Govt. Electrical inspector and Contractor’s electrical installation shall be maintained in sake and satisfactory operating condition. In order to provide proper voltage regulations all motors used by the contractor shall be of type approved by the Engineer-in-charge. All construction jobs and camp site of the contractor and his staff shall be suitably lighted by the contractor at his own expenses for proper execution and inspection.

(c) The contractor shall not be entitled to any compensation due to failure or Non- availability of power supply for any reason what-so-ever.

58. ARBITRATION As per clause 34 (1) to (5) of I.D form No. 111.

59. INCOME TAX DECUCTIONS 2% and surcharge as applicable of the gross amount of any bill i.e including cost of materials etc. shall be deducted towards income tax under section 194.c of income tax Act 1972 subject to any amendments made in future. No deduction towards income tax shall be made from contractor’s bills. if contractors is able to produce a certificate from the income tax department stating that he is exempted form such deductions.

60. TRADE TAX DECICTIONS Nothing in the contract shall relieve the contractor from the responsibility to pay any trade tax that may be levied under the U.P. Sales tax Act. 1948 as amended from the time to time in performance of this contract. Deduction of an amount equal to that specified in section 8-D of the aforesaid Act as in force or as the case may be, shall be made from gross amount of the payments to be made to the contractor equal-to 4% of the amount payable to the contractor, and a surcharge of 25% on Tax amount. No Trade Tax shall be deducted on the cost of materials issued by the department to the contractor. Above deductions are subject to any amendments made in future.

61. DATA AND DRAWING TO BE FURNISHED The contractor shall furnish the following information to the Engineer-in-charge within the period specified in any case.

(a) The detailed construction program and time schedule showing sequence of the operations within 10 days after the date of receipt of notice to proceed with the work.

(b) Monthly requirement of cement according to detailed program (c) Layout plans and details of construction plant and equipment for the execution of the

work including proposed sizes and capacities of principal items which the contractor proposes to install at the site of work, within one week of the date of receipt of notice to proceed with the work.

(d) The contractor shall submit his requirements of land at work site as early as possible after the award of contract.

(e) The approval by Engineer-in-charge of any program working drawings or layout of plants, slopes, storage, building, offices, unloading facilities and storage yard etc. shall not in any way be deemed to relieve the contractor from full responsibility for complete and accurate performance of the work in accordance with the contract drawings and specifications, neither shall such approval relieve the contractor from the liability placed upon him by any provision in the contract.

ContractorE.E.

62. EXECUTION OF WORK IN CONFORMITY WITH THE CONTRACT

DOCUMENT The whole of the work shall be executed in conformity with the contract documents as well as in accordance with such explanatory and detailed drawings and directions as may be furnished from time to time by the Engineer-in-charge for the guidance of the contractor.

63. WORKS TO BE EXECUTED TO THE SATISFACTION OF THE ENGINEER-IN-CHARGE

a) The contractor shall proceed with the works with diligence and expedition and the whole of the work herein specified as well as the mode of execution, shall be under the supervision and direction and shall be carried out to the entire satisfaction of the Engineer-in-charge, who shall have full power to order the contractor to alter, enlarge or diminish the forms, dimension portions or quantities of any of the works or to make use of the materials and workmanship of different description and quantities from those herein specified.

b) The whole of the work together with any temporary work associated here with shall be carried out in the most substantial, proper and workman like manner with the best materials and workmanship and in such order of time as the Engineer-in-charge may direct. The contractor shall attend to and execute without delay, all orders and instructions which may from time to time be issued by the Engineer-in-charge.

64. CONTRACTOR TO BE RESPONSIBLE FOR THE SUFFICIENCY OF

MEANS EMPLOYED (a) The contractor shall supply and take upon himself the entire responsibility of the

sufficiency of the scaffolding, staging, timbering, machinery tools, equipments and generally all the materials used for the fulfillment of this contract whether or not of the type enumerated and whether such means may or may not be approved or recommended by the Engineer-in-charge and the contractor must accept the risks and accidents or

damages from whatever cause they may arise, except where otherwise provided in this contract until completion of this contract.

(b) The contractor shall ensure that all such structures shall have adequate strength for the purpose for which they are constructed and the contractor shall maintain those in a proper condition to the satisfaction of Engineer-in-charge.

(c) The design of such structures are to be prepared by the contractor. Whenever so desired by the Engineer-in-charge the plans of such structures shall be submitted to the Engineer-in-charge for the approval before installation. Examination and approval by the Engineer-in-charge, however will be in the spirit of helpfulness but shall not relieve the contractor of his responsibility for their design construction and use and contractor shall be liable for injuries to persons or damages to properties and works on account of their faulty design or workmanship.

65. MATERIALS, WORKMANSHIP The work shall be executed in a thoroughly workmen like manner with materials and workmanship of the best quality and strictly in accordance with the specifications and the drawings or with such other drawings or written instructions as may from time to time be furnished to the contractor in accordance with terms of this contract and shall be completed in every respect with all materials and workmanship implied and necessary,

according to the fair interpretation and meaning of the same. Should there be any discrepancy between the drawing and specifications or any difference or dispute as to the dimensions to be worked out or the quality of the material to be used or the mode of execution or periodical quantity of the work to be executed or with respect to any subject

arising out of this contract, the decision of the Engineer-in-charge shall be final and binding on all parties, Rejected material shall be so disposed off as to obviate any

possibility of their use in works. The placement and period of disposal shall be as directed by the Engineer-in-charge.

ContractorE.E.

66. PERIOD AND HOURS OF WORKS

The contractor will plan the execution of work and inform the Engineer-in-charge of the

number and hours of shifts he proposes to work and obtain prior approval of his

proposals from the Engineer-in-charge, He shall work in shifts and hours as may be

specified by the Engineer-in-charge from time to time.

67. SPEED OF WORK The contractor shall at all time maintain the speed of work to conform to the latest

operative progress schedules, but the Engineer-in-charge may at any time, with one

month’s notice in writing, direct the contractor to slow down any part or whole of the

work for any reason whatsoever (which shall not be questioned) and the contractor shall

comply with such orders of the Engineer-in-charge. The compliance of such orders shall

not entitle the contractor to any claim or compensation except that reasonable extension

of time to be determined by Engineer-in-charge will be granted in case slowing down

results in delay in final completion of work.

68. SURRENDER OF OCCUPIED LAND The Government land as herein before mentioned shall be surrendered to the Engineer-in-

charge within one month after the issue of the completion certificate. Also no land, shall

be held by the contractor longer than the Engineer-in-charge shall deem necessary and

the contractor shall on the receipt of the due notice from the Engineer-in-charge may

certify as longer required by the contractor for the purpose of the work. All areas of

operations of contractor’s staff and colonies shall be handed back in good condition to the

Engineer-in-charge except area under works contractor as per this contract or those for

which specific approval has been obtained from the Engineer-in-charge.

(ii) The contractor shall make good to the satisfaction of the Engineer-in-charge any damage

to areas which he has to hand over back or to other property or land handed over to him

for purpose of this work.

69. CONDITION_FOR FINAL PAYMENT If the quantities of work items to be executed vary on account of changes in design,

drawings or any other reasons, a cost comparative statement shall be prepared for finally

executed quantities based on the

rates of various tenders received. The amount of final payment to the contractor shall not

exceed the amount of 1st

lowest bid thus calculated in the comparative statements.

70. SECURED ADVANCE

If the contractor requests for advance payment on the security of materials brought to the

site, Engineer-in-charge may make payment as per provision of Financial Hand Book

volume VI para 456.

71. PERIOD OF COMPLETION OF WORK The period of completion shall be seven months from the date at issue of notice to

proceed with the work.

72. FINDS ON THE WORKS Any finds on the site of the work such as relics of fossils of antique or other valuable

boards, minerals etc. shall be absolute property of the government and shall be handed

over intact by the contractor to the Engineer-in-charge. The contractor shall take

reasonable precaution to prevent his workman or any other person or persons from

removing or damaging such articles or things and shall immediately on discovery thereof

and before removal acquaint the Engineer-in-charge of such discovery.

ContractorE.E.

73. PRESERVATION OF EXISTING VEGETATION The contractor will preserve and protect all existing vegetation such as trees on or

adjacent to the site which do not unreasonably interfere with the construction. The

contractor will be held responsible for all unauthorized felling and damage to trees by

careless operation of equipment, stock piling of materials etc. Care will be taken by

the contractor in felling trees authorized for removal so as not to cause any damage to

vegetation or trees or to structures under construction or in existence or injury to

workman.

74. LIEN TO WITH HOLD ANY PAYMENT DUE TO THE

CONTRACTOR The government shall have a lien on and over all or any money that may become due and payable to the contractor under these pursuits and or also on and over the deposit of security amount or amounts under this contract which may become repayable to the contractor under the conditions of contract in respect of any debt or sum that may become due and payable to the Government by the contractor either alone of jointly with another or other persons either under this contract or under any other contract or transaction of any nature what-so-ever between the Government and the contractor whether alone or jointly with another or under provision of the government acts or any other statutory enactment in force in modification or substitutions thereof. The Government shall at all time be entitled to deduct the debit or sum of tax due from the contractor from the money, securities or deposits which may become payable or returnable to the contractor.

75. POSSESSION PRIOR TO COMPLETION The Engineer-in-charge shall have the right to take possession or use any completed part of work. such possession or use, shall not be deemed as taking over of any work not completed in accordance with the contract.

76. REJECTION OF WORK All the work under this contract shall be carried out strictly in accordance with the specifications and other conditions of the contract. If any work does not conform to the requirements of this contract, the said work will be rejected by the Engineer-in-charge. The contractor shall have to remove the rejected work within one week of receipt of notice from the Engineer-in-charge. The decision of the Engineer-in-charge in respect of the rejection of work shall be final and conclusive.

77. HANDING OVERLAND The land on which the work is to be constructed and land required for the use of contractor’s camp is being acquired by the Deptt. Land may, however, not be available

at the time of start of work. The contractor shall submit the construction program as per provisions of para 38 of conditions of contract and the Deptt. Shall try to make available the land before the date of start shown in the construction program for

different reaches of the Bond. If work in a certain reach for which land has been made available to the contractor is not proceeding according to the construction program, the

request of the contractor for additional land to start work in fresh reach shall not be considered genuine. No compensation shall be payable to the contractor of the Deptt. is not able to hand over land in time. However, suitable time extension may be granted to the contractor on this account on his request made in writing. The land for camp as approved by the Engineer-in-charge can be made available to the Contractor to the

extent considered reasonable. 78. LABOUR CESS

Labour cess shall be deducted from the bills of the contractor as per prevalent rules and their subsequent amendments from time to time.

Contractor E.E.

TECHNICAL SPECIFICATION

3.16.3 Rejection of Materials not Conforming to the Specifications. 137

3.16.4 Testing and Approval of Plant and Equipment 137

4 BRICK MASONRY 138

4.1 DESCRIPTION 138

4.2 MATERIALS 138

4.3 PERSONNEL 138

Table of Content

1 GENERAL 118

1.1 DRAWINGS 118

1.2 CLEARANCE OF WORK AREA 118

1.3 LAY-OUT 118

1.4 DRAINAGE DURING EXECUTION 119

1.5 DEWATERING. 119

2 EARTH WORK IN CANALS 120

2.1 General 120

2.2 Excavation 120

2.3 Important Points for Rehabilitation of Existing Canal Embankments 120

2.4 EARTH WORK IN FILLING: 121

2.4.1 BACK FILL: 121

2.4.2 FILLS OTHER THAN BACK FILLS: 122

2.5 MEASUREMENTS 122

2.6 RATES 123

2.7 TURFING 123

3 MATERIALS FOR STRUCTURES 125

3.1 GENERAL 125

3.2 SOURCES OF MATERIALS 125

3.3 BRICKS 125

3.4 STONES AND BLOCKS 125

3.4.1 Stones 125

3.4.2 Blocks 125

3.5 CAST IRON 126

3.6 CEMENT 126

3.7 COARSE AGGREGATES 1273.8 FINE AGGREGATES 128

3.9 STEEL 128

3.9.1 Cast Steel 128

3.9.2 Reinforcing Bars 129

3.10 STAINLESS STEEL 129

3.11 WATER 130

3.12 CONCRETE ADMIXTURES 131

3.12.1 General 131

3.12.2 Mineral Admixtures 131

3.12.3 Chemical Admixtures 131

3.13 REINFORCED AND PRESTRESSED CONCRETE PIPES 132

3.14 LOW DENSITY POLYETHYLENE FILMS (IS:2508-1984) 132

3.14.1 GRADES 132

3.14.2 REQUIREMENTS 132

3.15 STORAGE OF MATERIALS 135

3.15.1 General 135

3.15.2 Bricks 135

3.15.3 Aggregates 135

3.15.4 Cement 136

3.15.5 Reinforcement 136

3.15.6 Water 136

3.16 TESTS AND STANDARD OF ACCEPTANCE 136

3.16.1 Testing and Approval of Material 136

3.16.2 Sampling of Materials

4.4 CEMENT MORTAR 138

4.4.1 Proportioning and Mixing of Mortar 138

4.4.2 Testing of Mortar 138

4.5 SOAKING OF BRICKS 138

4.6 JOINTS 139

4.7 LAYING 139

4.8 JOINTING OLD AND NEW WORK 139

4.9 CURING 140

4.10 SCAFFOLDING 140

4.11 EQUIPMENT 140

4.12 FINISHING OF SURFACES 140

4.12.1 General 140

4.12.2 Jointing 140

4.12.3 Pointing 140

4.12.4 Plastering 141

4.12.5 Curing of Finishes 141

4.12.6 Scaffolding for Finishes 141

4.13 COPING FOR WING/RETURN/PARAPET WALL 141

4.14 ACCEPTANCE OF WORK 141

4.15 MEASUREMENTS FOR PAYMENT 142

4.16 RATE 1425 FORMWORK 143

5.1 DESCRIPTION 143

5.2 MATERIALS 143

5.3 DESIGN OF FORMWORK 143

5.4 WORKMANSHIP 143

5.5 LINING OF FORMWORK 145

5.6 PRECAUTIONS 145

5.7 PREPARATION OF FORMWORK BEFORE CONCRETING 145

5.8 REMOVAL OF FORMWORK 146

5.9 RE-USE OF FORMWORK 146

5.10 SPECIALISED FORMWORK 147

5.11 TESTS AND STANDARDS OF ACCEPTANCE 147


5.13 RATE 147

6 STEEL REINFORCEMENT 148

6.1 DESCRIPTION 148

6.2 GENERAL 148

6.3 PROTECTION OF REINFORCEMENT 148

6.4 BENDING OF REINFORCEMENT 148

6.5 PLACING OF REINFORCEMENT 149

6.6 BAR SPLICES 150

6.6.1 Lapping 150

6.6.2 Welding 150

6.7 TESTING AND ACCEPTANCE 151

6.8 MEASUREMENT FOR PAYMENT 151

6.9 RATE 151

7 STRUCTURAL CONCRETE 153

7.1 DESCRIPTION 153

7.2 MATERIALS 153

7.3 GRADES OF CONCRETE 153

7.4 PROPORTIONING OF CONCRETE 156

7.4.1 Requirements of Consistency 156

7.4.2 Requirements for Design Mixes 157

7.4.3 Requirements of Nominal Mix Concrete 159

7.4.4 Additional Requirements 160

7.4.5 Suitability of Proposed Mix Proportions 160

7.4.6 Checking of Mix Proportions and Water/Cement Ratio 160

7.4.7 Grading of Aggregates for Pumped Concrete 161

7.5 ADMIXTURES 161

7.5.1 Chemical Admixtures 161

7.5.2 Mineral Admixtures 161

7.6 SIZE OF COARSE AGGREGATES 162

7.7 EQUIPMENT 162

7.8 BATCHING, MIXING, TRANSPORTING, PLACING AND COMPACTION 163

7.8.1 General 163

7.8.2 Batching of Concrete 163

7.8.3 Mixing Concrete 164

7.8.4 Transporting Concrete 164

7.8.5 Placing of Concrete 165

7.8.6 Compaction of Concrete 166

7.9 CONSTRUCTION JOINTS 166 7.10 CONCRETING UNDER WATER 167

7.11 CONCRETING IN EXTREME WEATHER 168

7.11.1 Concreting in Cold Weather 168

7.11.2 Concreting in Hot Weather 168

7.12 PROTECTION AND CURING 168

7.12.1 General 168

7.12.2 Water Curing 169

7.12.3 Curing Compound 169

7.13 FINISHING 169

7.14 CONCRETE WITH BLENDED CEMENTS OR MINERAL ADMIXTURES 170

7.14.1 Production of Concrete 170

7.14.2 Modified Properties 170

7.14.3 Compatibility of Chemical Admixtures 170

7.15 TOLERANCES 170

7.16 TESTS AND STANDARDS OF ACCEPTANCE 170

7.16.4 Sampling and Testing 171

7.16.5 Test Specimen and Sample Strength 171

7.16.6 Frequency 171

7.16.7 Acceptance criteria 171


7.18 RATE 173

8 OPEN FOUNDATIONS 174

8.1 DESCRIPTION 174

8.2 MATERIALS 174

8.3 GENERAL

8.4 WORKMANSHIP

8.4.1 Preparation of Foundations

8.4.2 Setting Out

8.4.3 Construction

8.5 TESTS AND STANDARDS OF ACCEPTANCE

8.6 TOLERANCES

8.7 MEASUREMENT FOR PAYMENT

8.8 RATE

SUBSTRUCTURE

9.1DESCRIPTION

9.2MATERIALS

9.3GENERAL

9.4PIERS AND ABUTMENTS

9.5PIER CAP AND ABUTMENT CAP

9.6DIRT WALL, RETURN WALL AND WING WALL

9.7TESTS AND STANDARDS OF ACCEPTANCE

9.8TOLERANCES IN CONCRETE ELEMENTS

9.9MEASUREMENTS FOR PAYMENT

9.10 RATE

10CONCRETE SUPERSTRUCTURE

10.1 DESCRIPTION

10.2 MATERIALS

10.3 GENERAL

10.4 REINFORCED CONCRETE CONSTRUCTION

10.4.1 Solid Slabs

10.4.2 RCC T-Beam and Slab 10.5 TOLERANCES

10.5.1 Cast In-Situ Superstructure


10.7 MEASUREMENT FOR PAYMENT

10.8 RATE

11DELETE

12WELL FOUNDATION

1201 DESCRIPTION

1202 GENERAL

1203 SETTING OUT AND PREPARATIONS FOR SINKING

1204 CUTTING EDGE

1205 WELL CURB

1206 FLOATING CAISSION

1207 WELL STEINING

1208 WELL SINKING

1208.1 General

1208.2 Sand Blow in Wells

1208.3 Use of Kentledge for Sinking of Wells

1208.4 Use of Water Jetting

1208.5 Use of Jack Down Method

1208.6 Use of Explosives

1208.7 Use of Divers

1208.8 Use of Pnuematic Sinking

1208.8.1 General

1208.8.2 Man Locks & Shafts

1208.8.3 Valves

1208.8.4 Medical Supervision & Certification

1208.8.5 Lighting

1208.8.6 Safety Against Fire

1208.9 Precaution During Sinking

1208.10 Tilts and Shifts

1208.11 Seating of Wells

1209 Bottom Plug

1210 Sand Filling

1211 Top Plug

1212 Well Cap

1213 Tolerances

1214 Tests and Standards of Acceptance

1215 Measurement

1216 Rate

BEARINGS 1 DESCRIPTION

2 GENERAL 3 ELASTOMERIC BEARINGS 3.1 Materials 3.2 Manufacturing and Workmanship 3.3 Manufacturing Tolerances 3.4 Acceptance Specifications 3.5 Certification and Marking 3.6 Storage and Handling 3.7 Installation 3.8 Maintenance 4 POT BEARINGS 4.1 General 4.2 Materials 4.3 Manufacture 4.4 Inspection and Testing 4.5 Installation 4.6 Maintenance 5 INSPECTION AND TESTING 6 MEASUREMENTS FOR PAYMENT 7 RATE

Wearing Coat and Appurtenances

14.1 DESCRIPTION

14.2 WEARING COAT

14.2.1 Bituminous Wearing Coat

14.2.2 Cement Concrete Wearing Coat

14.3 RAILING AND CRASH BARRIER

14.3.1 General

14.3.2 Metal Railing/Crash Barrier

14.3.3 Cast In-Situ Concrete Railing/Crash Barrier

14.3.4 Precast Concrete Railing/Crash Barrier

14.4 APPROACH SLAB

14.5 DRAINAGE SPOUTS

14.5.1 Fabrication

SHEET PILES 1 GENERAL 2 DRIVING SHEET PILES 3 PAINTING SHEET PILES 4 MODE OF DRIVING OF SHEET PILES 5 PRECAUTION TO BE TAKEN IN SELECTING AND STRAIGHTENING PILES 6 MAKING JUNCTION PILES AND CORNER PILES 7 WELDING OF JUNCTION AND SPECIAL PILES 8 EMBEDDED SHEET PILES IN CONCRETE TRENCHES 9 MODE OF PAYMENT 9.1 Supplying Sheet Pile 9.2 Driving Sheet Pile

CONCRETE BLOCK PITCHING

16.1 MODE OF PAYMENT

BOULDER PITCHING 1 MODE OF PAYMENTS

PVC WATER-STOP SEALS

14.5.2 Placement

14.5.3 Finishing

14.6 WEEP HOLES


14.8 MEASUREMENTS FOR PAYMENT

14.9 RATE

1 MATERIAL 2 INSTALLATION PROCEDURE: 3 METHODS FOR JOINTING PVC WATERSTOPS WITH HEATER BLADE 4 PRECAUTIONS DURING WATER STOP INSTALLATION 5 MEASUREMENT AND PAYMENT

REPAIR OF STRUCTURES

19.1 Description

19.2 General

19.2.1 Environmental Aspect

19.2.2 Phasing

19.2.3 Management of Canal Flow and Traffic

19.2.4 Safety Precautions

19.2.5 Dismantling and Removal of Material

19.3 Sealing of Cracks by Injection of Epoxy Resin

19.3.1 General

19.3.3 Personnel

19.3.4 Material

19.3.5 Equipment for Injection

19.3.6 Preparation

19.3.7 Epoxy Injection

19.3.8 Precautions for Application

19.3.9 Testing

19.4 Epoxy Mortar for Replacement of Spalled Concrete

19.4.1 Material

19.4.2 Proportioning and Mixing

19.4.3 Surface Preparation

19.4.5 Application

19.4.6 Coverage

19.4.7 Cleaning and Maintenance of Equipment

19.4.8 Testing

19.4.9 Handling Precautions

19.4.10 Personnel and Environment Safety

19.4.11 Epoxy Bonding of New Concrete to Old Concrete

19.4.12 Testing

19.5 Cement Grouting

19.5.1 Material

19.5.2 Preparation

19.5.3 Proportioning, Mixing, and Equipment for Grouting

19.5.4 Application

19.5.5 Cleaning of Equipment

19.5.6 Testing

19.6 Guniting/Shotcrete

DISMANTLING CANAL STRUCTURES 1 Scope 2 Dismantling of Structures 3 Dismantling Pavements and Other Structures 4 Back-filling 5 Disposal of Materials 6 Measurements for Payment 7 Rates

OK Card System

SPECIFICATION FOR INSPECTION PATH 1 Sub Grade:

Environmental and social checks/Control

Disposal of wastes material from construction/demolition List of Table Table 3.1: Grading Requirements of Coarse Aggregate

Table 3.2: Grading Requirements of Fine Aggregates

Table 3.3: Grades of Reinforcing Bars

Table 7.1: Grades of Concrete Table 7.2: Requirement of Concrete for Different Exposure Condition using 20 mm Aggregate Table 7.3: Requirement of Concrete Exposed to Sulphate Attack

Table 7.4: Requirements of Consistency

Table 7.5: Current Margin for Initial Design Mix

Table 7.6: Requirements for Nominal Mix Concrete

Table 7.7: Maximum Nominal Size of Coarse Aggregates

Table 7.8: Minimum Frequency of Sampling

Table 11.1: Requirement for concrete in Piles

Table 11.2: Time for Curing Precast Piles

Table 11.3: Minimum Number of Tests

Table 12.1: Properties of Elastomer

Table 12.2: Shear Modulus at Nominal Temperature

Table 12.3: Tolerances

Table 12.4: Properties of Confined Elastomer

Table 12.5: Manufacturing Tolerances

Table 12.6: Dimensional Tolerance of Confined PTFE and Profile Tolerance of its Projection

Table 12.7: Coefficient of Friction for Stainless Steel Sliding on Properly Lubricated PTFE

TECHNICAL SPECIFICATIONS

(FOR CIVIL WORK)

GENERAL All works are to be carried out according to the Technical Specifications, relevant Indian Standard Codes of practice, UPID Specifications and as directed by the Engineer-in-charge, where necessary. Where specific Indian standards are not available, contractor shall follow relevant international standards and the work shall be carried out with best engineering practices. Wherever reference is made in the Contract to specific standards and codes to be met by the materials, Plant, and other supplies to be furnished, and work performed or tested, the

provisions of the latest current edition or revision of the relevant standards and codes in effect shall apply, unless otherwise expressly stated in the Contract. Where such standards and codes are national, or relate to a particular country or region, other authoritative standards that ensure substantial equivalence to the standards and codes specified will be accepted subject to the Engineer‘s prior review and written approval. Differences between the standards specified and the proposed alternative standards must be fully described in writing by the Contractor and submitted to the Engineer at least 28 days prior to the date when the Contractor desires the Engineer‘s approval. In the event the Engineer determines that such proposed deviations

do not ensure substantially equal performance, the Contractor shall comply with the standards specified in the documents.

1.1 DRAWINGS All works shall be carried out in accordance with the drawings to be supplied by the Engineer-in-Charge duly signed by the engineer from time to time. Construction drawings will be issued in stages by the department before the start of actual construction of the structures. After careful study of the drawings issued by the Engineer, contractor shall prepare, where necessary supplementary construction / fabrication drawings with field/construction information and shall submit the same to the Engineer for approval prior to construction. If some drawings are not available at the start of execution, the contractor shall make the construction programme so that work on available drawings will be taken up first.

1.2 CLEARANCE OF WORK AREA All rubbishes, bushes, wood and trees etc. will be cleared from the site and disposed as per disposal plan approved by the Engineer-in-Charge. All roots of trees and stumps shall be grubbed out 600 mm below the foundation level and holes to be filled with earth and well compacted. The cleared and grubbed area shall be maintained free of vegetable growth during the entire construction period. No separate payment is to be made for the item.

1.3 LAY-OUT Before start of work centre line of the canal shall be marked by suitable and firm pegs each at about 30m interval in straight reaches. In the curved reaches of the canal the curve shall be laid out and top and bottom edges of excavation and toe of embankment shall be suitably peg marked. The centre line in such reaches shall be marked by pegs at an interval of 5 m to ensure smooth curve profile during excavation/filling.

Temporary profiles of canal section in fill and cut reaches shall be made at intervals of 25m at curves and 50m in the straight reaches or as directed by Engineer-in-charge before start of earth work in the reach. The location of the structures as shown on the drawing be verified and fixed accurately with respect to the chainage and the centre line of the canal. The plan of the structure will be laid out as per approved drawing and the direction of the Engineer-in-charge.

UPID

All materials like pegs, stings, flags, etc. and labour for setting out works, carrying lines and level and construction of bench mark as may be required shall be provided by the contractor. All levels for the structures and earth work and lining shall be referred to a specified and established firm bench mark not subjected to subsidence/interference or disturbance. Temporary bench mark pillars shall be constructed at suitable locations near the site of proposed structures for reference of levels during construction, duly checked for correct values of levels. No extra payment will be made separately to the contractor on this account.

1.4 DRAINAGE DURING EXECUTION Suitable arrangements of drainage shall be provided to take surface water clear of the excavation during the progress of work. Sumps may be constructed at suitable places and water collected may be pumped out. When cutting on cross sloping ground, it is advisable to cut a catch water drain on the higher side to prevent water from flowing down. Wherever ground water is met during excavation, adequate arrangements shall be made for dewatering. The choice of method to be employed and type of equipment to be used would depend on and the volume of water.

If there is a continuous flow of water, a sub-drain with sumps at suitable intervals may be provided. Excavation from downstream to upstream side will be helpful to drain away all water from the working face.

For preventing water from the adjacent area of canal to excavation area, temporary bunding shall be constructed by the contractor without any extra cost. The temporary bunding shall be removed by the contractor at his own cost. All operations for proper drainage and to make the work area suitable for excavation shall be carried out by the contractor at his own costs i.e. no payment for dewatering shall be made.

1.5 DEWATERING. The contractors are required to get acquainted with site conditions about ground water and quantum of dewatering requirement during the construction of the structure and quotes their rates inclusive of cost of all arrangements and all operations of dewatering. Well points or deep or shallow open wells shall be used to dewater foundations depending on the condition prevailing at the construction site. The arrangement of pumps, their installation sequence and procedure of dewatering shall be subject to approval by the Engineer-in-charge.

Any method which causes loss of material from underneath the structure, previously constructed, shall be rejected. To ensure proper placement of foundation concrete the free water surface of depressed water table shall not be less than 15 cm below the foundation level. The pumped water carried in pipes or flumes shall be discharged into running drain at

such a distance from the edge of the foundation in such a manner that this water does not come back to the foundation pit through seepage. The pumped water shall not be allowed to pool up in any case even at good distances upstream, but shall be provided with quick drainage gradient in order that the returning water does not strain the pumps too much in lowering down the water table. No separate payment will be made for dewatering involved at any time during execution of work. UPID

EARTH WORK IN CANALS

2.1General

All works shall be carried out according to technical specifications, the Indian Standard Code(s) of practice for earth work on canal (IS 4701), IS 4839 (Part I), UPID specifications Volume-I, IRC – SP: 20 and as directed by Engineer-in-Charge, where necessary.

2.2 Excavation

Before commencement of the excavation in any reach the contractor shall inform and obtain in writing from the Engineer-in-Charge, necessary instructions. The contractor shall excavate whatever material may be encountered up to the depth of excavation shown on the Cross-section of the channels. All material, thus excavated, shall be the property of the Government.

Excavation to be carried out shall strictly conform to the plans and levels shown on the profile of excavation in the Cross-sections. The bed of the canal will have a longitudinal gradient as given in L-section and will be kept level transversely. The side slopes shall also conform to those given in the drawings and shall be neatly finished. Any excavation below the prescribed bed level shall not be paid.

Excavation of internal section in KBC shall be carried out by suitable earthmoving equipments. However, excavation may be allowed to be done manually by the Engineer in charge, if so required.

2.3 Important Points for Rehabilitation of Existing Canal Embankments For rehabilitation of old canal embankments the following care shall be taken for proper bonding of the freshly laid soil with the old embankment.

2.3.1 All trees, bushes, roots and other vegetation growth from the existing embankment shall be removed.

2.3.2 The base of the extension portion of embankment shall be stripped and roots and other vegetations shall be removed. The stripping operation is to be done up to the bottom of root zone of vegetation so that all roots are removed out of the surface. The stripping depth may vary at places depending upon type of vegetation growing on the area/slopes, the cost of all such stripping up to bottom of roots shall be deemed to be included in the unit rates of the excavations.

2.3.3 The slope of existing banks shall be benched to depth of 15 cm. to 30cm, as per requirement at site for proper bonding of the freshly laid soil with the old embankment. The cost on this account shall be deemed to be included in the unit rates of the excavations.

2.3.4 Earthwork shall be done in layers of specified thickness. Clods must be broken.

2.3.5 Under no circumstances, the embankment shall be widened by material dumped from the top of the existing embankment.

2.3.6 Adequate quantity of moistening/watering shall be done at the junction of the freshly

laid soil with the old embankment for proper bonding.

UPID

2.3.7 If initial moisture content in the soil is less than the optimum moisture content (OMC)

water shall be sprinkled over the freshly laid layer before compaction.

2.3.8 A tolerance of + 1% of OMC moisture content shall be permitted.

2.3.9 Where the width is sufficient/adequate, compaction shall be done mechanically by 8-10 tones power roller/vibratory power roller so as to achieve at least 95% of Procter density for cohesive soils and relative density of 70% for non-cohesive soil. Where space is not sufficient for the deployment of 8-10 Tones Power Rollers, the earth work shall be compacted by deploying appropriate smaller dimensioned vibratory power rollers (of the same compacting effort as of the 8-10 Tones plain power rollers) or using mechanical compacters/pneumatic compacters (by reducing the thickness of layers to + 10- 15cm) to achieve 95% proctor density.

Tests and their frequencies for Embankment Construction

SNo. Test Frequency of test Purpose Reference

1 Grain size One test per day or To know the classification ofIS : 2720- IV analysis periodically as soil actually put in

for directed by Engineer embankment classification

2 Specific gravity One test per day To know the classification ofIS : 2720-V soil actually put in embankment

3 Field density One test in 300m3 ofTo determine the and moisture earth work or in each placement density and

content layer laid onmoisture content

embankment

4 Standard One test per day for To determine MDDIS : 2720-VII Proctor test individual borrow area (maximum dry density) and

OMC (optimummoisture

content) of the soil and

compare the results with

laboratory value

5 Moisture One test in To know the moisture contentIS : 2720-II content each sample in the sample

6 Relative densityOne test in 300m3To know the relative density ofIS : 2720-XIV test of earth workcohesion less soil

placement

2.4 EARTH WORK IN FILLING: The earth work in filling involved in construction of canal structures will be of two types (a) back fill. (b) fill other than back fill.

2.4.1 BACK FILL: Back fill is defined as specifications and which

excavation refill which is required to be placed under these cannot

be deposited around the structures or adjacent embankment

UPID

until after the structure are completed. Such back fills may consist of either previous or impervious earth. However the thickness of previous materials adjacent to the structure in the backfills shall not be less than 600 mm at any place. The thickness of back fill with previous earth greater than 600 mm will be depending upon availability of previous materials at sites and will be decided by the Engineer-in-Charge. This will be laid in 225 mm layers and compacted so as to give maximum dry density of not less than 95% at optimum moisture content. Payment for this type of work shall be made for cubical contents of finished work.

2.4.2 FILLS OTHER THAN BACK FILLS: This shall consist of either previous or impervious materials. Such fills shall be done around the structures behind the back fill. The materials for the fill may be obtained from the excavation of foundation or excavation of borrow areas. Attempts will be made to use the materials obtained from foundation directly, in fills as far as practicable. Whenever the materials of the fill is received from the direct disposal of the foundation excavation no extra payment will be made as the cost is included in item of excavation of foundation trenches but when the materials is borrowed from the outside and not received from the direct disposal of the foundation excavation, the cost will be paid as per rates accepted in the item of filling. The unit of measurement will be per cubic metre.

The fill shall be laid in 225 mm layers and compacted so as to give maximum dry density of 85% at optimum moisture content. The fill not conforming to above stipulation shall be rejected and the work will have to be re-done without any extra payment for this type of fill. Payment shall be made for cubical content of the finished work less the cubical content directly utilized from the time of excavation of foundation trenches. Contractor’s rate for the item work shall include the cost of carriage, disposal, spreading watering, rolling,

compaction, levelling and dressing the same in suitable profile as per specification and direction of Engineer-in-charge, when the soil shall be carried from the borrow area. When disposal of excavated soil will be utilized in filling work then payment for watering and rolling only shall be made. The cost of other operation included in quoted rate will be

deducted.

2.5 MEASUREMENTS The measurements shall be taken correct to a cm. Before commencement of earthwork in each canal, initial cross sections at every 50m interval in straight reach and at every 25m interval in curved reaches shall be taken jointly by the department and authorized representative of the contractor, which shall be recorded in MB/ level book. Contractor/his authorized representative shall have to record his acceptance of levels and measurements on the MB/level book before start of work. The contractor shall submit the detail programme for carrying out the joint measurements. A notice for recording the measurements shall be issued to the contractor and even then, if the contractor or his authorized representative does not turn up on the desired date, time & place, the work of taking measurements will continue and it will be deemed as acceptable to the contractor.

If the earth from cutting internal section is not sufficient to achieve designed section after compaction, then cross section shall be taken before placing the borrowed earth to achieve designed section wherever required. Similarly after completion of work as per design/drawing, final cross sections shall be taken at the same locations. During the execution of work, cross-section at intermediate state shall also be taken if required. These cross sections shall be prepared in Auto-Cad by the contractor. All such cross sections shall be utilized to derive quantities of earthwork mentioned under different items in Bill of Quantities. Only joint measurement shall be the basis of the payment. It will be the

UPID

duty and sole responsibility of the contractor to get the joint measurements done as and when required before commencing any new activity.

Quantity of borrowed earth shall be derived on the basis of cross sections as described above. Quantity of earthwork in cutting shall be derived on the basis of initial & final cross section. This earth (only suitable quantity) shall be used for the rehabilitation of banks and surplus earth shall be disposed off as per Disposal plan. Settlement allowance on borrowed earth after mechanical compaction shall be deducted @ 5.0% to workout the payable quantity.

2.6 RATES

Rate for earthwork shall include and take in to account the following –

Making Profiles (Kaccha Namunas).

Setting out works, haul roads for excavation & disposal/borrows area etc.

Excess earth laying on top of banks and from excavation of internal section of canal above designed level and rehabilitation of banks.

Disposal of the surplus excavated material as per disposal plan or as per

direction of Engineer-in-charge taking into consideration environmental & social aspects.

Borrowing earth from approved borrow area including royalty charges, cost

of borrowed earth and rehabilitation of banks.

Preparation of cross sections in Auto-Cad.

All leads, lifts and dressing of earth.

Labour charges, providing all surveying and levelling instruments and material needed for measurements, checking of works and taking initial/final cross sections of canal.

Cost of maintenance of works during contract period.

Removal of all trees, bushes, vegetation, rubbish, roots, ant hills and any

other objectionable material before excavation or placing earth on embankment.

Spreading in layers, watering & compaction as per specification.

2.7 TURFING

Surface stabilization of slopes and the prevention of soil erosion and weathering will be accomplished by the establishment of grass or other herbage. The living grass roots mechanically reinforce the soil, and the decaying organic matter improves soil structure. The grass leaves, living or dead, protection the surface against rain and wind.

The grass sods to be used over slopes of embankment shall be cut in rectangular slope of 8 to 10 cm thick and laid so that their edges are in close contract and then gently rammed till they form a level and compact mat. When old surfaces are to be turfed, they shall be picked up to a depth of about 4 cm to give a hold to the sods. For sodding any grass which forms a thick short turf shall be used. To ensure a satisfactory result about grass to be used it may be necessary to consult agricultural scientist or department in the choice of particular type of grass suitable for the type of soil of the embankment. UPID

The grass sods or seed used on the surface are to be watered by sprinkler/light pumps till the grasses are grown properly and the roots hold the soil surface properly.

The measurement will be taken on the surface area of thickly grown grass only.

UPID

MATERIALS FOR STRUCTURES

3.1 GENERAL Materials to be used in the work shall conform to the specifications mentioned on the drawings, the requirements laid down in this section and specifications for relevant items of work.

If any material, not covered in these Specifications, is required to be used in the work, it shall conform to relevant Indian Standards, if there are any, or to the requirements specified by the Engineer.

3.2 SOURCES OF MATERIALS The Contractor shall identify the sources of materials like coarse aggregate and fine aggregate and notify the Engineer regarding the proposed sources prior to delivery. Samples of materials from the source shall be tested in the presence of Engineer for conformity to specifications. It shall also be ensured that the variation in test results of different samples is within acceptable limits.

For manufactured items like cement and steel reinforcement, the contractor shall intimate the Engineer the details of the source, testing facilities available with the manufacturer and

arrangements for transport and storage of material at site. If directed by the Engineer, the contractor shall furnish samples and test results of recently received material. The Engineer, at his discretion, in case of doubt, may require the contractor to test the materials in an independent laboratory approved by the Engineer and furnish test certificates. The cost of these tests shall be borne by the contractor. The sampling and testing procedures shall be as laid down in the relevant Indian Standards and where they are not available; the same shall be carried out as per the directions of the Engineer. Only materials from sources approved by the Engineer shall be brought to the site. If the material from the approved source proves

unacceptable at any time, the contractor shall identify new sources of acceptable materials conforming to specifications.

3.3 BRICKS Burnt clay bricks shall conform to the requirements of IS:1077, except that the minimum compressive strength when tested flat, shall not be less than 8.4 MPa for individual bricks and mean strength not less than 10.5 MPa for a group of 5 specimens. They shall be free from cracks and flaws and nodules of free lime. The brick shall have smooth rectangular faces with sharp corners and emit a clear ringing sound when struck. The size may be according to local practice with a tolerance of ± 5 percent.

3.4 STONES AND BLOCKS

3.4.1 Stones Stones shall be of the type specified. They shall be hard, sound, free from cracks, decay and weathering and shall be freshly quarried from an approved quarry. Stones with round surface shall not be used. The stones, when immersed in water for 24 hours, shall not absorb water of more than 5 percent of their dry weight when tested in accordance with IS:1124. The length of stones shall not exceed three times its height and the width on the base shall not be greater than three-fourth of the thickness of the wall nor less than 150 mm.

3.4.2 Blocks

UPID

Solid concrete blocks made of cement and suitable aggregates shall conform to relevant provisions of IS:2185 Part 1 in respect of dimension, mix, manufacturing, curing, drying and physical requirements. The minimum compressive strength of solid concrete blocks when tested as per IS:2185 Part 1 shall not be less than 10.5 MPa. Hollow light weight concrete blocks shall not be used in works.

3.5 CAST IRON

Cast iron shall conform to IS:210. The grade number of the material shall not be less than 14.

3.6 CEMENT

Cement to be used shall be any of the following types with the prior approval of the Engineer

Ordinary Portland cement, 33 Grade, conforming to IS: 269. b. Ordinary Portland cement, 43 Grade, conforming to IS: 8112.

c. Ordinary Portland cement, 53 Grade, conforming to IS: 12269.

d. Sulphate resisting Portland cement, conforming to IS: 12330.

e. Portland Pozzolana cement (fly ash based) conforming to IS:1489 (Part 1)

f. Portland slag cement conforming to IS:455

g. Rapid Hardening Portland cement, conforming to IS:8841 Low heat Portland cement conforming to IS:12608

Cement of 33 grade conforming to IS:269 shall be used only after ensuring that the minimum required design strength can be achieved without exceeding the maximum permissible cement content of 450 Kg/cum of concrete (excluding any mineral admixture).

Cements of 43 and 53 grades conforming to IS: 8112 and IS:12269 respectively may be used provided the minimum cement content mentioned elsewhere from durability considerations, is not reduced.

Sulphate resisting cement conforming to IS: 12338 shall be used when sodium sulphate and magnesium sulphate are present in large enough concentration to be aggressive to concrete. The recommended threshold values as per IS: 456 are: sulphate concentration in excess of 8.2 percent in surrounding soil or 380 ppm (8.03 percent) in ground water. Cement conforming to IS:12330 shall be carefully selected from strength considerations to ensure that the minimum required design strength can be achieved without exceeding the maximum permissible cement content of 458 kg/cum (excluding any mineral admixture).

Alternatively, Portland slag cement conforming to IS:455 with slag content more than 58 percent can be used instead of sulphate resisting cement when the sulphate content in the surrounding soil is less than 1 percent or the sulphate content in the ground water is less than 2508 ppm.

Cement conforming to IS: 8841 shall be used only for precast concrete products after specific approval of the Engineer.

Total chloride content shall be 8.1 percent by mass of cement for the cement to be used in structures other than prestressed concrete structures and 8.85% by mass of cement in prestressed concrete structures. Also, total sulphur content calculated as sulphuric anhydride (SO3) shall in no case exceed 3.5 percent.

UPID

Where chloride is encountered along with sulphates in soil or ground water, ordinary Portland cement with C3A content from 5·to 8 percent shall be preferably used in concrete·, instead of sulphate resisting cement.

Manufacturer's test certificate shall be submitted to the Engineer by the contractor for every consignment of cement. The certificate shall cover all the tests for chemical requirements, physical requirements and chloride content as per relevant codes as applicable.

Independent tests of samples drawn from the consignment, shall be carried out at the site laboratory or in an independent laboratory approved by the Engineer, immediately after delivery. The following properties shall be tested:

Compressive strength.

Setting time

The cost of the tests shall be borne by the Contractor. Cement in bags in local storage for more than 3 months after completion of tests, may be re-tested for compressive strength and setting times (initial and final) before use and may be rejected if it fails to conform to any of the requirements.

Lot size for independent testing of cement at site shall be the quantity received at site on any day, subject to a maximum of 500 tones.

3.7 COARSE AGGREGATES For plain and reinforced cement concrete (PCC and RCC) or prestressed concrete (PSC) works, coarse aggregates shall consist of clean, hard, strong, dense, non-porous and durable pieces of crushed stone, crushed gravel, natural gravel or a suitable combination thereof or other approved h1ert material. They shall not contain pieces of disintegrated stones, soft, flaky, elongated particles, salt, alkali, vegetable matter or other deleterious materials in such quantities as to reduce the strength and durability of the concrete, or to attack the steel reinforcement. Coarse aggregates having positive alkali-silica reaction shall not be used. All coarse aggregates shall conform to IS: 383 and tests for conformity shall be carried out as per IS: 2386, Parts I to VIII.

The contractor shall submit for the approval of the Engineer, the entire information indicated in Appendix Auf IS: 383.

Maximum nominal size coarse aggregate for various structural components in PCC, RCC or SPC, shall conform to Specifications as given in drawings and item of works.

The maximum value for flakiness index for coarse aggregate shall not exceed 35 percent.

The coarse aggregate shall satisfy the requirements of grading as given in Table 3.1:

Table 3.1: Grading Requirements of Coarse Aggregate Percentage Passing for Graded Aggregate of Nominal Size

IS Sieve Size

40mm 20mm 12.5 mm

63 mm - - -

40 mm 95-100 100 -

20 mm 30-70 95-100 100

UPID

12.5 mm - - 90- 100

10 mm 10-35 25-55 40-85

4.75 mm 0-5 0-10 0-10

3.8 FINE AGGREGATES

For masonry work, sand shall conform to the requirements of IS:2116.

Natural sand, crushed. stone sand or crushed gravel sand or a suitable combination of natural sand, crushed stone or gravel, shall be used as fine aggregates in plain, reinforced and prestressed concrete works. The fine aggregates shall be dense, durable, clean and free from veins and adherent coating and other deleterious substances. They shall not contain dust,

lumps, soft or flaky materials, mica or other deleterious materials in such quantities as to reduce the strength and durability of the concrete, or to attack the embedded steel. Mechanised sand washing machines should be used to remove impurities from sand. Fine aggregates having positive alkali-silica reaction shall not be used. All fine aggregates shall

conform to IS:383 and tests for conformity shall be carried out as per IS:2386, (Parts Ito VIII). The Contractor shall submit to the Engineer the entire information indicated in Appendix A of IS:383. The fineness modulus of fine aggregate shall neither be less than 2.0 nor greater than 3.5.

Fine aggregate for structural concrete shall conform to the grading requirements as given in Table – 3.2.

Table 3.2: Grading Requirements of Fine Aggregates

Percent Passing for

IS Sieve Size

Grading Zone I Grading Zone II Grading Zone Ill

10 mm 100 100 100

4.75 mm 90-100 90-100 90-100

2.36 mm 60-95 75-100 85-100

1.18 mm 30-70 55-90 75-100

600 micron 15-34 35-59 60-79

300 micron 5-20 8-30 12-40

150 micron 0-10 0-10 0-10

Note : When the grading falls outside the limits of any particular grading zone of sieves other than 600-micron IS Sieve by a total amount not exceeding 5 percent, it shall be regarded as falling within that grading zone. However for crushed stone sand, the permissible limit on 150-micron IS Sieve is increased to 20 percent. Reference shall be made to Clause: 4.3 of IS:383.

3.9 STEEL

3.9.1 Cast Steel The use of cast steel shall be limited to bearings and other similar parts. Steel for castings shall conform to Grade 280-520N of IS: 1030. In case where subsequent welding is unavoidable in the relevant cast steel components, the letter N at the end of the grade

UPID

designation of the steel casting shall be replaced by letter W. To increase the corrosion resistance properties, 0.3% to 0.5% copper may be added.

3.9.2 Reinforcing Bars For plain and reinforced cement concrete (PCC and RCC) or prestressed concrete (PSC) works, the reinforcement/untensioned steel as the case may be, shall consist of the following grades of reinforcing bars.

Table 3.2: Grades of Reinforcing Bars

Bar Type Conforming to Governing ISCharacteristic Elastic

Grade Designation Specifications Strength fy MPa ModulusGP

Fe240 IS:432 Part I Mild Steel 240 200

Fe415 IS:1786 High Strength Deformed 415 200

Fe 500 or Fe 5000 IS:1786 High Strength Deformed 500 200

Fe 550 or Fe 550D IS:1786 High Strength Deformed 550 200

Fe600 IS:1786 High Strength Deformed 600 200 Note: If any grade of steel given in the above table is not available steel of next higher grade may be used.

All steel shall be procured from 'Original producers' who manufacture billets directly from iron ores and roll the billets to produce steel conforming to IS:1786. No re-rolled steel shall be incorporated in the works. However, in case !he original producers give certificate that they are unable to supply the steel within the required time period or that they are not producing bars of the required diameter, the Engineer may allow the procurement of steel from other suppliers, provided that the reinforcement is manufactured from billets procured from the original producers. In such cases, the manufacturer's certificate alone shall not be considered as sufficient and the steel shall be got tested by the Engineer in the NABL

accredited laboratories only, as a third party check· . It shall be ensured that all the test results conform to IS: 1786 requirements.

Only new steel shall be delivered to the site. Every bar shall be inspected before assembling on the work and defective, brittle or burnt bars shall be discarded. Bars with cracked ends shall be discarded.

For the steel procured from .original producers also, the Engineer I Employer may carry out occasional checks on materials through third party as mentioned above, for confirming the test results shown in the certificates, in case of any doubt regarding the quality of steel supplied.

3.10 STAINLESS STEEL Stainless steel shall be austenitic chromium-nickel steel, possessing rust, acid and heat resistant properties conforming to IS: 6603 and IS: 6911. Mechanical properties/grade for such stainless steel shall be as specified by the accepting authority, but in no case inferior to mild steel. Generally, stainless steel is available as per AISI grades. AISI 304, which is equivalent to grade 04 Cr 18 Ni 110 of IS: 6911 satisfies the requirements for mechanical properties of structural steel. Other grades of stainless steel for specific purposes may be provided as per specific requirements. For application in adverse/corrosive environment, stainless steel shall conform to AISI 316L or 02G17 Ni Mo2 of IS: 6911. UPID

3.11 WATER Water used for mixing and curing shall be clean and free from oils, acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious to concrete or steel. In case of doubt regarding development of strength, the suitability of water proposed to be used for the production of concrete shall be ascertained by carrying out tests for the compressive strength of concrete and initial setting time of cement using the same water.

The sample of water taken for testing shall represent the water proposed to be used for concreting, taking into account seasonal variations, if any. The sample shall not receive any treatment before testing other than that being given to the regular supply of water proposed for use in concrete. The sample shall be stored in a clean container previously rinsed out with similar water. Average 28 days compressive strength of at least three 150 mm concrete cubes prepared with water proposed to be used shall not be less than 90 percent of the average strength of three similar concrete cubes prepared with distilled water. The cubes shall be prepared, cured and tested in accordance with the requirements of IS:516.

The initial setting time of test block made with the appropriate cement and the water proposed to be used shall not be less than 30 minutes and shall not be more than 30 minutes from the initial setting time of control test block prepared with the same cement and distilled water. The test blocks shall be prepared and tested in accordance with the requirements of IS: 4031 (Part 5). pH value of water shall not be less than 6. Potable water is generally considered satisfactory for mixing concrete. Mixing and curing with sea water shall not be permitted. As a guide, the following concentrations represent the maximum permissible values:

To neutralize 100 ml sample of water, using phenolphthalein as an indicator, it should not require more than 5 ml of 0.02 normal NaOH. For details of test refer IS:3025 (Part 22).

To neutralize 100 ml sample of water, using mixed indicator, it should not require more than 25 ml of 0.02 normal H2SO4. For details of test refer IS: 3025(Part 23).

The Permissible limit's for solids shall be as follows

Tested as Per Permissible Limit max

Organic IS:3025 (Pt.18) 200 mg/lit

Inorganic IS:3025 (Pt. 18) 3000 mg/lit

Sulphates IS:3025 (Pt. 28) 400 mg/lit

(SO3)

Chlorides (Cl) IS:3025 (Pt. 32) 2000 mg/lit for concrete work not

containing embedded steel and 500

mg/lit for prestressed/reinforced

concrete work

Suspended IS:3025 2000 mg/lit matter (Pt.17P

UPID

All samples of water (including potable water) shall be tested and suitable measures taken, where necessary, to ensure conformity of the water to the requirements stated herein.

3.12 CONCRETE ADMIXTURES

3.12.1 General Admixtures may be added to the concrete before or during mixing with a view to modifying, one or more of the properties of concrete in the plastic or hardened state.

3.12.2 Mineral Admixtures Any of the following mineral admixtures may be used as part replacement of Portland cement with the approval of the Engineer.

Fly ash: conforming to of IS: 3812-3

Granulated slag: Ground granulated slag obtained by grinding granulated slag conforming

to IS: 12089.

Silica fume: Silica fume is very fine, non- crystalline Si02, obtained as a by-product of

Silicon and Ferro- Silicon alloy industries and shall conform to IS: 15388

3.12.3 Chemical Admixtures

3.12.3.1 Information Required from the Manufacturer Chemical admixtures are proprietary items of manufacture and shall be obtained only from established manufacturers with proven track record, quality assurance and full-fledged laboratory facilities for the manufacture and testing of concrete.

The contractor shall provide the following information concerning each. Admixture, after obtaining the same from the manufacturer:

Normal dosage and detrimental effects, if any, of under dosage and over dosage.

The chemical names of the main ingredients.

iii) The chloride content, if any, expressed as a percentage by weight of the admixture.

Values of dry material content, ash content and relative density which can be used for Uniformity Tests.

Whether it leads to the entrainment of air when used as per the manufacturer's recommended dosage, and if so to what extent.

Confirmation regarding its compatibility with type of cement.

Whether it increases the risk of corrosion of reinforcement or other embedments.

Whether it affects the durability

3.12.3.2 Physical and Chemical Requirements Admixtures shall conform to the requirements of IS:9103. In addition, the following conditions shall be satisfied.

"Piasticisers" and "Super-Piasticisers" shall meet the requirements indicated for "Water reducing Admixture".

Except where resistance to freezing and thawing and to disruptive action of deicing salts is required, the air content of freshly mixed concrete in accordance with the pressure method given in IS:1199, shall not be more than 2 percent higher than that of

UPID

the corresponding control mix and in any case not more than 3 percent of the test mix.

The chloride content of the admixtures shall not exceed 0.2 percent when tested in accordance with IS:6925. In addition, the maximum permissible limit of chloride content of all the constituents as indicated in Section 1700 of these Specifications shall also not be exceeded.

Uniformity tests on the admixtures are essential to compare qualitatively the composition

of different samples taken from batch to batch or from the same batch at different times.

The tests that shall be performed along with permissible variations are as follows:

Dry Material Content: within 3 percent and 5 percent of liquid and solid

Ash content: within 1 percent of the value stated by the manufacturer.

Relative Density (for liquid admixtures) : within 2 percent of the value stated by the

manufacturer. All tests relating to concrete admixtures shall be conducted periodically at an independent laboratory and the results compared with the data given by the manufacturer.

3.13 REINFORCED AND PRESTRESSED CONCRETE PIPES Reinforced concrete pipes for structures shall be of NP4 type conforming to the requirements of IS:458. Prestressed concrete pipes (NP4) conforming to IS: 784 can also be used depending on the requirement.

3.14 LOW DENSITY POLYETHYLENE FILMS (IS:2508-1984)

3.14.1 GRADES The material (film) is classified according to the optical properties, impact strength and slip. The film of grade 314 shall be used. Grade 314 shall indicate that the film is of high clarity, low impact strength and extra high slip.

3.14.2 REQUIREMENTS

3.14.2.1 General

Appearance - The film shall be uniform in colour, texture and finish. The material shall besubstantially free from pin-holes and un-dispersed raw materials, streaks and particles of foreign matter. There shall be no other visible defects, such as holes, tears or blisters. The edges shall be free from nicks and cuts visible to unaided eye.

The natural films shall be free from pin-holes.

Film Form - The film shall be furnished in the form of flat sheet or rolls or in the form of flattubing or in any other form as agreed to between the Employer and the Contractor.

Odour - The film shall be free from any objectionable odour.

UPID

Density - The density of the film, when determined in accordance with Appendix-l ofIS:2508 and method prescribed in code or method 5 of IS:8543 (Part l/Set2)-1979*. However, in case of dispute, the latter shall be the referee method.

Black Film - When tested in accordance with:

10 of IS : 2530-1963, the percentage of carbon black in material shall be 2.5 ±0.5 percent by mass; and

16 of IS : 2530-1963, the dispersion of the carbon black shall be satisfactory.

3.14.2.2 Dimensional Requirements

Nominal Thickness and Nominal Width

Nominal thickness is the theoretically desired thickness of a film for a particular application; and

Nominal width is the theoretically desired width of a film for a particular application.

Tolerance on Thickness

When tested in accordance with Annexure-2 of IS Code 2508, tolerance on nominal thickness at any given point and the average thickness of polyethylene film for various thicknesses shall be as follows:

Nominal Thickness Tolerance, Percent

Up to and including 40 m ± 25

Above 40 m ± 20

Tolerance on Width

The tolerance on width shall be as given below:

Nominal Width (mm) Tolerance (mm)

Up to 500 ±5

Above 500 and up to 1250 ±8



Above 3 000 and up to 7500 +150, -65

Above 7500 and up to 15000 +200, -100

Yield Tolerance

The actual yield shall be determined in accordance with the method given in Annexure-3 of

IS:2508 and shall be within the following tolerance limits of the nominal yield: UPID

One roll

Lots of 250 Lots over 250 kg and upto 1250 kg

Lots over 1250

10 percent 10 percent

5 percent

3 percent

Tensile Strength at Break The tensile strength at break when tested as prescribed in Annexure-4 of IS Code 2508 for all thicknesses of polyethylene film shall be not less than II.77 MN/m2 ( 120 kgf/ cm2 ) in lengthwise direction and 8.33 MN/m2 ( 25 kgf /cm2 ) in crosswise direction.

Elongation at Break The elongation at break when tested as prescribed in Annexure-4 of IS Code 2508, for various thicknesses of polyethylene film, shall be not less than the value given below:

Thickness of the Film Elongation at Break, Min

From 12.5 µm up to but not including 75 µm 100 350

75 µm and above 200 400

Optical Properties

The 450 gloss and haze of the film,. When determined in accordance with Annexure-5 of

IS:2508, shall conform to the requirements given below:

Grade 450 Gloss Haze

Low clarity film Below 30 Greater than 15 Percent

Normal clarity film 30 to 55 10 to l5 percent

High clarity film Greater than 55 6 to 10 percent

Impact Resistance

The impact resistance of the film shall be as:

High Impact Resistant Film - When tested by the procedure given in A-6, the impact failure load obtained from a drop height of 152.4 cm shall be not less than that given below against the appropriate average thicknesses of the film:

Average Thickness of Film, Impact Failure Load, Min

m N (gf)

150 1.90 ( 190)

175 2.15 (215)

200 2.50 ( 250 )

225 2.85 ( 285 ) UPID

Slip - The kinetic coefficient of friction for the material when tested in accordance with

Annexure-7 of IS Code 2508 shall be as follows:

Extra high slip film Up to and including 0.20

Heavy DUQ Film - Low density polyethylene films for canal lining, construction work and allied purposes, shall have an MFI not more than 0.30 g/10 min when tested by the method given under 7 of IS : 2530-1363*. The tensile strength of such films shall be not less than 140

kgf/cm2 in machine direction and 110 kgf/cm2 in transverse direction. Films shall also meet the requirement of impact strength as given in 4.7.3 of IS:2508.

3.14.2.3 MARKING

Marking

Each roll folded film shall be marked legibly with the following information:

Manufacturer‘s name and recognized trade-mark, if any;

Grade of the film;

Width of the roll/folded film;

Mass of the roll, folded film;

Thickness of the film; and

Batch number and date of manufacture.

BIS Certification Marking

The product should also be marked with Standard Mark of BIS.

3.15 STORAGE OF MATERIALS

3.15.1 General All materials shall be stored at proper places so as to prevent their deterioration, intrusion of foreign matter and ensure their satisfactory quality and fitness for the work. The storage space must also permit easy inspection, removal and re-storage of the materials. All such materials, even though stored in approved godowns/places, must be subjected to acceptance test prior to their immediate use.

3.15.2 Bricks Bricks shall not be dumped at site, but shall be stacked in regular tiers as they are unloaded, to minimize breakage and defacement. Bricks selected for use in different situations shall be stacked separately. Sufficient supply of bricks as required for the works, shall be available at site at any time.

3.15.3 Aggregates Aggregate stockpiles may be made on ground that is hard, well drained and devoid of vegetation.

Coarse aggregates, unless otherwise agreed by the Engineer in writing, shall be delivered to the site in separate sizes (2 sizes when nominal size is 25 mm or less and 3 sizes when the nominal size is 32 mm or more). In case of aggregates placed directly on the ground the material in the stock pile only up to a level of 30 cm above the ground level shall be taken out UPID

and used initially. Remaining material shall be permitted to be used in the final stages of work only after it has been fully cleaned.

3.15.4 Cement Cement shall be transported, handled and stored on the site in such a manner as to avoid deterioration or contamination. Cement shall be stored above ground level in perfectly dry and water-tight sheds and shall be stacked to a height of not more than eight bags. Wherever bulk storage containers are used, their capacity should be sufficient to cater to the requirement at site. The containers shall be Cleaned at least once every 3 months.

Cement shall be used in the sequence in which it is delivered at site. Each consignment shall be stored separately so that it may be readily identified and inspected. Any consignment or part of a consignment of cement which has deteriorated in any way during storage, shall not be used in the works and shall be removed from the site by the Contractor at his own cast. The Contractor shall prepare and maintain proper records at site in respect of delivery, handling, storage and use of cement and these records shall be available for inspection by the Engineer at all times.

The Contractor shall submit a monthly return to the Engineer showing the quantities of cement received and issued during the month and in stock at the end of the month.

3.15.5 Reinforcement The reinforcement bars, shall be stored above the surface of the ground upon platforms, skids or other supports, and shall be protected from mechanical injury and from deterioration by exposure.

3.15.6 Water Water shall be stored in containers/tanks covered at top and cleaned at regular intervals in order to prevent intrusion of foreign matter or growth) of organic matter. Use of water from shallow, muddy or marshy sources, shall not be permitted. The intake pipe shall be suitably enclosed to exclude silt, mud, grass and other solid materials and there shall be a minimum depth of 0.60 m of water below the intake at all times.

3.16 TESTS AND STANDARD OF ACCEPTANCE In case of imported cement, the same series of tests shall be carried out before acceptance. All materials, even though stored in an approved manner shall be subjected to an acceptance test in accordance with the relevant IS specification prior to their immediate use. Independent testing of cement for every consignment shall be done by the Contractor at site or in the laboratory approved by the Engineer before use. Any cement with lower quality than that shown in manufacturer's certificate shall be debarred from use

3.16.1 Testing and Approval of Material The Contractor shall furnish test certificates from the manufacturer/supplier of materials along with each batch of material(s) delivered to site.

The Contractor shall set up a field laboratory with necessary equipment for testing of all materials, finished products used in the construction as per requirements of conditions of contract and the relevant specifications. The testing of all the materials shall be carried out by the Engineer for which the shall make all the necessary arrangements and bear the entire cost.

UPID

Test which cannot be carried out in the field laboratory have to be got done at the Contractor's cost at any recognized laboratory/testing establishments approved by the Engineer.

3.16.2 Sampling of Materials Samples provided to the Engineer for inspection are to be in labelled boxes suitable for storage.

Samples required for testing and approval must be supplied well in advance by at least 48 hours or before the minimum period required for carrying out the relevant tests. Delay to works arising from the late submission of samples, will not be acceptable as a reason for delay in completion of the works.

If materials are brought from abroad, the cost of sampling/testing whether in India or abroad shall be borne by the Contractor.

3.16.3 Rejection of Materials not Conforming to the Specifications. Any stack or batch of material(s) of which sample(s) does (do).not conform to the prescribed tests and quality shall be rejected by the Engineer and such materials shall be removed from site by the Contractor at his own cost. Such rejected materials shall not be made acceptable by any rectifications.

3.16.4 Testing and Approval of Plant and Equipment All plants and equipment used for preparing, testing and production of materials for incorporation into the permanent works, shall be in accordance with manufacturer's specifications and shall be got approved by the Engineer before use.

UPID

BRICK MASONRY

4.1 DESCRIPTION This work shall consist of construction of structures with bricks jointed together by cement mortar, in accordance with the details shown on the drawings or as approved by the Engineer.

4.2 MATERIALS All materials to be used in the work shall conform to the requirements laid down in Section 3.0 of the specifications.

4.3 PERSONNEL Construction of brick work shall be carried out only by masons having sufficient experience/ training in the work.

4.4 CEMENT MORTAR

4.4.1 Proportioning and Mixing of Mortar

Cement and sand shall be mixed in specified proportions given on the drawings. Cement shall be proportioned by weight, taking the unit weight of cement as 1.44 tonne per cubic metre. Sand shall be proportioned by volume with due allowance for bulking. All mortar shall be mixed with a minimum quantity of water to produce desired workability consistent with· required density. The mix shall be clean and free from soil, acid, alkali, organic matter or other deleterious substances.

The mixing shall be done in a mechanical mixer operated manually or by power. As an exception, and mixing can also be resorted to as long as uniform density of the mix and its strength are assured. Hand mixing shall be permitted only for very small and isolated works like canal structures works, subject to the prior approval of the Engineer. Hand mixing shall be carried out on clean watertight platform, where cement and sand shall be first mixed dry in the required proportion by being turned over and over, backwards and forwards, several times till the mixture is of uniform colour. Thereafter, minimum quantity of water shall be added to bring the mortar to the consistency of a stiff paste. The mortar shall be mixed for at least two minutes after addition of water.

Mortar shall be mixed only in such quantity as required for immediate use. The mix which

has developed initial set shall not be used. Initial set of mortar with ordinary Portland Cement

shall normally be considered to have taken place in 30 minutes after mixing. In case the

mortar has stiffened during initial setting time because of evaporation of water, it can be re-

tempered by adding water as frequently as needed to restore the requisite consistency, but

such re-tempering shall not be permitted 30 minutes after mixing. Mortar remaining unused

for more than 30 minutes after mixing, shall be rejected and removed from site of work.

4.4.2 Testing of Mortar Necessary tests to determine compressive strength of the mortar, its consistency and water resistivity shall be carried out in accordance with IS:2250. For compressive strength tests, the frequency of testing shall be 1 cube for every 2 cu m of mortar, subject to a minimum of work.

4.5 SOAKING OF BRICKS

UPID

All bricks shall be thoroughly soaked in a tank filled with water for a minimum period of one hour prior to being laid. Soaked bricks shall be removed from the tank sufficiently in advance so that they are skin dry at the time of actual laying. Such soaked bricks shall be stacked at a clean place where they are not contaminated with dirt, earth, etc.

4.6 JOINTS The thickness of joints shall not exceed 10 mm. All joints on exposed faces shall be tooled to give concave finish.

4.7 LAYING All brickwork shall be laid in an English bond, even and true to line, plumb and level and all joints accurately kept In accordance with the drawing or as directed by the Engineer. Half and cut bricks shall not be used except when necessary to complete the bond. Closer in such cases shall be cut to the required size and used near the ends of the walls. The bricks used at the face and also at all angles forming the junction of any two walls shall be selected whole bricks of uniform size, with true and rectangular faces.

All bricks shall be laid with frogs up on a full bed of mortar except in the case of tile bricks. Each brick shall be properly bedded and set in position by slightly pressing while laying, so that the mortar gets into all its surface pores to ensure proper adhesion. All head and side joints shall be completely filled by applying sufficient mortar to brick already placed and on brick to be placed. All joints shall be properly flushed and packed with mortar so that no hollow spaces are left. No bats or cut bricks shall be used except to obtain dimensions of the different courses for specified bonds or wherever a desired shape so requires.

The brick work shall be built in uniform layers and for this purpose, wooden straight edge with graduations indicating thickness of each course including joint shall be used. Corners and other advanced work shall be raked back. Brickwork shall be done true to plumb or in specified batter. All courses shall be laid truly horizontal, and vertical joints shall be truly vertical. Vertical joints in alternate courses shall come directly one over the other. During construction, no part of work shall rise more than one metre above the general construction level, to avoid unequal settlement and improper jointing. Where this is not possible, the work shall be raked back according to the bond (and not toothed) at an angle not steeper than 45 degree with prior approval of the Engineer. Toothing may also be permitted where future extension is contemplated.

Before laying bricks in foundation, the foundation slab shall be thoroughly hacked, swept clean and wetted. A layer of mertar net less than 12 mm thick shall be spread on the surface of the foundation slab before the first course of bricks is laid.

4.8 JOINTING OLD AND NEW WORK Where fresh masonry is to join with masonry that is partially/entirely set, the exposed jointing surface of the set masonry shall be cleaned, roughened and wetted, so as to achieve the best possible bend with the new work. All loose bricks and mortar or other material shall be removed.

In the case of vertical or inclined joints, it shall be further ensured that proper bond between the old and new masonry is obtained by interlocking the bricks. Any portion of the brickwork that has been completed shall remain undisturbed until thoroughly set. UPID

In case of sharp corners specially in skew bridges, a flat cutback of 100 mm shall be provided so as to have proper and bonded laying of bricks.

4.9 CURING Green work shall be protected from rain by suitable covering and shall be kept constantly moist on all faces for a minimum period of seven days. Brick work carried out during the day shall be suitably marked indicating the date on which the work was done, so as to keep a watch on the curing period. The top of the masonry work shall be left flooded with water at the close of the day. Watering shall be done carefully so as not to disturb or wash out the green mortar. During hot weather, all finished or partly completed work shall be covered or wetted in such a manner as to prevent rapid drying of the brickwork.

During the period of curing, the brick work shall be suitably protected from all damages. At the close of day's work or for other period of cessation, watering and curing shall have to be maintained. Should the mortar perish i.e. become dry, white or powdery through neglect of curing, work shall be pulled down to the extent required and rebuilt as directed by the Engineer. If any stains appear during watering, the same shall be removed-from the surface.

4.10 SCAFFOLDING The scaffolding shall be sound, strong and safe to withstand all loads likely to come upon it. The holes which provide resting space for horizontal members shall not be left in masonry under one metre in width or immediately near the skew backs of arches. The holes left in the masonry work for supporting the scaffolding shall be filled and made good. Scaffolding shall be got approved by the Engineer, but its safety shall be the responsibility of the Contractor.

4.11 EQUIPMENT All tools and equipment used for mixing, transporting and laying of mortar and bricks shall be clean and free from set mortar, dirt or other injurious foreign substances.

4.12 FINISHING OF SURFACES

4.12.1 General All brickwork shall be finished in a workmanlike manner with the thickness of joints, manner of striking or tooling as described in these specifications.

The surfaces can be finished by jointing, pointing or plastering, as shown on the drawings.

For a surface which is to be subsequently plastered or pointed, the joints shall be squarely raked out to a depth of 15 mm, while the mortar is still green. The raked joints shall be well brushed to remove dust and loose particles and the surface shall be thoroughly cleaned and wetted.

4.12.2 Jointing In jointing, the face of the mortar shall be worked out while still green to give a finished surface flush with the face of the brick work. The faces of brick work shall be cleaned to remove any splashes of mortar during the course of raising the brick work.

4.12.3 Pointing Pointing shall be carried out using mortar not leaner than 1:3 by volume of cement and sand or as shown on the drawing. The mortar shall be filled and pressed into the raked joints before giving the required finish. The pointing shall be ruled type for which it shall, while

452 UPID

still green, be ruled along the centre with half round tools of such width as may be specified by the Engineer: The superfluous mortar shall then be taken off from the edges of the lines and the surface of the masonry shall be cleaned of all mortar. The work shall conform to IS: 2212. Raised pointing which projects beyond the face of stone, brick or block shall be avoided.

4.12.4 Plastering Plastering shall be done where shown on the drawing. Superficial plastering may be done, if necessary, only in structures situated in fast flowing rivers or in severely aggressive

environment. Plastering shall be started from top and worked down. All holes shall be properly filled in advance of the plastering, while the scaffolding is being taken down. Wooden screeds 75 mm wide and of the thickness of the plaster shall be fixed vertically 2.5 m to 4 m apart, to act as gauges and guides in applying the plaster. The mortar shall be laid on the wall between the screeds using the plasterer's float and pressing the mortar so that the raked joints are properly filled. The plaster shall then be finished off with a wooden straight edge reaching across the screeds. The straight edge shall be worked on the screeds with a small upward and sideways motion 50 mm to 75 mm at a time. Finally, the surface shall be finished off with a plasterer's wooden float. Metal floats shall not be used.

When re-commencing plastering beyond the work suspended earlier, the edges of the old plaster shall be scraped, cleaned and wetted before plaster is applied to the adjacent areas. No portion of the surface shall be left unfinished for patching up at a later period. The plaster shall be finished true to plumb surface and to the proper degree of smoothness as directed by the Engineer.

The average thickness of plaster shall not be less than that specified. The minimum thickness over any portion of the surface shall not be less than the specified thickness by more than 3mm.

Any cracks which appear in the surface and all portions which sound hollow when tapped, or are found to be soft or otherwise defective, shall be cut in rectangular shape and re-done as directed by the Engineer.

4.12.5 Curing of Finishes Curing shall be commenced as soon as the mortar used for finishing has hardened sufficiently so as not to be damaged during curing. The curing shall be done for a period of at least 7 days, during which the finishing shall be suitably protected from all damages.

4.12.6 Scaffolding for Finishes

Stage scaffolding independent of the structure, shall be provided for the work of finishing.

4.13 COPING FOR WING/RETURN/PARAPET WALL

This work shall consist of providing an architectural coping for wing/return/parapet walls.

The material used shall be cement mortar 1:3 or as shown on the drawings. The cement mortar shall be laid evenly to an average thickness of 15 mm to the full width of the top of the wall and in a band of 150 mm depth along the top outer face of the walls.

4.14 ACCEPTANCE OF WORK All work shall be true to lines and levels as indicated on the drawing or as directed by the Engineer, subject to tolerances as indicated in these specifications.

453 UPID

Mortar cubes shall be tested in accordance with IS: 2250 for compressive strength, consistency of mortar and its water receptivity. The frequency of testing shall be one sample for every 2 cubic metres of mortar subject to a minimum 3 samples for a day's work. In case of plaster finish, the minimum surface thickness shall not be less than the specified thickness by more than 3 mm.


4.15.1 All brick work shall be measured in cubic metres.Any extra work done by the Contractor in excess of the specified dimensions, shall be Ignored.

4.15.2 In arches, the length of arch shall be measured as the average of the lengths along the extrados and the intrados.

4.15.3 The work of plastering and pointing shall be measured in square metres of the surface treated.

4.15.4 Coping shall be measured in linear metres.

4.16 RATE

4.16.1 The contract unit rate for brick work shall include the cost of all labour, materials, tools and plant, scaffolding and other expenses incidental to the satisfactory completion of the work, sampling, testing and supervision as described in these specifications and as shown on the drawings.

4.16.2 The contract unit .rate for plastering shall include the cost of all labour, materials, tools and plant, scaffolding and all incidental expenses, sampling, testing and supervision, as described in these specifications.

4.16.3 The contractunit rate for pointing shall include erecting and removal of scaffolding, all

labour, materials, and equipment incidental to completing the pointing, raking out

joints, cleaning, wetting, filling with mortar, trowelling, pointing and watering,

sampling and testing and supervision as described in these specifications.

4.16.4 The contract unit rate for coping shall include cost of all labour, materials, tools and plant, sampling and testing and supervision as described in these specifications.

454 UPID

Section VII: Works Requirements

FORMWORK 5.1 DESCRIPTION Formwork shall include all temporary or permanent forms required for forming the concrete of the shape, dimensions and surface finish, as shown .on the drawing or as directed by the Engineer, together with all props, staging, centering, scaffolding and temporary construction required for their support.

5.2 MATERIALS Materials and components used for formwork shall be examined for damage or excessive deterioration before use/re-use and shall be used only if found suitable after necessary repairs. In case of timber formwork, the inspection shall not only cover physical damages but also signs of attacks by decay, rot or insect attack or the development of splits. Forms shall be constructed with metal or timber. The metal used for forms shall be of such thickness that the forms remain true to shape. All bolts should be countersunk. The use of approved internal steel ties or steel or plastic spacers shall be permitted. Structural steel tubes used as support for forms shall have a minimum wall thickness of 4 mm. Other materials may also be used if approved by the Engineer.

5.3 DESIGN OF FORMWORK

5.3.1 The design, erection and removal of formwork shall conform to "Guidelines for Formwork, False work and Temporary Structures" and these specifications. The forms shall be such as to ensure that they can be conveniently removed without disturbing the concrete. The design shall facilitate proper and safe access to all parts of formwork for inspection.

5.3.2 The Contractor shall furnish the design and drawing of complete formwork (i.e. the forms as well as their supports) for approval of the Engineer before .any erection is taken up. If proprietary system of formwork is used, the Contractor shall furnish detailed information to the Engineer for approval. Notwithstanding any approval or review of drawing and design by the Engineer, the Contractor shall be and safety of formwork entirely responsible for the adequacy

5.4 WORKMANSHIP 5.4.1 The formwork shall be robust and strong and the joints shall be leak-proof Ballies

shall not be used as staging. Staging must have cross bracings and diagonal bracings in both directions. Staging shall be provided with an appropriately designed base plate resting on firm strata.

5.4.2 The number of joints in the formwork shall be kept to a minimum by using large sized panels. The design shall provide for proper "soldiers" to facilitate alignment. All joints shall be leak proof and must be properly sealed. Use of PVC joint sealing tapes, foam rubber or PVC T-section 1 is essential to prevent leakage of grout.

5.4.3 As far as practicable, clamps shall be used to hold the forms together. Where use of nails is unavoidable, minimum number of nails shall be used and these shall be of the double-headed type. Alternatively, if the nails are of the normal type, they shall be left partially projecting without being driven to their full length, so that they can be withdrawn easily.

455 UPID


5.4.4 Use of ties shall be restricted, as far as practicable. Wherever ties are used they shall be used with HDPE sheathing so that they can easily be removed. No parts prone to corrosion shall be left projecting or near the surface. The sheathing shall be grouted with cement mortar of the same strength as that of the structure.

5.4.5 Unless otherwise specified, or directed, chamfers or fillets of size 25 mm x 25 mm shall be provided at all angles of the formwork to avoid sharp corners. The chamfers, beveled edges and mouldings shall be made in the formwork itself. Opening for fixtures and other fittings shall be provided in the shuttering as directed by the Engineer.

5.4.6 Shuttering for walls, sloping members and thin sections of considerable height shall be provided with temporary openings to permit inspection and cleaning out before placing of concrete.

5.4.7 The formwork shall be constructed with pre-camber to the soffit to allow for deflection of the formwork. This shall be in addition to the pre-camber for the permanent structure as shown on the drawings.

5.4.8 Where centering trusses or launching trusses are adopted for casting of superstructure,

the joints of the centering trusses, whether welded, riveted or bolted shall be

thoroughly checked periodically. Also, various members of the centering trusses

should be periodically examined for proper alignment and unintended deformation

before proceeding with the concreting. They shall also be periodically checked for any

deterioration in quality due to steel corrosion. Launching truss, casting truss of span

more than 40 m and travelling forms, shall be load tested before they are put.to use.

5.4.9 The formwork shall be so made as to produce a finished concrete true to shape, line and levels and dimensions as shown on the drawings, subject to the tolerances specified in respective Sections of these specifications, or as directed by the Engineer·

5.4.10 Where metal forms are used, all bolts and rivets shall be countersunk and well ground to provide a smooth, plane surface. Where timber is used it shall be well seasoned, free from loose knots, projecting nails, splits or other defects that may mar the surface of concrete.

5.4.11 Forms shall be made sufficiently rigid by the use of ties and bracings to prevent any displacement or sagging between supports. They shall be strong enough to withstand all pressure, ramming and vibration during and after placing the concrete. Screw jacks or hard wood wedges where required shall be provided to make up any settlement in the formwork either before .or during the placing of concrete.

5.4.12 The formwork shall ensure the correct final shape of the structure, with the calculated amount of positive or negative camber. The deformation of false work, scaffolding or propping and the instantaneous or deferred deformation due to various causes arising in prestressed structures shall be properly accounted for.

456 UPID


5.4.13 Suitable camber shall be provided to horizontal members of structure, specially in long

spans, to counteract the effects of deflection. The formwork shalt be so fixed as to provide for such camber.

5.4.14 The formwork shall be coated with an approved release agent that will effectively prevent sticking and will not stain the concrete surface. Lubricating oils (machine oils) shall be prohibited for use as coating.

5.5 LINING OF FORMWORK The formwork shall be lined with material approved by the Engineer so as to provide a smooth finish of uniform texture and appearance. This material shall leave no stain on the concrete and shall be so fixed to its backing as not to impart any blemishes. It shall be of the same type and obtained from only one source throughout for the construction of any one structure. The contractor shall make good any imperfections in the resulting finish as required by the Engineer. Internal ties and embedded metal parts shall be carefully detailed and their use shall be subject to the approval of the Engineer.

5.6 PRECAUTIONS

The following precautions shall be observed: It shall be ensured that any cut-outs or openings provided in any structural member to facilitate erection of formwork are closed with the same grade of concrete as that of the structure, after formwork is removed. Provision for safe access to the formwork shall be made at all levels as required. Close watch shall be maintained to check for settlement of formwork during concreting and any settlement shall be promptly rectified. Natural ground shall be checked for bearing capacity and likely settlement before erection of the staging. For shutters used for deep and narrow member, temporary openings in the sides shall be provided to facilitate pouring and compaction of concrete.

5.7 PREPARATION OF FORMWORK BEFORE CONCRETING The inside surfaces of forms shall, except in the case of permanent formwork or where otherwise agreed to by the Engineer, be coated with a release agent supplied by approved manufacturer or of an approved material to prevent adhesion of concrete to the formwork. Release agents shall be applied strictly in accordance with the manufacturer's instructions and shall not be allowed to come in contact with any reinforcement or prestressing tendons and anchorages. Different release agents shall not be used in formwork for exposed concrete.

Before re-use of forms, the following actions shall be taken:

The contact surfaces of the forms shall be cleaned carefully and dried before applying a release agent.

It should be ensured that the release agent is appropriate to the surface to be coated. The

same type and make of release agent shall be used throughout on ·similar formwork materials and different types should not be mixed.

The form surfaces shall be evenly and thinly coated with release agent. The vertical

surface shall be treated before horizontal surface and any excess wiped out.

457 UPID


It shall be ensured that the reinforcement or the surface of the hardened concrete shall not

come in contact with the release agent.

All forms shall be thoroughly cleaned immediately before concreting.

The Contractor shall give the Engineer due notice before placing any concrete in the forms to permit him to inspect and approve the formwork. However, such inspection shall not relieve the contractor of his responsibility for safety of formwork, men, machinery, materials and finish or tolerances of concrete.

5.8 REMOVAL OF FORMWORK The scheme for removal of formwork (i.e. de-shuttering and de-centering) shall be planned in advance and furnished to the Engineer for scrutiny and approval. No formwork or any part thereof shall be removed without prior approval of the Engineer.

The formwork shall be so removed as not to cause any damage to concrete. Centering shall be gradually and uniformly lowered in such a manner as to permit the concrete to take stresses due to its own weight uniformly and gradually to avoid any shock or vibration.

Form work shall not be released unless the concrete has achieved strength of at least twice the stress the concrete may be subjected at the time of the removal of formwork. When no test is conducted for determination of strength of concrete and where the lime of removal of formwork is not specified the same shall be as under:

a) Walls, piers, abutments, columns and vertical faces 12 to 48 hours as may be

of structural members decided by the Engineer

b) Soffits of Slabs (with props left under) 3 days

c) Props left under slabs 14 days

d) Soffits of Girders (with props left under 7 days

e) Props (left under girders) 21 days

The above time schedule is applicable when ordinary Portland Cement is used without any admixtures at an ambient temperature exceeding 10°C

For concrete made with Portland pozzolona cement, Portland slag cement or mineral admixtures, additional cube samples shall be taken for verifying the strength of concrete to decide the time of deshuttering.

Where there are re-entrant angles in the concrete sections, the formwork should be removed at these sections as soon as possible after the concrete has set, in order to avoid cracking due to shrinkage of concrete.

5.9 RE-USE OF FORMWORK When the formwork is dismantled, its individual components shall be examined for damage and damaged pieces shall be removed for rectification. Such examination shall always be carried out before their use again. Before re-use all components shall be cleaned of deposits of soil, concrete or other unwanted materials. Threaded parts shall be oiled after cleaning.

458 UPID


All bent steel props shall be straightened before re-use. The maximum permissible deviation from straightness is 1/600 of the length. The maximum permissible axial loads in used props shall be suitably reduced depending upon their condition. The condition of the timber components, plywood and steel shuttering plates shall be examined closely for distortion and defects before re-use. 5.10 SPECIALISED FORMWORK Specialised formwork such as slip form, wherever used shall be designed and detailed by competent agencies and a set of complete working drawings and installation instructions supplied to the Engineer. In case proprietary equipment is used, the supplier shall furnish drawings, details, installation instructions etc, in the form of manuals along with the formwork.

For slipforrn, the rate of climb of the formwork shall be designed for each individual case taking into account various parameters ·including the grade of concrete, concrete strength, · concrete temperature, ambient temperature and concrete admixtures In order to verify the time and sequence of striking/removal of specialised formwork, routine field tests· for the consistency and strength development of concrete are mandatory. For specialised formwork, the form lining material may be either plywood or steel sheet of appropriate thickness. 5.11 TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. 5.12 MEASUREMENTS FOR PAYMENT Unless stated otherwise, the rate for concrete in plain concrete or reinforced concrete or prestressed concrete, shall be deemed to include all formwork required in accordance with this Section, which shall not be measured separately. Where it is specifically stipulated in the Contract that the formwork shall be paid for separately, measurement of formwork shall be taken in square metres of the surface area of concrete which is in contact with formwork.

5.13 RATE The unit rate of plain. concrete or reinforced concrete or prestressed concrete as defined in respective Sections of these Specifications, shall be deemed to cover the costs of all formwork and staging, including cost of all materials, labour, tools and plant required for design, construction and removal of formwork and supervision as described in this Section including properly supporting the members until the concrete is cured, set and hardened as required.

Where the contract unit rate for formwork is specially provided as a separate item in the contract, it shall include the cost of all materials, labour, tools and plant required for design, construction and removal of formwork and supervision as described in this Section including properly supporting the members until the concrete is cured, set and hardened as required

459 UPID


STEEL REINFORCEMENT

6.1 DESCRIPTION This work shall consist of furnishing and placing coated or uncoated mild steel or high strength deformed reinforcement bars of the shape and dimensions shown on the drawings and conforming to these Specifications or as approved by the Engineer.

6.2 GENERAL Steel for reinforcement shall meet the requirements of Section 3.0 of these Specifications. Reinforcement may be either mild steel or high strength deformed bars. They may be uncoated or coated with epoxy.

6.3 PROTECTION OF REINFORCEMENT Uncoated reinforcing steel shall be protected from rusting or chloride contamination. Reinforcements shall be free from rust mortar, loose mill scale, grease, oil or paints. This may be ensured either by using reinforcement fresh from the factory or by thoroughly cleaning it using any suitable method such as sand blasting, mechanical wire brushing etc., as directed.by the Engineer. Reinforcements shall be stored above the ground in a clean and dry condition, on blocks, racks or platforms and shall be suitably marked to facilitate inspection and identification.

Portions of uncoated reinforcing steel and dowels projecting from concrete shall be protected within one week after initial placing 'pf concrete, with a brush coat of neat cement mixed with water to a consistency of thick paint. This coating shall be removed by lightly tapping with a hammer or other tool not more than one week before placing of the adjacent pour of concrete. Coated reinforcing steel 1all be protected against damage to the coating. If the coating on the bars is damaged during transportation or handling and cannot be repaired, the same shall be rejected.

6.4 BENDING OF REINFORCEMENT Bar bending schedule shall be furnished by the Contractor and got approved by the Engineer before start of work.

Reinforcing steel shall conform to the dimensions and shapes given in the approved Bar Bending Schedules.

Bars shall be bent cold to the specified shape and dimensions or as directed by the Engineer using a proper bar bender, operated by hand or power to obtain the correct shape and radii of bends.

Bars shall not be bent or straightened in a manner that will damage the parent material or the coating.

Bars bent during transport or handling shall be straightened before being used on work. They shall not be heated to facilitate straightening.

460 UPID


6.5 PLACING OF REINFORCEMENT The reinforcement cage should generally be fabricated in the yard at ground level and

then shifted and placed in position. The reinforcement shall be placed strictly in accordance with the drawings and shall be assembled in position only when the structure is otherwise ready for placing of concrete. Prolonged time gap between assembling of reinforcement and casting of concrete, which may result in rust formation on the surface of the bars, shall not be permitted.

Reinforcement bars shall be placed accurately in position as shown on the drawings. The bars, crossing one another shall be tied together at every intersection with binding wire (annealed), conforming to IS:280 to make the skeleton of the reinforcement rigid such that the reinforcement does not get displaced during placing of concrete, or any other operation. The diameter of binding wire shall not be less than 1 mm.

Bars shall be kept in position usually by the following methods:

In case of beam and slab construction, industrially produced polymer cover blocks of thickness equal to the specified cover, shall· be placed between the bars and formwork, subject to satisfactory evidence that the polymer composition is not harmful to concrete and reinforcement. Cover blocks made of concrete may be permitted by the Engineer, provided they have the same strength and specification as those of the member.

In case of dowels for columns and walls, the vertical reinforcement shall be kept in position by means of timber templates with slots cut in them accurately, or with cover blocks tied to the reinforcement. Timber templates shall be resolved after the concreting has progressed upto a level just below their location. Layers of reinforcements shall be separated by spacer bars at approximately one metre intervals. The minimum diameter of spacer bars shall be 12 mm or equal to maximum size of main reinforcement or maximum size of coarse aggregate, whichever is greater. Horizontal reinforcement shall not be allowed to sag between supports.

Necessary stays, blocks, metal chairs, spacers, metal hangers, supporting wires

etc. or other subsidiary reinforcement shall be provided to fix reinforcement firmly in its correct position.

Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks etc.,

as devices for positioning reinforcement shall not be permitted.

Bars coated with epoxy shall be placed on supports that do not damage the coating. Supports shall be installed in a manner such that planes of weakness are not created in hardened concrete. The coated reinforcing steel shall be held in place by use of plastic or plastic coated binding wires especially manufactured for the purpose.

Placing and fixing of reinforcement shall be inspected and approved by the Engineer before concreting is commenced.

461 UPID


6.6 BAR SPLICES

6.6.1 Lapping

All reinforcement shall be furnished.in full lengths as indicated on the drawing. No splicing of bars, except where shown on the drawing, shall be permitted without approval of the Engineer. The lengths of the splice shall be as indicated on drawing or as approved by the Engineer. Where practicable, overlapping bars shall not touch each other, and shall be kept apart by 25 mm or 1.25 times the maximum size of coarse aggregate, whichever is greater. If this is not feasible, overlapping bars shall be bound with annealed steel binding wire not less than 1 mm diameter and twisted tight in such a manner as to maintain minimum clear cover to the reinforcement from the concrete surface. Lapped splices shall be staggered or located at points along the span where stresses are low.

6.6.2 Welding

6.6.2.1 Splicing by welding of reinforcement will be permitted only if detailed on the drawing or approved by the Engineer. Weld shall develop an ultimate strength equal to or greater than that of the bars connected.

6.6.2.2 While welding may be permitted for mild steel reinforcing bars conforming to IS:432, welding of deformed bars conforming to IS:1786 shall in general be prohibited. Welding may be permitted in case of bars of other than Fe 240 grade including special welding grade of Fe 415 grade bars conforming to IS:1786, for which necessary chemical analysis has been secured and the carbon equivalent (CE) calculated from the chemical composition using the formula :

CE = C + Mn + Cr+Mg+V + Ni+cu

6 5 5

is 0.4 or less.

6.6.2.3 The method of welding shall conform to IS:2751 and IS:9417 and any supplement specifications to the satisfaction of the Engineer.

Welding may be carried out by metal arc welding process. Oxy-acetelene welding shall not be permissible. Any other process may be used subject to the approval of the Engineer and necessary additional requirements to ensure satisfactory joint performance. Precautions on overheating, choice of electrode, selection of correct current in arc welding etc., should be strictly observed.

All bars shall be butt welded except for smaller diameter bars (diameter of less than 20 mm) which may be lap welded. Single-V or Double-V butt joints may generally be used. For vertical bars single bevel or double bevel joints may be used.

Welded joints shall be located well away from bends and shall be not less than twice the bar diameter away from a bend.

Generally, shop welding in controlled conditions is to be preferred, where feasible. Site welding where necessary shall, however, be permitted when the facilities, equipment, process, consumables, operators and welding procedure, are adequate to produce and maintain uniform quality at par with that attainable in shop welding, to the satisfaction of the Engineer.

462 UPID


Joint welding procedures which are to be employed shall invariably be established by a procedure specification. All welders and welding operators to be employed shall be qualified by tests prescribed in IS: 2751. Inspection of welds shall conform to IS: 822 and destructive or non-destructive testing may be undertaken when deemed necessary. Joints with weld defects detected by visual inspection or dimensional check inspection shall not be accepted.

Suitable means shall be provided for holding the bars securely in position during welding. It must be ensured that no voids are left in welding. When welding is done in two or three stages, the surface shall be cleaned properly after each stage. Bars shall be cleaned of all loose scale, rust, grease, paint and other foreign matter before carrying out welding. Only competent and experienced welders shall be employed on the work with the approval of the Engineer. No welding shall be done on coated bars.

M.S. electrodes used for welding shall conform.to IS: 814

6.6.2.4 Weldedjoints shall preferably be located at points where steel will not be subject to more than 75 percent of the maximum permissible stresses and welds so staggered that at anyone section, not more than 20 percent of the bars are welded.

6.6.2.5 Specimens of welded pieces of reinforcement taken from the site, shall be tested. The number and frequency of tests shall be as directed by the Engineer.

6.7 TESTING AND ACCEPTANCE The material shall be tested in accordance with relevant IS specifications and necessary test certificates shall be furnished. Additional tests, if required, will be got carried out by the Contractor at his own cost.

The supply, fabrication and placing of reinforcement shall be in accordance with these Specifications and shall be as checked and accepted by the Engineer.

Manufacturer's test certificate regarding compliance with Indian Standards for each lot of steel, shall be obtained and submitted to the Engineer. If required by the Engineer, the Contractor shall carry out confirmatory test in the presence of a person authorized by the Engineer. Cost of these tests shall be borne by the Contractor. The sampling and testing procedure shall be as laid down in IS: 1786 if any test piece selected from a lot fails, no re-testing shall be done and the lot shall be rejected.

6.8 MEASUREMENT FOR PAYMENT Reinforcement shall be measured in length including hooks, if any, separately for different diameters as actually used in work, excluding overlaps. From the length so measured, the weight of reinforcement shall be calculated in tonnes on the basis of IS:1732. Wastage, overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and annealed steel wire or other methods for binding and placing, shall not be measured and cost of these items shall be deemed to be included in the rate for reinforcement.

6.9 RATE The contract unit rate for coated/uncoated reinforcement shall cover the cost of material, royalty, fabricating, transporting, storing, bending, placing, binding and fixing in position as

463 UPID


shown on the drawings and as per these Specifications and as directed by the Engineer, including all labour, equipment, supplies, incidentals, sampling, testing and supervision. The unit rate for coated reinforcement shall be deemed to also include cost of all material, labour, tools and plant, royalty, transportation and expertise required to carry out the coating work as well as sampling, testing and supervision required for the work.

464 UPID


STRUCTURAL CONCRETE

7.1 DESCRIPTION The work shall consist of producing, transporting, placing and compacting of structural concrete including fixing formwork and temporary works etc. and incidental construction in accordance with these Specifications and in conformity with the lines, grades and dimensions, as shown on the drawings or as directed by the Engineer

7.2 MATERIALS

All materials shall conform to Section 3.0 of these Specifications.

7.3 GRADES OF CONCRETE

7.3.1 The grades of concrete shall be designated by the characteristic strength as given in Table 7.1 where the characteristic strength is defined as the strength of concrete below which not more than 5 percent of the test results are expected to fall.

Table 7.1: Grades of Concrete Type of Concrete/Grade Designation

Nominal High Performance Characteristic

Mix Standard Concrete Concrete Strength in MPa

concrete

M15 M15 15

M20 M20 20

M25 25

M30 M30 30

.. M40 M35 35

M45 M40 40

M50 M45 45

M50 50

M55 55

M60 60

M65 65

M70 70

M75 75

M80 80

M85 85

M90 90 Normal Mix Concrete is made on the basis of nominal mix proportioned by weight of its

main ingredients - cement, coarse and fine aggregates and water

Standard concrete is made on the basis of design mix proportioned by weight of its

ingredients, which in addition to cement, aggregates and water, may contain chemical admixtures to achieve certain target values of various properties in fresh condition, achievement of which is monitored and controlled during production by suitable tests. Generally, concrete of grades up to M50 are included in this type.

465 UPID


High Performance Concrete is similar to standard concrete but contains additional one or more mineral admixtures providing binding characteristics and partly acting as inert filler material which increases its strength, reduces its porosity and modifies its other properties in fresh as well as hardened condition. Concrete of grades upto M90 are included in this type.

For concrete of grades higher than M90, the design parameters may be obtained from

specialized literature and experimental results.

7.3.2The minimum grades and maximum water/cement in Table 7.2.

of concrete and corresponding minimum cement content ratios for different exposure conditions shall be as indicated

7.3.3For concrete subjected to sulphate attack the minimum grades of concrete, minimum cement content and maximum water/cement ratios and cement for different, concentration of sulphate content shall be as indicated in Table 7.2.

Table 7.2: Requirement of Concrete for Different Exposure Condition using 20 mm Aggregate

Exposure Condition

Maximum Water MinimumCement Minimum Grade Cement Ratio Content, kg/m3 of Concrete

Moderate 0.45 340 M25

Severe 0.45 360 M30

Very Severe 0.40 380 M40

Note: All three provisions given in the above table for a particular exposure condition shall be

satisfied.

The term cement for maximum w/c ratio and minimum cement content shown in Table

includes all cementitious materials. The maximum limit of flyash and ground granulated blast furnace slag in the blended cement shall be as specified in IS:1489 (Part 1) and IS:455 respectively.

For plain cement concrete, with or without surface reinforcement, the minimum grade of

concrete can be lowered by 5 MPa and maximum water/cement ratio exceeded by 0.05

Cement content shown in the above table shall be increased by 40 kg/m3 for use of 12.50 mm nominal size aggregates and decreased by 30 kg/m3 for use of 40 mm nominal size aggregates.

466 UPID


Table 7.3: Requirement of Concrete Exposed to Sulphate Attack

Concentration of Sulphates as SO Minimum

Maximum

In Soils

In Ground

Minimum Grade of Type of Water/

Water, g/1 Cement Concrete

Total SO,,% so, in 2:1

Class Cement Cement

Content,

Water: Soil

(Note ii) Ratio

kg/m'

Extract, gn

-OPC,

1) Traces < 1.0 < 0.3 PPGor 280 0.5 M25

PSC

-OPC,

2) 2.0 to 0.5 1.0 to 1.9 0.3 to 1.2 PPCor 330 0.5 M25 PSC

-SRPC

-SRPC, 330 0.5 M25

3) 0.510 1.0 1.9 to 3.1 1.2 to 2.5 -PPC or

PSC 350 0.45 M30

4) 1.0 to 2.0 3.1 to 5.0 2.5to 5.0 -SRPC 370 0.45 M35

-SRPC

5) >2',0• >5.0

>5.0

with

400 0.4 M40

protective

coatings

Note: If the requirements of maximum water/cement ratio, minimum grade of concrete minimum cement content from other durability considerations as given in Table 7.2 are more stringent than those given in this table, then the former will govern.

OPC: Ordinary Portland Cement, PPC: Portland Pozzolona Cement. PSC: Portland Slag

Cement, SRPC: Sulphate Resisting Portland Cement.

The minimum cement content shall be as low as possible but not less than the quantities specified in Table 7.2 and 7.3.

The maximum cement-content excluding any mineral admixtures (Portland cement component alone) shall not exceed 450 kg/cu.m.

7.3.4 Concrete used in any component or structure shall be specified by designation along with prescribed method of design of mix i.e. Design `Mix or Nominal Mix’. For all items of concrete, only design mix shall be used, except where nominal mix concrete is permitted as per drawing or by the Engineer. Nominal mix may be permitted only for minor works or other incidental construction, where strength requirements are upto M20 only. Nominal mix may also be permitted for non-structural concrete or for screed below open foundations.

467 UPID


7.3.5 If the Contractor so proposes, the Engineer may permit the use of concrete of higher grade than that specified on the drawing, provided the higher grade concrete meets the specifications applicable. The additional cost of such higher grade concrete shall be borne by the Contractor.

7.4 PROPORTIONING OF CONCRETE Prior to the start of construction, the Contractor shall design the mix in case of design mix concrete or propose nominal mix in case of nominal mix concrete, and submit to the Engineer for approval, the proportions of materials, including admixtures to be used. Water-reducing admixtures' (including plasticisers or super-plasticisers) may be used at the Contractor's option, subject to the approval of the Engineer.

7.4.1 Requirements of Consistency The mix shall have the consistency which will allow proper placement and compaction in the required position. Every attempt shall be made to obtain uniform consistency. Slump test shall be used to measure consistency of the concrete.

The optimum consistency for various types of structures shall be as indicated in Table 7.4 or as directed by the Engineer. The slump of concrete shall be checked as per IS: 516

Table 7.4: Requirements of Consistency

Slump (mm) (at the

Type Time of Placing of Concrete)

1) a) Structure with exposed inclined surface requiring low 25

slump concrete to allow proper compaction

b) Plain cement concrete 25

2) RCC structure with widely spaced reinforcements; e.g. 40-50

solid columns, piers, abutments, footings, well steining

3) RCC structure with fair degree of congestion of 50-75

reinforcement; e.g. pier and abutment caps, box culverts,

well curb, well cap, walls with thickness greater than 300

mm

4) RCC and PSC structure with highly congested 75-125

reinforcements e.g. deck slab girders, box girders, walls

with thickness less than 300 mm

5) Underwater concreting through tremie e.g. bottom plug, 150-200

cast in-situ piling

Notwithstanding the optimum consistency indicated against Sl. No. 1to 3, the situation should be property assessed to arrive at the desired workability with the adjustment of admixture in each case, where the concrete is to be transported through transit mixer and placed using

468 UPID


concrete pump. Under these circumstances, the optimum consistency during placement for the items of work of Sl. No. 1 to 3, can be considered ranging from 75 mm to 150 mm. This is, however, subject to satisfying the other essential criteria of strength, durability etc. and approval of the Engineer.

7.4.2 Requirements for Design Mixes

7.4.1 Target Mean Strength The target mean strength of specimen shall exceed the specified characteristic compressive strength by at least the current margin.

The current margin for a concrete mix shall be determined by the Contractor and shall be taken as 1:64 times the standard deviation of sample test results taken from at least 40 separate batches of concrete of nominally similar proportions produced at site by the same plant under similar supervision, over a period exceeding 5 days, but not exceeding 6 months. Where there is insufficient data to satisfy the above, the current margin the initial design mix shall be taken as' given in Table 7.5.

Table 7.5: Current Margin for Initial Design Mix

Concrete Grade

Current Margin (MPa)

Target Mean

Strength (MPa)

M15 10 25

M20 10 30

M25 11 36

M30 12 42

M35 12 47

M40 12 52

M45 13 58

M50 13 63

M55 14 69

M60 14 74

M65 15 80

M70 15 85

469 UPID


Concrete Grade

Current Margin (MPa)

Target Mean

Strength (MPa)

M75 15 90

M80 15 95

M85 16 101

M90 16 106

The initial current margin given in Table 7.5 shall be used till sufficient data is available to determine the current margin as per Sub-Clause 7.4.2.1 (i)

7.4.2.2 Trial Mixes The Contractor shall give notice to the Engineer to enable him to be present at the time of carrying out trial mixes and preliminary testing of the cubes. Prior to commencement of trial mix design, all materials forming constituents of proposed design mix should have been tested and approval obtained in writing from the Engineer. Based on test results of material, draft mix design calculation for all grades of concrete to be used in the works, shall be prepared after taking into account the provisions in the Contract Technical Specifications, Guidelines of IS:10262, IS:SP:23 and IRC:112 and submitted to the Engineer for approval. Prior to commencement of concreting, trial mix design shall be performed for all grades of

concrete and trial mix which has been found successful, shall be submitted by the Contractor and approval obtained. During concreting with the approved trial mix design, if source of any constituents is changed, the mix design shall be revised and tested for satisfying the strength requirements.

The initial trial mixes shall be carried out in a laboratory approved by the Engineer. However, Engineer may permit the initial trial mixes to be prepared at the site laboratory of the Contractor, if a full-fledged concrete laboratory has been established well before the start of construction, to his entire satisfaction sampling and testing procedures shall be in accordance with these Specifications. When the site laboratory is utilized for preparing initial mix design, the concrete production plant and means of transport employed to make the trial mixes shall be similar to those proposed to be used in the works. For each trial mix, a set of six cubes shall be made from each of three consecutive batches for purposes of testing. Three cubes from each set of six shall be tested at an age of 28 days and three at an earlier age approved by the Engineer. The cubes shall be made, cured, stored, transported and tested in accordance with these Specifications. The mean strength of the nine cubes at 28 days shall exceed the specified characteristic strength by the current margin minus 3.5 MPa. 7.4.2.3 Control of Strength of Design Mixes

Adjustment to Mix Proportions Adjustment to mix proportions arrived at in the trial mixes, shall be made subject to the Engineer's approval, In order to minimize the variability of strength and to maintain the target mean strength. Such adjustments shall not be

470 UPID


Change of Current Margin When required by the Engineer, the Contractor shall recalculate the current margin in accordance with Clause 7.4.2.1. The recalculated value shall be adopted as directed by the Engineer, and it shall become the current margin for concrete produced thereafter. Additional Trial Mix In case any changes are observed in the properties of fresh concrete and/or strength of hardened concrete on the basis of early age tests, additional mixes and tests shall be carried out during production, so as to control and bring the quality of concrete within acceptable limits. In case of any change in the source or properties of materials, the design of mix shall be established afresh.

7.4.3 Requirements of Nominal Mix Concrete Requirements for nominal mix concrete unless otherwise specified shall be as given in Table 7.6

Table 7.6: Requirements for Nominal Mix Concrete

Maximum

Total Quantity of Dry Aggregate

Quantity proportion of of Water for 50 by Mass per 50 kg of Cement

Concrete Fine to Coarse kg

to be taken as the Sum of

Grade Aggregate (by of Cement Individual Masses of Fine and

Mass) (Litres)

Coarse Aggregates (kg)

PCC RCC

M 15 350 Generally 1:2,25

subject to upper

M20 250 limit 1:1.5 and25 22 lower limit of

1:2.5

471 UPID


7.4.4 Additional Requirements

Concrete shall meet any other requirements as specified on the drawing or as directed by the

Engineer. The overall limits of deleterious substances in concrete shall be as follows: Total acid soluble chloride content in the concrete mix expressed as chloride ions shall not exceed the following values by mass of cement.

Total acid soluble chloride content in the concrete mix expressed as chloride ions shall not exceed the following values by mass of cement.

Prestressed concrete

0.10 percent

Reinforced concrete (in severe, very severe

or extreme exposure condition) 0.20 percent

Reinforced concrete in moderate exposure Condition 0.30 p e r c e n t

The total water soluble sulphate content of the concrete mix expressed as SO3, shall not exceed 4 percent by mass of cement in the mix.

For concrete made with Portland pozzolona cement, Portland blast furnace slag cement or mineral admixtures, the setting time and rate of gain of strength are different from those for concrete made with OPC alone. Such modified properties shall be taken into account while deciding the de-shuttering time, curing period, early age loading and time of prestressing. Additional cube samples may be required to be taken for verifying the concrete properties.

7.4.5 Suitability of Proposed Mix Proportions

The Contractor shall submit the following information for the Engineer’s approval:

Nature and source of each material

Quantities of each material per cubic metre of fully compacted concrete

Either of the following:

Appropriate existing data as evidence of satisfactory previous performance for the target mean strength, current margin, consistency and water/cement ratio and any other additional requirement (s) as specified.

Full details of tests on trial mixes.

Statement giving the proposed mix proportions for nominal mix concrete.

Any change in the source of material or in the mix proportions shall be subject to the Engineer's prior approval.

7.4.6 Checking of Mix Proportions and Water/Cement Ratio In proportioning concrete, the quantity of both cement arid aggregate shall be determined by weight. Where the weight of cement per bag as given by the manufacturer is accepted, a reasonable number of bags shall be weighed separately to check the net weight. Where cement is weighed from bulk stock at site and not by bag, it shall be weighed separately from the aggregates. Water shall either be measured by volume in calibrated tanks or weighed. All measuring equipment shall be maintained in a clean and serviceable condition. Their accuracy shall be periodically checked.

The specified water/cement ratio shall always be kept constant and at its correct value. To this end, moisture content in both fine and coarse aggregates shall be determined as

472 UPID


frequently as possible, the frequency for a given job being determined by the Engineer according to the weather conditions. The amount of water to be added shall then be adjusted to compensate for variations in the moisture content. For the determination of moisture content in the aggregates IS:2386 (Part Ill) shall be referred. Suitable adjustments shall also be made in the weight of aggregates to allow for their variation in weight due to variation in their moisture content.

7.4.7 Grading of Aggregates for Pumped Concrete Materials for pumped concrete shall be batched consistently and uniformly. Maximum size of aggregate shall not exceed one-third of the internal diameter of the pipe. The grading of aggregates shall be continuous and shall have sufficient ultra-fine materials (material finer than 0.25 mm). Proportion of fine aggregates passing through 0.25 mm shall be between 15 and 30 percent and that passing through 0.125 mm sieve shall not be less than 5 percent of the total volume of aggregate. Admixtures to increase workability can be added. When pumping long distances and In hot weather, set-retarding admixtures can be used. Fluid mixes can be pumped satisfactorily after adding plasticisers and super plaslicisers. Suitability of concrete shall be verified by trial mixes and by performing pumping test.

7.5 ADMIXTURES 7.5.1 Chemical Admixtures Chemical admixtures such as superplasticisers, or air entraining, water reducing, accelerating and retarding agents for concrete, may be used with the approval of the Engineer.

As the selection of an appropriate concrete admixture is an integral part of the mix design, the manufacturers shall recommend the use of any one of their products only after obtaining complete information of all the actual constituents of concrete as well as methodologies of manufacture, transportation and compaction of concrete proposed to be used in the work. Admixtures/additives conforming to IS: 9103 may be used subject to approval of the Engineer. However, admixtures/additives generating hydrogen or nitrogen and containing chlorides,

The general requirements for admixtures are given in Clause 3.12 of these Specifications.

Compatibility of the admixtures with the cement and any other pozzolona or hydraulic addition shall be ensured by for avoiding the following problems

Requirement of large dosage of super plasticiser for achieving the desired workability, Excessive retardation of setting,

Excessive entrainment of large air bubbles,

Unusually rapid stiffening of concrete,

Rapid loss of slump

Excessive segregation and bleeding. 7.5.2 Mineral Admixtures

For use of mineral admixtures, refer Clauses 7.1 and 7.2

473 UPID


7.6 SIZE OF COARSE AGGREGATES

The size (maximum nominal) of coarse aggregates for concrete to be used in various components shall be as given in Table 7.7.

Table 7.7: Maximum Nominal Size of Coarse Aggregates Components Maximum Nominal Size of

Coarse Aggregate (mm)

I RCC well curb 20

Ii RCC/PCC well staining 40

Iii Well cap or Pile Cap Solid type piers and 40 abutments

iv RCC work in girder, slabs wearing coat, kerb, 20 approach slab, hollow piers and abutments,

pier/abutment caps, piles

v PSC Work 20

vi Any other item As specified by the Engineer

Maximum nominal size of aggregates shall also be restricted to the smaller of the following values:

10 mm less than the minimum lateral clear distance between individual

reinforcements 10 mm less than the minimum clear cover to the reinforcement

One quarter of minimum thickness of member.

The proportions of the various individual sizes of aggregates shall be so adjusted that the grading produces the densest mix and the grading curve corresponds to the maximum nominal size adopted for the concrete mix.

7.7 EQUIPMENT

Unless specified otherwise, equipment for production, transportation and compaction

of concrete shall be as under:Production of Concrete: For overall bridge length of less than 200 m – batch type concrete mixer, diesel or

electric operated, with a minimum size of 200 litres automatic water measuring system and integral weigher (hydraulic/pneumatic type).

For overall bridge length of 200 m or more – concrete batching and mixing plant fully automatic, with minimum capacity of 15 cum per hour.

All measuring devices of the equipment shall be maintained in a clean and serviceable condition. Their accuracy shall be checked over the range in use, when set up at each site and thereafter, periodically as directed by the Engineer.

The accuracy of the measuring devices shall fall within the following limits:

Measurement of Cement: ± 3 percent of the quantity of

cement in each batch

Measurement of Water: ± 3 percent of the quantity of water

in each batch

Measurement of Aggregate: ± 3 percent of the quantity of

474 UPID


aggregate in each batch

Measurement of Admixture: ± 3 percent of the quantity of admixture in each batch

Transportation of Concrete:

Concrete dumpers

Powered hoists

Chutes

Buckets handled by cranes

Transit truck mixer

Concrete pump

Concrete distributor booms

Belt conveyor

Cranes with skips

Tremies

For Compaction Concrete:

i) Internal vibrators Size 25 mm to 70 mm

Form vibrators minimum 500 watts

Screed vibrators full width of carriageway (upto two lanes)

7.8 BATCHING, MIXING, TRANSPORTING, PLACING AND COMPACTION

7.8.1 General Prior to start of concreting, the Contractor shall submit for approval of the Engineer, his programme along with list of equipment proposed to be used by him for hatching, mixing, transporting and placing concrete.

7.8.2 Batching of Concrete

In batching concrete:

The quantity of cement, aggregate and mineral admixtures, if used, shall be determined by mass.

Chemical admixtures, if solid, shall be determined by mass.

Liquid admixtures may be measured in volume or mass, and

Water shall be weighed or measured by volume in a calibrated tank.

The concrete shall be sourced from on-site or off-site hatching and mixing plants, or from approved Ready Mixed Concrete plants, preferably having quality certification. Except where supply of properly graded aggregate of uniform quality can be maintained over a period of work, the grading of aggregate should be controlled by obtaining the coarse aggregate in different sizes and blending them in the right proportions when required, the different sizes being stocked in separate stock piles. The materials should be stock piled

475 UPID


several hours, preferably a day before use. The grading of coarse and fine aggregate should be checked as frequently as possible to ensure that the specified grading is maintained. The water/cement ratio shall always be maintained constant at its correct value. To this end, determination of moisture content in both fine and coarse aggregates shall be made as frequently as possible, depending on weather conditions. The amount of added water shall be adjusted to compensate for any observed variations in the moisture content. To allow for the variation in mass of aggregate due to variation in moisture content, suitable adjustment in the mass of aggregate, shall also be made. Accurate control shall be kept on the quantity of mixing water, which when specified, shall not be changed without approval.

7.8.3 Mixing Concrete

7.8.3.1 Mixing at Site All concrete shall be machine mixed. In order to ensure uniformity and good quality of concrete the ingredients shall be mixed in a power driven batch mixer with hopper and suitable weigh batching arrangement or in a central mix plant. Hand mixing shall not be permitted. The mixer or the plant shall be at an approved location considering the properties of the mixes and the transportation arrangements available with the Contractor. The mixer or the plant shall be approved by the Engineer.

Mixing shall be continued till materials are uniformly distributed, a uniform colour of the entire mass is obtained and each individual particle of the coarse aggregate shows complete coating of mortar containing its proportionate amount of cement. In no case shall mixing be done for less than 2 minutes. It shall be ensured that the mixers are not loaded above their rated capacities and are operated at a speed recommended by the manufacturer. When mineral admixtures are added at the mixing stage, their thorough and uniform blending with cement shall be ensured, if necessary by longer mixing time. The addition of water after the completion of the initial mixing operation, shall not be permitted.

Mixers which have been out of use for more than 30 minutes shall be thoroughly cleaned before putting in a new batch and also before changing from one. Type of cement to another.

7.8.3.2 Ready Mix Concrete Use of ready mix concrete proportioned and mixed off the project site and delivered to site in a freshly mixed and unhardened state conforming to IS:4926, shall be allowed with the approval of the Engineer.

7.8.4 Transporting Concrete Mixed concrete shall be transported from the place of mixing to the place of final deposit as rapidly as possible by methods which will prevent the segregation or loss of the ingredients. The method of transporting or placing of concrete shall be approved by the Engineer.

Concrete shall be transported and placed as near as practicable to its final position so that no contamination, segregation or loss of its constituents materials take place. Concrete may be transported by transit mixers or properly designed buckets or by pumping. Transit mixers or other hauling equipment when used should be equipped with the means of discharge of concrete without segregation. During hot or cold weather, concrete shall be transported in deep containers. Other suitable methods to be reduce the loss of water by evaporation in hot weather and heat loss in cold weather may also be adopted.

476 UPID


When concrete is conveyed by chute, the plant shall be of such size and design as to ensure practically continuous flow. Slope of the chute shall be so adjusted that the concrete flows without excessive quantity of water and without any segregation of its ingredients. The delivery end of the chute shall be as close as possible to the point of deposit. The chute shall be thoroughly flushed with water before and after each working period and the water used for this purpose shall be discharged outside the formwork.

7.8.5 Placing of Concrete All formwork and reinforcement contained in it shall be cleaned and made free from standing water, dust, snow or ice immediately before placing of concrete.

No concrete shall be placed in any part of the structure until the approval of the Engineer has been obtained. If concreting is not started within 24 hours of the approval being given, the approval shall have to be obtained again from the Engineer. Concreting shall proceed continuously over the area between the construction joints. Fresh concrete shall not be placed against concrete which has been in position for more than 30 minutes, unless a proper construction joint is formed.

The concrete shall be deposited as nearly as practicable in its original position to avoid re-handling. Methods of placing should be such as to preclude segregation. Care should be taken to avoid displacement of reinforcement or movement of formwork. To achieve this, concrete should be lowered vertically in the form and horizontal movement of concrete inside the forms should, as far as practicable, be minimized.

The concrete shall be placed and compacted before its initial setting so that it is amenable to compaction by vibration. The workability of concrete at the time of placement shall be adequate for the compaction equipment to be used. If there is considerable time gap between

mixing and placing of concrete, as in the case of ready mixed concrete plants or off-site batching and mixing plants, concrete mix shall be designed to have appropriately higher workability at the time of discharge from the mixer, in order to compensate the loss of workability during transit. This is generally achieved by suitable chemical admixtures. Keeping these considerations in view, the general requirement for ready mixed concrete plants or off-site batching and mixing plants, is that concrete shall be discharged from the truck mixer within two hours of the time of loading. A longer period may be permitted if suitable retarding admixtures are used.

In wall forms, drop chutes attached to hoppers at the top should preferably be used to lower concrete to the bottom of the form. As a general guidance, the permissible free fall of concrete may not exceed· 1.5 metres and under no circumstances shall it be more than 2 metres. When free fall of larger height is involved, self-compacting concrete having adequate fluidity, cohesiveness and viscosity and which uniformly and completely fills every corner of the formwork by its own weight without segregation, shall be used.

Except where otherwise agreed to by the Engineer, concrete shall be deposited in horizontal layers to a compacted depth of not more than 450 mm when internal vibrators are used and not more than 300 mm in all other cases. Concrete when deposited shall have temperature of not less than 5°C and preferably not more than 30°C and in no case more than 40°C. In case of site mixing, fresh concrete shall be placed and compacted in its final position within 30 minutes of its discharge from the mixer. When the concrete is carried in properly designed agitator operating continuously, the

477 UPID


concrete shall be placed and compacted within 1 hour of the addition of cement to the mix and within 30 minutes of its discharge from the agitator. It may be necessary to add retarding admixtures to concrete, if trials show that the periods indicated above are unacceptable. In all such matters, the Engineer's decision shall be final.

7.8.6 Compaction of Concrete Concrete shall be thoroughly compacted by vibration or other means during placing and worked around the reinforcement, tendons or duct formers, embedded fixtures and into corners of the formwork to produce a dense homogeneous void-free mass having the required surface finish. When vibrators are used, vibration shall be done continuously during the placing of each batch of concrete until the expulsion of air has practically ceased and in a manner that does not promote segregation. Over-vibration shall be avoided to minimize the

risk of forming a weak surface layer. When external vibrators are used, the design of formwork and disposition of vibrator shall be such as to ensure efficient compaction and to avoid surface blemishes. Vibrations shall not be applied through reinforcement and where vibrators of immersion type are used, contact with reinforcement and all inserts like ducts etc., shall be avoided.

When internal vibrators are used, they shall be inserted vertically to the full depth of the layer

being placed and ordinarily shall penetrate the layer below for a few centimetres. The vibrator should be kept in place until air bubbles cease escaping from the surface and then withdrawn slowly to ensure that no hole is left in the concrete, care being taken to see that it remains in continued operation while being withdrawn. The internal vibrators shall be inserted in an orderly manner and the distance between insertions should be about one and half times the radius of the area visibly affected by vibration. Additional vibrators in serviceable condition shall be kept at site so that they can be used in the event of breakdown. Mechanical vibrators used shall comply with IS: 2502, IS:2506, IS:2514 and IS:4656.

7.9 CONSTRUCTION JOINTS Construction joints shall be avoided as far as possible. In no case shall the locations of such joints be changed or increased from those shown on the drawings except with the express approval of the Engineer.

Joints should be positioned where they are readily accessible for preparation and concreting. Construction joints should be positioned to minimize the effects of the discontinuity of the durability, structural integrity and appearance of the structure. As far as possible, joints should be provided in non-aggressive zones, but if joints in aggressive zones cannot be avoided, they should be sealed. Joints should be located away from the regions of maximum stress caused by loading; particularly where shear and bond stresses are high.

Before resuming work at a construction joint when concrete has not yet fully hardened, all laitance shall be removed thoroughly. The surface shall be roughened, taking care to avoid dislodgement of coarse aggregates. Concrete shall be brushed with a stiff brush soon after casting; while the concrete has only slightly stiffened. If the concrete has partially

hardened, it may be treated by wire brushing or with a high pressure water jet, followed

by drying with an air jet, immediately before the new concrete is placed. Fully hardened concrete shall be treated with mechanical hand tools or grit blasting, taking care not to split or crack aggregate particles. The practice of first placing a layer of mortar or grout when concreting joints, shall be avoided. The old surface shall be soaked with water, without

478 UPID


leaving puddles, immediately before starting concreting. The new concrete shall be thoroughly compacted against it.

Where there is likely to be a delay before placing the next concrete lift, protruding reinforcement shall be protected. In all cases, where construction joints are made, the joint surface shall not be contaminated with release agents, dust, or sprayed curing membrane and reinforcement shall be firmly fixed in position at the correct cover. The sequence of concreting, striking of forms and positioning of construction joints for every individual structure, shall be decided well in advance of the commencement of work.

7.10 CONCRETING UNDER WATER When it is necessary to deposit concrete under water, the methods, equipment, materials and proportions of mix to be used, shall be got approved from the Engineer before any work is started.

Concrete shall not be placed in water having a temperature below 5°C. The temperature of the concrete, when deposited, shall not be less than 16°C, nor more than 30°C. Coffer dams or forms shall be sufficiently tight to ensure still water conditions, if practicable, and in any case to reduce the flow of water to less than 3 m per minute through the space into which concrete is to be deposited. Coffer dams or forms in still water shall be sufficiently tight to prevent loss of mortar through the joints in the walls. Pumping shall not be done while concrete is being placed, or until 24 hours thereafter. To minimize the formation of laitance, care shall be exercised not to disturb the concrete as far as possible while it is being deposited.

All under water concreting shall be carried out by tremie method only. The number and spacing of the tremies should be worked out to ensure proper concreting. However, it is necessary to have a minimum number of 2 tremies for any concreting operation, so that even if one of the tremies goes out of commission during concreting, the other one can be used to complete the work. The tremie concreting when started should continue without interruption for the full height of the member being concreted. The capacity of the concrete production and placement equipment should be sufficient to enable the underwater concreting to be completed uninterrupted within the stipulated time.

The top section of the tremie shall have a hopper large enough to hold one full batch of the mix or the entire contents of the transporting bucket, as the case may be. The tremie pipe shall not be less than 200 mm in diameter and shall be large enough to allow a free flow of concrete and strong enough to withstand the external pressure of the water in which it is

suspended, even if a partial vacuum develops inside the pipe. Preferably, flanged steel pipe of adequate strength shall be used. A separate lifting device shall be provided for each tremie pipe with its hopper at the upper end. Unless the lower· end of the pipe is equipped with an approved automatic check valve, the upper end of the pipe shall be plugged with a wadding

of gunny sacking or other approved material before delivering the concrete to the tremie pipe through the hopper, so that when the concrete is forced down from the hopper to the pipe, it

will force the plug (and along with· it any water in the pipe) down the pipe and out of the bottom end, thus establishing a continuous stream of concrete. It will be necessary to raise the tramie slowly in order to allow a uniform flow of concrete. At all times after placing of

concrete is started and until all the required quantity has been placed, the lower end of the tremie pipe shall be kept below the surface of the plastic concrete and shall not be taken out of concrete. This will cause the concrete to build up from below instead of flowing out over

479 UPID


the surface and thus avoid formation of layers of laitance. It is advisable to use retarders or suitable superplasticizers to retard the setting time of concrete, which shall be established before the commencement of work.

7.11 CONCRETING IN EXTREME WEATHER

7.11.1 Concreting in Cold Weather Where concrete is to be deposited at or near freezing temperature, precautions shall be taken to ensure that at the time of placing, it has a temperature of not less than 5°C and that the temperature shall be maintained above 4°C until the concrete has hardened. When necessary, concrete ingredients shall be heated before mixing but cement shall not be heated artificially

other than by the heat transmitted to it from other ingredients of the concrete. Stock- piled aggregate may be heated by the use of dry heat or steam. Aggregates shall not be heated directly by gas or on sheet metal over fire. In general, the temperature of aggregates or water shall not exceed 65°C. Salt or other chemicals shall not be used for the prevention of freezing. No frozen material or materials containing ice shall be used. All concrete damaged by frost

shall be removed. Concrete exposed to freezing weather shall have entrained air and the water content of the mix shall not exceed 30 liters per 50 kg of cement. To counter slower setting of concrete, accelerators can be used with the approval of the Engineer. However, accelerators containing chloride shall not be used.

7.11.2 Concreting in Hot Weather

When depositing concrete in hot weather, precautions shall be taken so that the temperature of wet concrete does not exceed 30°C while placing. This shall be achieved by using chilled mixing water, using crushed ice as a part of mixing water, shading stock piles of aggregates from direct rays of the sun, sprinkling the stock piles of coarse aggregate with water to keep them moist, limiting temperature of cement below 30°C at the time of use, starting curing before concrete dries out and restricting time of concreting as far as possible to early mornings and late evenings. When ice is used to cool mixing water, it will be considered as part of the water in design mix. Under no circumstances shall the mixing operation be considered complete until all ice in the mixing drum has melted. The Contractor will be

required to state his methodology for the Engineer's approval when temperatures of concrete are likely to exceed 30°C during the work.

7.12 PROTECTION AND CURING

7.12.1 General

Concreting operations shall not commence until adequate arrangements for concrete curing

have been made by the Contractor. Curing and protection of concrete shall start immediately

after compaction of the concrete.

The concrete shall be protected from:

Premature drying out particularly by solar radiation and wind

High internal thermal gradients

Leaching out by rain and flowing water

Rapid cooling during the first few days after placing

Low temperature or frost

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

Vibration caused by traffic including construction traffic.

480 UPID


7.12.2 Water Curing Water for curing shall be as specified in Section 3.0 of these specifications.

Sea water shall not be used for curing. Sea water shall not come into contact with concrete members before they have attained adequate strength.

The concrete should be kept constantly wet by ponding or covering or use of sprinklers/ perforated pipes for a minimum period of 14 days after concreting, except in the case of concrete with rapid hardening cement, where it can be reduced to 5 days. Water should be applied on surfaces after the final set. Curing through watering shall not be done on green concrete. On formed surfaces, curing shall start immediately after the forms are stripped. The concrete shall be kept constantly wet with a layer of sacking, canvas, hessian or similar absorbent material: 7.12.3 Curing Compound Membrane forming curing compounds consisting of waxes, resins, chlorinated rubbers etc. may be permitted by the Engineer in special circumstances. Curing compounds shall not be used on any surface which requires further finishing to be applied. All construction joints shall be moist cured and no curing compound shall be permitted in locations where concrete surfaces are required to be bonded together.

Liquid membrane forming compounds shall conform to ASTMC 309 and the curing efficiency shall be as per ASTMC 156.

Curing compounds shall be continuously agitated during use. All concrete cured by this method shall receive two applications of the curing compound. The first coat shall be applied immediately after acceptance of concrete finish. If the surface is dry, the concrete shall be saturated with water and curing compound applied as soon as the surface film of water disappears. The second application shall be made after the first application has set. Placement in more than two coats may be required to prevent streaking. The membrane formed shall be stripped off after 14 days, when curing is complete. Impermeable membranes, such as sheet materials for curing concrete conforming to ASTM C 171 or polyethylene sheeting covering closely the concrete surface, may also be used to provide effective barrier against evaporation.

7.13 FINISHING Immediately after the removal of forms, exposed bars or bolts, if any, shall be cut inside the concrete member to a depth of at least 50 mm below the surface of the concrete and the resulting holes filled with cement mortar. All fins caused by form joints, all cavities produced by the removal of form ties and all other holes and depressions, honeycomb spots, broken edges or corners, and other defects, shall be thoroughly cleaned, saturated with water and carefully pointed and ·rendered true with mortar. The mortar shall be of cement and fine

aggregate mixed in the proportions used in the grade of concrete that is being finished and of as dry a consistency as possible. Considerable pressure shall be applied in filling and pointing to ensure thorough filling in all voids. Surfaces which have been pointed shall be kept moist for a period of twenty four hours. Special pre-packaged proprietary mortars shall be used where appropriate or where specified in the drawing.

481 UPID


All construction and expansion joints in the completed work shall be left carefully tooled and free from any mortar and concrete. Expansion joint filler shall be left exposed for its full length with clean and true edges.

Immediately on removal of forms, the concrete work shall be examined by the Engineer before any defects are made good. The work that has sagged or contains honeycombing to an extent detrimental to structural safety or architectural appearance of the member shall be rejected. Surface defects of a minor nature may be accepted. On acceptance of such work, the same shall be rectified as directed by the Engineer.

7.14 CONCRETE WITH BLENDED CEMENTS OR MINERAL ADMIXTURES

7.14.1 Production of Concrete In order to improve the durability of the concrete, use of blended cement or blending of mineral admixtures, is permitted. The maximum limit of flyash and ground granulated blast furnace slag in concrete, shall be as specified Blending at site shall be permitted only through a specific facility with complete automated process control to achieve the specified design quality or through RMC plants with similar facility.

7.14.2 Modified Properties For concrete made with Portland Pozzolona Cement, Portland Blast furnace slag cement or mineral admixtures, the setting time and rate of gain of strength are different from those of concrete made with OPC alone. Cognizance of such modified properties shall be taken in deciding de-shuttering time, initial time of prestressing, curing period and for early age loading.

7.14.3 Compatibility of Chemical Admixtures Compatibility of chemical admixtures and superplasticizers with Portland Pozzolona cement, Portland blast furnace slag cement and mineral admixtures shall be ensured by trials outlined in Clause 7.5.

7.15 TOLERANCES Tolerances for dimensions/shape of various components shall be as indicated in these Specifications or shown on the drawings or as directed by the Engineer.


7.16.1 Concrete shall conform to the surface finish and tolerance as prescribed in these Specifications for respective components.

7.16.2 Random sampling and lot by lot acceptance inspection shall be made for the 28 days cube strength of concrete.

7.16.3 Concrete under acceptance, shall be notionally divided into lots for the purpose of sampling before commencement of work. The basis of delimitation of lots shall be as follows:

No individual lot shall be more than 30 cu.m in volume

Different grades of mixes of concrete shall be divided into separate lots.

Concrete of a lot shall be used in the same identifiable component of the bridge.

482 UPID


7.16.4 Sampling and Testing Concrete for preparing 3 test cubes shall be taken from a batch of concrete at point of delivery for construction, according to procedure laid down in IS: 1199.

A random sampling procedure shall be adopted which ensures that each of the concrete batches forming the lot under acceptance inspection has equal chance of being chosen for taking cubes.

150 mm cubes shall be made, cured and tested at the age of 28 days for compressive strength in accordance with IS: 516. The 28 day test strength result for each cube shall form an item of the sample. Tests at other age shall also be performed, if specified.

Where automated batching plant/Ready Mixed Concrete Plant is located away from the place of use and the time gap between production and placement is more than the initial setting time or where any ingredients are added subsequent to mixing, separate sets of samples shall be collected and tested at batching plant and at location of placement. The results shall be compared and used to make suitable adjustment at batching plants so that properties of concrete at placement are as per the requirements.

7.16.5 Test Specimen and Sample Strength Three test specimens shall be made from each sample for testing at 28 days. Additional cubes may be required for various purposes such as to determine the strength of concrete at 7 days or for any other purpose.

The test strength of the sample shall be the average of the strength of 3 cubes. The individual variation should not be more than ±15 percent of the average. If variation is more, the test results if the sample is invalid.

7.16.6 Frequency

The minimum frequency of sampling of concrete of each grade shall be in accordance with

Table 7.8

Table 7.8: Minimum Frequency of Sampling

Quantity of Concrete in Work, m3 No. of Samples

1-5 1

6-15 2

16-30 3

31-50 4

51 and above 4 plus one additional sample for each additional 50 m3 or

part thereof

At least one sample shall be taken from each shift of work.

7.16.7 Acceptance criteria

7.16.7.1 Compressive Strength

483 UPID


1) Cubes

The concrete shall be taken as having the specified compressive strength when both the following conditions are met:

The mean strength determined from any group of four consecutive non-overlapping

samples exceeds the specified characteristic compressive strength by 3 MPa. Strength of any sample is not less than the specified characteristic compressive strength minus 3 MPa.

The quantity of concrete represented by the test results include the batches from which the first and last samples were taken, together with all intervening batches.

2) Cores When the concrete does not satisfy both the conditions given in (1) above, representative cores shall be extracted from the hardened concrete for compression test in accordance with the method described in IS: 1199 and tested to establish whether the concrete satisfies the requirement of compressive strength.

Evaluation of compressive strength by taking cores may also be done in case of doubt regarding the grade of concrete used either due to poor workmanship or based on results of cube strength tests.

The locations from which core samples are to be taken and their number shall be decided so as to be representative of the whole of the concrete under consideration. However, in no case shall fewer than three cores be tested. Cores shall be prepared and tested as described in IS: Concrete in the member represented by a core test shall be considered acceptable if the average equivalent cube strength of the cores is equal to at least 85 percent of the cube strength of the grade of concrete specified for the corresponding age and no individual core has strength less than 75 percent of the specified strength.

7.16.7.2 Chloride and Sulphate Content The total chloride and sulphuric anhydride (S03) content of all the constituents of concrete as a percentage of mass of cement in the mix, shall not exceed the values given in this Section.

7.16.7.3 Density of Fresh Concrete Where minimum density of fresh concrete is specified, the mean of any four consecutive non-overlapping samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 percent of the specified value.

7.16.7.4 Density of Hardened Concrete Where minimum density of hardened concrete is specified, the mean of any four consecutive non-overlapping samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 percent of the specified value.

7.16.7.5 If the concrete is not able to meet any of the standards of acceptance as prescribed, the effect of such deficiency on the structure shall be investigated

484 UPID


by t e Contractor as directed by the Engineer. The Engineer may accept the concrete as sub-standard work. Any additional work required by the Engineer for such acceptance, shall be carried out by the Contractor at his cost In case the concrete is not found to be acceptable even after investigation, the Contractor shall remove the rejected concrete forthwith:

When durability of concrete is desired the rapid chloride ion permeability test as stated under Clause 7.14 shall also be performed in addition to above tests.

7.17 MEASUREMENTS FOR PAYMENT Structural concrete shall be measured in cubic metres. In reinforced or prestressed concrete, the volume occupied by reinforcement or prestressing cables and sheathing shall not be deducted. The slab shall be measured as running continuously through and the beam as the portion below the slab.

7.18 RATE The contract unit rate for structural concrete shall cover costs of all materials, labour, tools, plant and equipment required for mixing, transporting and placing in position·, vibrating and compacting, finishing and curing as per this Section or as directed by the Engineer, including all incidental expenses, sampling and testing, quality assurance and supervision. Unless mentioned separately as an item in the contract, the contract unit rate for concrete shall also include the cost of providing, fixing and removing formwork required for concrete work as per Section 3.0 of these Specifications.

If the concrete is found to be acceptable by the Engineer as sub-standard work, the Contractor shall be subjected to reduction in his contact unit rate. For deficiency in compressive strength of concrete when accepted by the Engineer, the reduction in rate shall be applied as under:

485 UPID


OPEN FOUNDATIONS

8.1 DESCRIPTION The work shall cover furnishing and providing plain or reinforced concrete foundation placed in open excavation, in accordance with the drawings and these Specifications or as directed by the Engineer.

8.2 MATERIALS

Materials shall conform to Section 3.0 of these Specifications.

8.3 GENERAL A method statement indicating the following shall be submitted by the Contractor for approval of the Engineer, well in advance of the commencement of construction of open foundation:

Sources of materials

Design, erection and removal of formwork

Production, transportation, laying and curing of concrete

Personnel employed for execution and supervision

Tests and sampling procedures

Equipment details

Quality Management System to be adopted including Quality Manual

Any other relevant information.

Details of necessary arrangements for execution under water wherever necessary, shall be included in the method statement.

Dimensions, lines and levels shall be set out and checked with respect to permanent reference lines and permanent bench mark so that the foundations are located correctly and in accordance with the drawings.

Formwork, steel reinforcement and structural concrete for open Foundations shall conform to Section 5.0, 6.0 and 7.0 respectively of these Specifications.

8.4 WORKMANSHIP

8.4.1 Preparation of Foundations Excavation for laying the foundation shall be carried out in accordance with Section 300 of these Specifications. The last 300 mm of excavation shall be done just before laying of lean concrete below foundation. Excavation shall be made only to the exact depth as shown on the drawing. In the event of excavation having been made deeper than that shown on the drawing or as ordered by the Engineer, the extra depth shall be made up with M10 concrete in case of foundation resting on soil and with concrete of the same grade as that of the foundation, in case of foundation resting on rock. This shall be done at the cost of the Contractor and shall be considered as incidental to the work.

Open foundations shall be constructed in dry conditions and the Contractor shall provide for adequate dewatering arrangements, wherever required, to the satisfaction of the Engineer. Where light blasting is required for excavation in rock or other hard strata, the same shall be carried out in accordance with Clause 302 of these Specifications. Where blasting is likely to

486 UPID


endanger adjacent foundations or other structures, controlled blasting with all necessary precautions shall be resorted to.

8.4.2 Setting Out The plan dimensions of the foundation shall be set out at the bottom of foundation trench and checked with respect to original reference line and axis.

8.4.3 Construction Excavation for open foundations shall be carried out in accordance with Section 300 of

these Specifications. For guidance regarding safety precautions to be taken, IS:3764 may be referred.

For foundation resting on soil, a layer of M10 concrete of minimum thickness 100 mm

shall be provided above the natural ground to provide an even surface to support the foundation concrete. Before laying of lean concrete layer, the earth surface shall be cleaned of all loose material and wetted. Care shall be taken to avoid muddy surface. If any part of the surface has become muddy due to over-wetting, the same shall be removed. If required, the M10 concrete may be laid to a thickness of more than 100 mm, as per the direction of the Engineer. No construction joint shall be provided in the lean concrete. For foundations resting of rock, the rock surface shall be cleaned of any lose material and then levelled with a layer of concrete of the same grade as that of the foundation, so as to provide an even surface.

No point of the surface of the lean concrete, in the case of foundation on soil or the

surface of hard rock, in the case of foundation on hard rock, shall be higher than the founding level shown on the drawing or as ordered by the Engineer. Levels of the surface shall be taken at intervals of not more than 3 metres centre-to-centre in each direction, subject to a minimum of nine levels on the surface.

No formwork is necessary for the lean concrete layer. Side formwork shall be used for foundation concrete work. When concrete is laid in slope without top formwork, the slump of the concrete shall be carefully maintained to ensure that compaction is possible without slippage of freshly placed concrete down the slope. In certain cases it may be necessary to build the top formwork progressively as the concreting proceeds up the slope. Reinforcement shall be laid as shown on the drawing.

Before laying foundation concrete, the lean concrete or hard rock surface shall be cleaned

of all loose material and lightly moistened. Foundation concrete of required dimensions and shape shall be laid continuously up to the location of construction joint shown on the drawing or as directed by the Engineer.

The concrete surface shall be finished smooth with a towel. The location of construction joint and its treatment shall be done as per requirements of Section 1700 of these Specifications. Formwork shall not be removed earlier than 24 hours after placing of concrete. Where formwork has been provided for top surface, the same shall be removed as soon as concrete has hardened. Curing of concrete shall be carried out by wetting of formwork before removal. After its removal, curing shall be done by laying not less than 100 mm thickness of loose moistened sand free from clods or gravel, over the concrete. The sand shall be kept continuously moist for a period of 7 days. Before backfilling is commenced, the loose sand shall be removed and disposed of as directed by the Engineer.

487 UPID


Normally, open foundations shall be laid dry. Where dewatering is necessary for laying of concrete, it shall be carried out adopting any one of the following methods or any other method, approved by the Engineer:

A pit or trench of suitable size, deeper than the founding level as necessary, is dug

beyond the foundation excavation so that the water flows into it and the excavated surface at founding level is fully drained.

Water table is depressed by well point system or other methods.

Steel/concrete caissons or sheet pilling are used for creating an enclosure for the

foundations, which can subsequently be dewatered.

No pumping of water shall be permitted from the time of placing of concrete up to 24 hours after placement.

In situations where foundations cannot be laid dry or where percolation is too heavy to keep foundation strata dry, concrete may be laid under water only by tremie. In case of flowing water or artesian spring, the flow shall be stopped or reduced to the feasible extent at the time of placing the concrete.

Where blasting is required, it shall be carried out in accordance with Section 300 of these

Specifications, observing all precautions indicated therein. Where blasting is likely to endanger adjoining foundations or other structures, necessary precautions such as controlled blasting, providing rubber mat cover to prevent flying of debris etc., shall be taken to prevent any damage.

All spaces excavated and not occupied by the foundations or other permanent works shall

be refilled with earth up to surface of surrounding ground with sufficient allowance for settlement. All backfill shall be thoroughly compacted and in general, its top surface shall be neatly graded. Backfilling shall be in accordance with Section 300 of these Specifications.

In case of excavation in rock, the annular space around the footing shall be filled with

M15 concrete up to the level of top of rock. Filling with M15 concrete shall also be carried out for excavations having depth up to 1.5 m in ordinary rock or 0.6 m in hard rock. In case, the excavations are even deeper so as to require further filling up to the level of top of rock, the same shall be done by boulders grouted with cement.

Protective works, where provided shall be completed before the onset of floods so as to

avoid the risk of the foundation getting undermined.

8.5 TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria.

The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.

488 UPID


8.6 TOLERANCES

a) Variation in dimensions : +50 mm, -10 mm

b) Misplacement from Specified position in plan : 15 mm

Surface unevenness measured with 3 m straight edge: 5 mm

d) Variation of levels at the top : ± 25 mm

8.7 MEASUREMENT FOR PAYMENT Excavation in foundation shall be measured in cubic metres based on the quantity ordered or as shown on the drawing.

Lean concrete shall be measured in cubic metres in accordance with Section 7.0 of these Specifications, based on the quantity ordered or as shown on the drawing.

Concrete in foundation shall be measured in cubic metres in accordance with Section 7.0 of these Specifications, based on the quantity ordered or as shown on the drawing.

Reinforcement steel shall be measured in cubic metres in accordance with Section 6.0 of these Specifications, based on the quantity ordered or as shown on the drawing.

8.8 RATE The contract unit rates for excavation in foundation, lean concrete, including dewatering and blasting where required, concrete in foundation and reinforcement steel shall include all works as given in respective Sections of these Specifications and cover all incidental items for furnishing and providing open foundation as mentioned in this Section and as show on the drawings.

489 UPID


SUBSTRUCTURE

9.1 DESCRIPTION The work shall cover furnishing and providing masonry or reinforced concrete substructure in accordance with the drawings and as per these Specifications or as directed by the Engineer.

9.2 MATERIALS


9.3 GENERAL

9.3.1 A method statement for construction indicating the following shall be submitted by the Contractor for approval of the Engineer, well in advance of the commencement of substructure.

Sources of materials,

Design, erection and removal of formwork,


Personnel employed for execution and supervision,

Tests and sampling procedures,

Equipment details,


Safety measures

Any other relevant information

Arrangements for execution underwater wherever necessary, shall be included in the method statement.

9.3.2 Dimensions, lines and levels shall be set out and checked with respect to permanent reference lines and permanent bench mark so that the substructure is constructed in accordance with the drawings.

9.3.3 Brick masonry, formwork, steel reinforcement and concrete for piers, abutments, pier caps, abutment caps, dirt walls, return walls and wing walls shall conform to Sections 4.0, 5.0, 6.0 and 7.0

9.4 PIERS AND ABUTMENTS

9.4.1 For concrete piers, horizontal construction joints shall be avoided as far as possible, by pouring the entire required concrete in one operation. Where construction joints are unavoidable, they shall be treated in accordance with Section 7.0 of these Specifications or in accordance with special provisions as directed by the Engineer. No vertical construction joint shall be permitted.

Construction joints shall not be permitted in splash zones.

The work shall be strictly in accordance with the drawings or as directed by the Engineer.

9.4.2 In case of tall piers and abutments, use of slipform shall be preferred. The design,

erection and raising of slipform shall be subject to special specifications which will be

490 UPID


furnished by the Contractor. The concrete shall also be subjected to additional specifications as necessary. All specifications and arrangements for use of slipform and placing of concrete therein shall be subjected to the approval· of the Engineer.

9.4.3 The top surface of foundation/well cap/pile cap over which new concrete is to be laid, shall be scraped with wire brush and all loose materials removed. In case reinforcing bars projecting from foundations are coated with cement slurry, the same shall be removed by tapping, hammering or wire brushing. Care shall be taken to remove all loose materials around reinforcements. Just before-commencing masonry or concrete work, the surface shall be thoroughly wetted.

9.4.4 The surface finish shall be smooth, except on the earth face of abutments which shall be rough finished.

9.4.5 In case of abutments likely to experience considerable movement on account of earth pressure from backfill of approaches and settlement of foundations, the construction of the abutment shall be followed by filling up of embankment in layers to the full height to allow for the anticipated movement during construction. Casting of superstructure resting on the abutment shall be taken up only thereafter.

9.5 PIER CAP AND ABUTMENT CAP

9.5.1 The locations and levels of pier cap, abutment cap, pedestals and bolts for fixing bearings, shall be checked carefully to ensure alignment in accordance with the drawings.

9.5.2 The surface of cap shall be finished smooth and shall have a slope for draining off water as shown on the drawings or as directed by the Engineer. For short span slab bridges with continuous support on pier caps, the surface shall be cast horizontal. The top surface of the pedestal on which bearings are to be placed shall also be cast horizontal.

9.5.3 The surface on which elastomeric bearings are to be placed shall be wood float finished to a level plane which shall not vary more than 1.5 mm from straight edge placed in any direction across the area. The surface on which other bearings (steel bearings, pot bearings) are to be placed shall be cast about 25 mm below the bottom level of bearings or as indicated on the drawings.

9.6 DIRT WALL, RETURN WALL AND WING WALL

9.6.1 In case of cantilever return walls, no construction joint shall be permitted. The dirt wall and cantilever return walls shall be cast in one operation.

9.6.2 For gravity type masonry and concrete return and wing wall, the surface of foundation shall be prepared in the same manner as that prescribed for construction of abutment. No horizontal construction joint shall be provided. Vertical construction joint may be provided, if shown on the drawing or as directed by the Engineer.

9.6.3 Vertical expansion gap of 20 mm shall be provided in return wall/wing wall at every

10 metre intervals or as directed by the Engineer. The 20 mm gaps shall be filled with

491 UPID


suitable type of asphaltic/bituminous board, so as to prevent embankment material from coming out. The cost of such board shall be borne by the Contractor and shall be incidental to the work.

9.6.4 For masonry/concrete return walls and wing walls, weep holes shall be provided as prescribed for abutments or as shown on the drawings.

9.6.5 The finish of the surface on the earth side shall be rough while that of the front face shall be smooth.

9.6.6 Coping for wing wall/return wall in brick masonry/stone masonry shall conform to Section 2.0 of these Specifications.


9.7.1 The materials shall be tested in accordance with these Specifications and shall meet the prescribed requirements.

9.7.2 The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.

9.8TOLERANCES IN CONCRETE ELEMENTS

Variation in cross-sectional dimensions : +10 mm, -5 mm

Misplacement from specified position in plan : 10 mm

Variation of levels at the top : ±10 mm

Variations of reduced levels of bearing areas : ±5 mm

Variations from plumb over full height : ±10 mm

Surface unevenness measured with 3 m : 5 mm

straight edge

All surfaces except bearing areas : 5 mm

Bearing areas : 3 mm


9.9.1 Masonry in substructure shall be measured in cubic metres in accordance with Section 4.0 of these Specifications, based on the quantities ordered or as shown on the drawings.

492 UPID


9.9.2 Concrete in substructure shall be measured in cubic metres in accordance with Section 7.0 of these Specifications, based on the quantity ordered or as shown on the drawings. No deduction shall be made for weep holes.

9.9.3 Steel in concrete of substructures shall be measured in tonnes, in accordance with Section 6.0 of these Specifications, based on the quantity ordered or as shown on the drawings.

9.9.4 Weep holes shall be measured based on the numbers provided or as shown on the drawings.

9.10 RATE

The contract unit rates for masonry, concrete, reinforcement and weep holes shall include all works as given in respective Sections of these Specifications and cover all incidental items for furnishing and providing substructure as mentioned in these Specifications and shown on the drawings.

493 UPID


10 CONCRETE SUPERSTRUCTURE

10.1 DESCRIPTION The work shall cover furnishing and providing of concrete superstructure in accordance with the drawings and as per these Specifications or as directed by the Engineer.

10.2 MATERIALS


10.3 GENERAL

10.3.1 A method statement for construction, indicating the following, shall be submitted by the Contractor for approval of the Engineer, well in advance of the commencement of the construction of superstructure.

Sources of Materials

Design, erection and removal of formwork


Prestressing system, if applicable

Personnel employed for execution and supervision

Tests and sampling procedure

Equipment details


Safety measures

Any other relevant information

10.3.2 Dimensions, lines and leve.ls shall be set out and checked with respect to permanent reference lines and permanent bench mark so that the completed superstructure is in full accordance with the drawings and as approved by the Engineer.

10.3.3 The formwork, steel reinforcement and structural concrete for concrete superstructure shall conform to Section 5.0, Section 6.0, and Section 7.0 respectively, of these Specifications.

10.4 REINFORCED CONCRETE CONSTRUCTION

10.4.1 Solid Slabs Where adjacent span of slab has already been cast, the expansion joint and filler board shall be placed abutting the already cast span, which shall form the shutter on that side of the new span to be cast. The reinforcement for the blocks, kerbs railings etc bedded in the slab shall be tied in position before casting of slab. The entire slab shall be cast in one go. Where the slab is continuous over two spans or more, the entire span of the first slab arid the length of the slab in the next adjacent span up to the point of contraflexure, shall be cast in one go, the

same sequence of concreting being repeated for additional spans as required. No other construction joint shall be allowed except with the express permission of the Engineer. In very wide slabs, however, longitudinal construction joints may be permitted with the approval of the Engineer. Constructions joints, if provided, shall be made in the prescribed manner as

per Clause 7.9 of these Specifications. The portions of solid slab near expansion joints shall be cast along with reinforcements and embedments for expansion joints. For this purpose, the portion of solid slab near expansion joints may be cast in a subsequent stage, if permitted by the Engineer.

494 UPID


Where wearing coat is required to be provided after the slab has been cast, the surface of the slab shall be finished rough, but true to lines and levels as shown on the drawings, before the concrete has hardened.

The top of the slab shall be covered .with clean moist sand as soon as the surface has hardened. Curing shall be carried out as per Section 5.0 of these Specifications. If bearings are provided for the solid slab, the same shall be placed in position in accordance with the drawings, before casting of slab.

10.4.2 RCC T-Beam and Slab Provision of construction joint shall conform to the drawings or as per directions of the Engineer. No construction joint shall be provided between the bottom bulb and the web. If not indicated on the drawing, construction joint may be provided at the junction of the web and the fillet between the web and the deck slab, with the approval of the Engineer.

The portions of deck slab near expansion joints shall be cast along with reinforcements and embedments for expansion joints. For this purpose, the portion of deck slab near expansion joints may be cast in a subsequent stage, if permitted by the Engineer.

The surface of the deck slab shall be finished rough but true to lines and levels as shown on the drawings before the concrete has hardened. Care shall be taken for setting of bearings as indicated on the drawings

10.5 TOLERANCES

10.5.1 Cast In-Situ Superstructure

Variations in thickness of top and bottom slab for box girders, top and bottom flange for T-girders, top and bottom flange for T-Girders and slabs

Variations in web thickness

Variations in overall depth or width

Variation in length overall and length between bearings

Permissible surface unevenness in deck slab when measured with a 3 m straight edge or template

-5 mm to +10 mm

-5 mm to +10 mm

+5 mm

Shall not exceed ± 10 mm or ± 0.1 percent of the span length, whichever

is less Mm

10.6 TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.

495 UPID


10.7 MEASUREMENT FOR PAYMENT Concrete in superstructure shall be measured in accordance with Section 7.0 based on the quantity ordered or as shown on the drawings. Steel reinforcement (untensioned) in superstructure shall be measured in accordance with Section 6.0 based on the quantity ordered or as shown on the drawings.

10.8 RATE The contract unit rates for concrete, steel reinforcement shall include all works as given in respective Sections of these Specifications and cover all incidental items for furnishing and providing superstructure as mentioned in this Section and as shown on the drawings.

496 UPID


11. ------------------------------------ DELETED-------------------------------------------------------

497 UPID


12. WELL FOUNDATION

1201 Description The work shall consist of construction of well foundation, taking it down to the founding

level by sinking through all kinds of substrata, plugging the bottom, filling the well with approved material ,plugging the top and providing a well cap, in accordance with the details shown on the drawings and as per these specifications ,or as directed by the Engineer.

1202 GENERAL

1202.1 Wells may have a circular, or D-shape in plan may consist of one, two or

more compartments in plan.

1202.2 In case of well foundations of size larger than 12m diameter, supplemental

construction specifications will be necessary.

1202.3 The subsurface geotechnical investigations to be carried out before

commencement of work of well foundations shall be in accordance with

relevant clauses Section 1900 of these Specifications.

1202.4 In case blasting is anticipated for facilitating sinking through difficult strata

such as boulders and rock, special protective/strengthening measures for the

curb and steining of the well will be required

1202.5 Pneumatic sinking may have to be resorted to in cases where the well has to be

sunk through rock/hard strata or where there are obstacles such as tree trunks,

large sized boulders etc., which cannot be removed by open dredging. In such

cases, the decision regarding adoption of pneumatic sinking shall be taken on

the basis of results of confirmatory bores and as directed by the Engineer

1203 SETTING OUT AND PREPARATIONS FOR SINKING

1203.1 Necessary reference points shall be accurately fixed to mark x-x axis along

the direction of traffic and y-y axis normal to direction of traffic. Such

reference points shall be away from the zone of blow-ups or possible

settlements which may result from well sinking operations and shall be

connected to the permanent stations with the base line on the banks. The

centre of the individual wells shall be marked with reference to these stations.

The distances between the wells shall be checked with the help of precision

instruments.

1203.2 A temporary benchmark shall be established near the well foundation, away

the zone of blow-ups or possible settlement. The bench mark shall be checked

regularly with respect to the permanent bench mark established at the bridge

site.

1203.3 For wells located on the banks of the or in dry area ,the bed may be

prepared by excavating the soil up to 1.5m ,followed by leveling and dressing before placing the cutting edge .

498 UPID


1203.4 For wells which are to be located in water ,a sand island shall be constructed for laying the cutting edge and well curb. Sand islands are practicable for water depths of up to 5m under stable bed soil conditions .Where the depth of water is greater than 5m or in fast flowing rivers or for locations where soil is too week to sustain sand island, floating, caissons may have to be added.

The plan dimensions of sand islands shall be such as to have a working space of at least 2 m all around the steining of the well. Sand Islands shall be maintained to perform their functions, until the well is sunk to a depth below the original bed level at least equal to the depth of water at that location.

The sand island shall be held be position and protected against scour by means of wooden ballies properly braced or sheet piles. The top level of the sand island to be decided by the Engineer, shall be sufficiently above the prevailing water level so that it is not affected by wave action.

1203.5 Equipment shall be deployed for construction of well foundation as required and as directed by the Engineer. Generally, the following equipment may be required for the work: carne with grab buckets – capacity 0.5 cum to 2.0 cum

submersible pumps

air compressor, air locks and other accessories where pneumatic sinking of well is anticipated

chisels of appropriate sizes

aqua – header for cutting rocky strata

diving helmets and accessories

batching plants for concrete production

equipment for transportation, placing and compaction of concrete

1204 CUTTING EDGE

1204.1 The cutting edge shall be made from structural steel sections conforming to

Section 1900 of these Specifications and shall be strong enough to facilitate

sinking of the well through the type of strata expected to be encountered. The weight of the cutting edge shall not be less than 40 kg per metre length. It shall be

properly anchored into the well curb as shown on the drawing.

1204.2 When there are two or more compartments in a well, the bottom of the cutting

edge of the inner walls shall be kept at about 300 mm above that of outer

walls.

1204.3 In V shaped cutting edge, the inclined plate should meet the vertical plate in

such a way that full strength connection by welding is feasibility.

1204.4 The parts of cutting edge shall be erected on level firm ground about 300 mm

above prevalent water level. Temporary supports shall be provided to facilitate

fabrication and for maintaining the assembly in true shape. The fabrication may be carried out in the shop or at site. Steel sections shall not be heated and forced into shape. However, “V” cuts may be made in the horizontal portion, uniformly throughout the length, to facilitate cold bending. After bending,

499 UPID


such “V” cuts should be closed by welding. Joints in the lengths of structural

sections, unless otherwise specified, shall be fillet welded using single cover

plate to ensure the requisite strength of the original section.

1205 WELL CURB

1205.1 The well curb shall be such that it will offer minimum resistance while sinking

but will be strong enough to be able to transmit superimposed loads from the

steining to the bottom plug. The shape and outline dimensions of the curb shall

be as shown in IRC: 78. The internal angle of the curb shall be about 30o to

37o depending upon geotechnical data of the strata through which the well is to

be sunk.

1205.2 The well curb shall be in reinforced concrete having concrete mix in

accordance with Table 1700-2 and Table 1700-3 and with minimum

reinforcement of 72 kg/cum excluding bond rods. The steel shall be suitably

detailed to prevent spreading and splitting of curb during sinking. The outer

face of the curb shall be vertical. The bottom ends of vertical bond rods of

steining shall be fixed securely to the cutting edge with check nuts or by

welds. Concreting of the well curb shall be done in one continuous operation.

1205.3 Steel formwork for well curb shall be fabricated strictly in conformity with the

drawing. The formwork on outer face of curb may be removed within 24 hours

after concreting while that on inner face shall be removed only after 72 hours.

1205.4 In case blasting is anticipated, the inner face of the well curb shall be protected

with steel plates of thickness not less than 10 mm up to the top of the well

curb. If considered necessary, the inner face of steining may also be protected

with steel plates of 6 mm thickness up to a height of 3 m above the top of the

well curb or as specified by the Engineer. The curb as well as 3 m height of

steining above the curb, shall be provided with additional hoop reinforcement

of 10 mm diameter bars at 150 mm spacing. Additional hoop reinforcement

shall be provided in the steining for a further height of up to two times the

thickness of steining above the plates, so as to avoid cracking which may arise

on account of sudden change in the effective section due to curtailment of

plate.

1206 FLOATING CAISSONS

1206.1 Floating caissons are generally fabricated at or near the banks on dry land or in

dry docks and then towed into position. For floating caissons, a detailed

method statement covering fabrication, floating and sinking operations, shall

be prepared and furnished to the Engineer. Such statement shall include the

total tonnage of steel involved, fabrication and welding specifications, list of

materials and plant and a description of operations and manpower required for

the work.

1206.2 Floating caissons shall be of structural steel conforming to Section 1900 of

these Specifications. The joints of the fabricated structure shall be

absolutely leak-tight and shall be checked against leakage before floating

500 UPID


and being towed to site. The reinforcement of the curb and steining of the

well shall be fixed inside the shell by welding before the caisson is floated.

Stability of floating caissons shall be ensured against overturning and

capsizing under the action of water current, wave pressure and wind while

being towed and kept in position. To maintain the stability o f the shell

while being floated, it may be provided with ballast in the form of water

filling up to required level or filling with small amount of concrete. It shall

be ensured that the draught of the floating caisson is always less than the

depth of water available, so as to facilitate its smooth hindrance-free

movement while being towed.

1206.3 Height of caisson shall be planned to ensure that at any given time, at least

one metre of the shell shall be above water level. In case the location is

affected by the action of waves, the height shall be suitably increased to

avoid water spilling into the caisson. In case the bed has soft soil, the

caisson shall be provided with 3 to 5 metres of additional height, as it may

sink by itself after grounding in bed. Simultaneous sinking and concreting

is required to prevent caisson from tilting. In sandy stratum especially with

strong water current, appropriate additional height of caisson is necessary

for accommodating local scour.

1206.4 The floating caisson shall be held in position against untoward movement

by wire ropes/chains, using winches mounted on stationary suitable

platforms/buoys or similar anchoring systems. Anchoring in minimum

three directions, shall be provided to prevent unacceptable longitudinal and

lateral movement. The anchoring system shall permit small movements in

order to facilitate correct positioning of the caisson at the exact location of

the well and until the stage when it is just getting grounded. Special care is

necessary where variation in water level is frequent, e.g. in tidal zones.

1206.5 After being held in correct position, concreting of the floating caisson shall

be commenced. The concrete mixed in batching plants, shall be carried to

the floating caisson on barges and placed in position through concrete

pumps or tremie. When large volumes of concreting are involved, the

batching plant concrete pump, crane etc, may all be mounted on a barge

kept in the vicinity of the caisson. As no vibration is possible inside the

shell, it shall be ensured that the concrete has a slump of 150 to 200;

alternatively, self-compacting concrete can be used. The concrete shall be

carefully placed uniformly all around the caisson so that it settles vertically

without any tendency to tilt.

1207 WELL STEINING

1207.1 The dimensions, shape, concrete strength and reinforcements of the well

steining shall strictly conform to those shown on the drawings. The

501 UPID


formwork shall preferably be of M.S. sheets shaped and stiffened suitably. In case timber forms are used, they shall be lined with plywood or M.S. sheets.

1207.2 The height of the first lift of steining to be cast above the well curb shall not be

more than 2 m and subsequent lifts shall not exceed the diameter of the well or

the depth of well to be sunk below the bed level at any time. For stability, the

first lift of steining shall be cast only after sinking the curb at least partially.

Concreting of steining may be carried out in subsequent lifts of about 2 to 2.5

m. Attempts should be made to minimize the number of construction joints.

The concreting layers shall be limited to 450 mm restricting the free fall of

concrete to not more than 1.5 m. Laitance formed at the top surface of a lift

shall be removed to expose coarse aggregates before setting of concrete at the

proposed construction joint. As far as possible, construction joints shall not be

kept at the location of laps in the vertical steining bars.

1207.3 The steining of the well shall be built in one straight line from bottom to top

such that if the well is titled, the next lift of steining will be aligned in the

direction of the tilt. The work will be checked carefully with the aid of

straight edges of lengths approved by the Engineer. Plumb bob or spirit level

shall not be used for alignment. After sinking of a stage is complete,

damaged portions if any, of steining at top of the previous stage shall be

properly repaired before constructing the next stage.

1207.4 For Measuring of steining, it shall be marked with at least 4 gauges, two intraffic

direction and two normal to traffic direction, distributed equally on the outer face of the

well. The marking shall be in the For measuring the height form of a 100 mm wide strip

painted on the steining, with every metre marked in black paint. Marking of the gauges shall

be done carefully and accurately with a steel tape, starting with zero at the bottom of the

cutting edge. The marking shall be continued upwards as each lift of steining is added.

1207.5 After reaching the founding level, the well steining shall be inspected to check for any damage or cracks. The Engineer will direct and the Contractor shall execute

the remedial measures, if required, before acceptance of the well steining. In case the well is

found to be unacceptable even after remedial measures are carried out, then it shall stand

rejected.

1208

WELL

SINKING

1208.1 General The well shall be sunk true and vertical through all types of strata. No well shall be permitted to be placed in a pre-dredged hole. Sinking or loading of the well with kentledge shall be commenced only after the steining

has been cured for at least 48 hours or as specified in the drawings. The well shall be sunk by excavating the material uniformly from inside the dredge hole

using cranes with grab buckets of appropriate capacity. Use of water jetting, explosives

502 UPID


and divers may be adopted for sinking of wells through difficult strata, with prior approval

of the Engineer. Well sinking can also be carried out by jack down method. Normally

dewatering of well should not be permitted as a means for sinking the well. It shall never be

resorted to if there is any danger of sand blowing under the well. Dewatering shall however

be done when well is to be founded in rock. Pneumatic sinking may have to be resorted to

where obstacles such as tree trunks, large sized boulders etc. are met or when there is hard strata which cannot be removed by open

dredging. The necessity f o r a dopting pneumatic sinking shall be decided by the Engineer.

Complete history of sinking of each well giving details of concreting, sinking and problems

met, if any, shall be maintained in the format given in Appendix 1200/1.

1208.2 Sand Blows in Wells Dewatering of the well shall not be carried out if sand blows are expected. Any equipment

or men working inside the well, shall be brought outside the well as soon as there are any

indications of sand blow occurring. Sand blow can often be minimized by keeping the level

of water inside the well higher than the water table and also by adding heavy kentledge.

1208.3 Use of Kentledge for Sinking of Well

Kentledge shall be placed in an orderly and safe manner on the loading platform and in

such a way that it does not interfere with the excavation of the material from inside the

dredge hole and also does not in any way damage the steining of the well. Where tilt has occurred or there is a danger of well developing a tilt, the position of the load

shall be regulated in such a manner as to provide greater sinking effort on the higher side of

the well. 1208.4 Use of water Jetting

Water jetting can be used to facilitate sinking of wells through clay/hard strata. The decision

regarding use of water jetting shall be taken at the design stage itself, based on geotechnical

investigations which may be indicating presence of hard, clayey strata. For carrying out

water jetting, the required number of steel pipes of 40 to 50 mm diameter shall be embedded

in the steining of the well, spaced evenly around its periphery. The bottom of the steel pipe

shall taper down to a nozzle exiting in the sloping face of the well curb. The diameter of the

nozzle shall be 6 mm. The steel pipe shall be kept about 1m above the top of each lift of

steining, so that it can be extended by means of suitable couplers before the next lift of

steining is cast. When the well reaches the hard strata and the need for water jetting arises,

the tops o f the embedded pipes shall be connected to pumps of required capacity for

pumping in water at high pressure. The water jet issuing from the nozzle of the pipe under

high pressure, cuts through the hard material and loosens it, permitting the well to sink at a

faster rate than would otherwise have

503 UPID


been possible. When water jetting is to be adopted, the Contractor shall furnish a method

statement for approval of the Engineer covering all aspects of the work including the

number, capacity and location of the high pressure pumps and other ancillaries required for

executing the work.

1208.5 Use of Jack Down Method The Jack down method of sinking shall be adopted as per requirement or as directed by the

Engineer. The first step shall be to install ground anchors outside the periphery of the well.

The number, location and depth of ground anchors are decided based on the properties of

the surrounding soil to develop the necessary resisting force through skin friction. The drill

holes of about 150 mm diameter along with casings shall be taken down to a depth of about

20 m or more below the founding level of the well, depending on requirements of design.

After the holes have been drilled to the required depth, prestressing strands of adequate

diameter and capacity are cut to the desired length and lowered into the holes. The holes

shall then be grouted with cement slurry with non-shrink additive. Once the grouting is

completed till the ground level, the casing is removed. The removal of the casing shall be

done before the grout sets. In case rock is met with, the anchors shall be socketed into rock.

Heavy duty pressurization girders fabricated of steel, shall be placed over stools resting on

the steining of the well, against which the hydraulic jacks connected to the ground anchors,

can exert pressure to push the well down. The hydraulic jacks shall be of capacity 500 T or

more as per requirement. Before applying pressure from the jacks, 1 m deep sump is created

inside the well by dredging. Pressure on different jacks is exerted in such a manner as to

neutralize any tendency of the well to tilt. With the use of the jacks and controlled dredging,

high rates of sinking can be achieved and the chances of sand blowing can also be reduced.

For use of jack down method of sinking, the Contractor shall furnish a method statement for

approval of the Engineer, giving full details of construction of ground anchors, fabrication

of pressurizing girder, type, number and capacity of jacks to be used, method of dredging

and application of jack down force and all other relevant aspects for proper execution of the

work.

1208.6 Use of Explosives

Mild explosive charges may be used as an aid for sinking of the well. All prevalent laws

concerning handling, storing and using of explosives shall be strictly followed. All safety

precautions shall be taken as per IS:4081 "Safety Code for Blasting and related Drilling

Operations", to the extent applicable, whenever blasting is resorted to. When the likelihood of resorting to blasting is predicted in advance, protection of the bottom portion of the well shall be done as per Clause 1205.4. Blasting of any sort shall be done only with prior permission and in the presence of the

Engineer. Blasting shall not be done before the concrete in the steining has hardened

sufficiently and is more than 7 days old.

504 UPID


After blasting operations are completed, the well curb and steining should be examined for any cracks and remedial measures taken if required. If blasting has been done after the well has reached the design foundation level, normally 24 hours shall be allowed to lapse before the bottom plug is laid. The charges shall be exploded well below the cutting edge by making a sump so as to avoid

chances of any damage to the curb or to the steining of the well. A minimum sump of 1 m

depth should be made before resorting to blasting. Use of large charges, 0.7 kg or above,

may not be allowed, except under expert direction and with the permission of the Engineer.

The pattern of charges may be suitably arranged with delay detonators so as to reduce the

number of charges fired at a time. The burden of the charge may be limited to 1 m and the

spacing of holes may normally be kept as 0.5 m to 0.6 m. There should be no equipment inside the well nor shall there be any worker in the close vicinity of the well at the time of exploding the charges. If rock blasting is to be done for seating of the well, the damage caused by flying debris

should be minimised by covering blasting holes with rubber mats before detonating the

charge.

1208.7 Use of Divers

Divers may be used for removal of obstructions during sinking, carrying out rock blasting

and for inspection. All safety precautions shall be taken as per any acceptable safety code or

any statutory regulations in force, when divers carry out work under water in the well.

Only persons trained in diving operations shall be employed after being certified fit for

diving by an approved doctor. They shall work under expert supervision. The raising of the

diver from the bottom of wells shall be controlled so that decompression rate conforms to

the rate as laid down in relevant regulations.

The diving and other equipment shall be of acceptable standard and certified to this effect by

an approved independent agency. They shall be well maintained as per requirements for safe

use.

Arrangement for ample supply of low pressure clean cool air shall be ensured through an

armoured flexible hose pipe. Standby compressor shall be provided to cover the

contingency of breakdown of the compressor.

Separate high pressure connection shall be made for use of pneumatic tools. Electric lights

where provided shall be at 50 volts(maximum).

1208.8 Use of Pneumatic Sinking

1208.8.1 General

505 UPID


The Engineer shall familiarize himself with particular reference to ‘caisson diseases’ and

working of the medical air-lock. A doctor competent to deal with cases of “caisson diseases

‘or other complications arising as a result of working under high pressure, shall be stationed

at the construction site when pneumatic sinking is under progress.

The Contractor shall provide complete facilities and ensure strict enforcement of requirements outlined in these specifications. Safely provisions as contained in 18:4138 and in these specifications shall be strictly followed

Pneumatic sinking shall limited to a depth of 30 m below ground level.

1208.8.2 Man Locks and Shafts Locks, reducers, and shaft used in connection with caissons shall be of riveted construction throughout. The material used in their manufacture shall be steel plate with thickness not less than 6 mm. Shafts shall be subjected to hydrostatic or air pressure test so as to ensure leak-tightness a

pressure of at least 0.5 MPa. The pressure at which testing has been done shall be clea. and

visibly displayed. The shaft shall be provided with safe, proper and suitable staircase for its entire length

including landing platforms which shall be not more than 6 m apart. Where this is

impracticable due to space constraints, suitable ladders along with landing platforms shall

be installed. These shall be kept clear and in good condition at all times and shall be

constructed, inspected and maintained to the entire satisfaction of the Engineer. A 1 m wide platform with 1 m high railing shall be provided all round the caisson air locks.

Where 15 or more men are employed, caissons shall have two locks, one of which shall be

as a man-lock. Locks shall be located so that the lowest part of the bottom door shall not be less than 1 m above the highest water level in the well The supply of fresh air to the working chamber shall at all times be sufficient to permit

work to be done without any danger or excessive discount .All air supply lines shall be

fitted with check valves. A man lock shall be used solely for the compression or decompression of workers and not

for the passage of plant and material and shall be maintained in a reasonably clean and

sufficiently warm site. However, any hand tool or hand used for the purpose of the work

may be carried into the man lock Where it is not reasonably practicable to provide a separate man lock for use by workers

only, the lock it is an actual use for compression or decompression of a person, shall be

reasonably clean an sufficiently warm state and shall not be put simultaneously to any other

use.

1208.8.3 Valves Exhaust valves shall be provided, having risers extending to the upper part of the chamber.

506 UPID


These shall be whenever necessary specially after a blast. Precautions shall be taken that men are not allowed to resume work after a blast, until the gas and smoke have cleared.

1208.8.4 Medical Supervision and certification

Every employee absent from work for 10 or more consecutive days due to illness or any

other disability shall be required to pass the regular physical examination by the doctor

before being permitted to return to work. After a person has been employed continuously in compressed air for a period of 2 months,

he shall be re-examined by the doctor and shall not be permitted to work until such re-

examination has been and report is satisfactory. No person known to be addicted the excessive use of intoxicants shall be permitted to work in compressed air. The doctor shall, all times, keep a complete and full record of examination made by him,

which shall contain dates examinations, a clear and full description of the persons examined

,his doctor shall, his age and physical condition at the time of examination and a statement

as to the period for which he has been engaged in such work. Records shall be kept shall be

kept at the place where the work is in progress and shall be subject to inspection by

authorized officers. Every man lock shall always have a doctor or a responsible person in attendance. In case the

person in charge is not a doctor, he must have positive means of promptly communicating

with and securing the service of a competent doctor in case of emergency. Such

arrangements shall invariably be subjected to the approval of the Engineer. All cases of compressed –air-illness shall be reported and copies of all such reports shall be kept in file at the place of work.

1208.8.5 Lighting

All lighting in compressed air chambers shall be operated by electricity. Two independent

electric lighting systems with independent sources of supply shall be used. These shall be so

arranged that the emergency source shall become automatically operative in case of failure

of the regularly used source.

The minimum intensity of light on any walkway ladder, stairway, or lower working level

shall be one-quarter (1/4) candle power. In all work places, the lighting always be such as to

enable workmen to see their way about clearly. All external parts of lighting fixtures and electrical equipment lying within 2.5 m above the floor shall be constructed non-

combustible, non-absorbing insulating materials. If metal is used, it must be effectively

earthed. Portable lamp shall non-combustible, non-absorbing insulating sockets, approved

handles, basket guards and approved cables. The use of worn out or defective portable and

pendant conductors is prohibited

1208.8.6 Safety Against Fire Hazard

507 UPID


No oil, gasoline, or other combustible material shall be stored within 30 m of any shaft,

caisson or tunnel opening. It shall be positively ensured that leaking flammable liquids do

not flow into such areas. Oil may be stored in suitable tanks in isolated fireproof buildings,

which are not less than 15m away from any shaft, caisson, or tunnel opening or any building

directly connected thereto.

Where feasible, a fire hose connected to a suitable source of water shall be provided at the

top of every caisson. Where fire mains are not accessible, water shall be stored in tanks near

the top of every caisson, provided fire pails or suitable pumps are kept available. Approved

fire extinguishers shall also be provided.

1208.8.7 Sanitation

Properly heated, lighted and ventilated dressing rooms shall be provided for all employees

engaged in compressed air work. Such rooms contain lockers and benches and be open and

accessible to person during intermissions between shifts. Adequate toilet accommodation of

one for every five employees shall be provided. Care shall be taken to keep all parts of the caissons and other working compartments,

including locker rooms, rest rooms and other equipment in good sanitary condition and free

from refuse, decaying or other objectionable matter. Smoking shall be strictly prohibited and matches and smoking materials shall not be allowed to be brought into the locker rooms. A separate dry room shall be provided where working clothes may be dried in a reasonable time.

1208.8.8 Protection Against Gases

In all cases where release of gas is expected as in in the case of sinking through alluvium

impregnated with decayed vegetable matter, the use of Davy Safety Lamp shall be

compulsory.

1208.8.9 Additional Safety provisions

The weight of the pneumatic platform and that of staining and kentledge, if

any, shall be sufficient to resist the uplift from air inside, skin friction being

neglected in this case. If at any section, the total weight acting downwards is

less than the uplift pressure of air inside, additional kentledge shall be placed

on the well.

If it is not possible to make the well heavy enough during excavation,

"blowing down" may be used. The men should be withdrawn and air

pressure reduced. The well should then begin to move with small reduction

in air pressure. "Blowing down" should only be used when the ground is

such that it will not heave up inside the chamber when the pressure is

508 UPID


reduced. When the well does not move with the reduction in air pressure,

kentledge should be added. "Blowing down" should be in short stages and

the drop should not exceed, 0.5 m at any stage. To control sinking during

blowing down, use of packing is recommended.

The pneumatic sinking plant and other allied machinery shall not only be of

proper design and make, but also shall be operated by competent and well

trained personnel. Every part of the machinery and its fixtures shall be

minutely examined before installation and use. Availability of appropriate

spares, standbys, safety of personnel as recommended in IS: 4138 for

working in compressed air must be ensured at site. Codes for safety and for

working in compressed air other labour laws and practices prevalent in the

country, as specified to provide safe, efficient and expeditious sinking shall

be followed.

Inflammable materials shall not be taken into air locks and smoking shall be

prohibited. Wherever gases are suspected to be issuing out of dredge hole,

the same shall be analysed by trained personnel and necessary precautions

adopted to avoid hazard to life and equipment.

Where blasting is resorted to, it shall be carefully controlled and all required

precautions shall be observed. Workers shall be allowed inside after blasting

only when a competent and qualified person has examined the chamber and

steining thoroughly and found the same to be safe.

1208.9

Precautions During Sinking

a) When wells have be sunk close to each other and clear distances between them is less than the diameter of wells, sinking shall be

taken up on all wells and they shall be sunk alternately so that the sinking

proceeds uniformly. Simultaneous and even dredging shall be carried out in

the wells in such a manner that the difference in the levels the sump and

cutting edge in the adjacent wells does not exceed half the clear gap between

them. Plugging of all the wells shall be done together.

During sinking of double D-shaped wells, the excavation in both the dredge holes should be carried out simultaneously and equally.

Bore chart shall be referred to constantly during sinking for taking adequate

care while piercing different types of strata. The type of soil as obtained

during the well sinking should be compared with bore chart so as to take

prompt decisions.

Before seasonal floods, all wells on which sinking is in progress shall be sunk to sufficient depths below the designed scour level. Further, they shall

509 UPID


be temporarily filled and plugged so that they do not suffer any tilt or shift during the floods.

All necessary precautions shall be taken against any possible damage to the

foundations of existing structures in the vicinity of the wells, prior to

commencement of dredging from inside the well.

The dredged material shall not be allowed to accumulate around the well. It

shall be dumped and spread, as far away as possible, and then continuously

and simultaneously removed, as directed by the Engineer. In case the river

stream flows along one of the well-being sunk, the dredged material shall not

be dumped on the dry side of the bank but on the side on which the river

current flows.

Very deep sump shall not be made below the well curb, as it entails risk of

jumping (sudden sinking) of the well. The depth of sump shall be generally

limited to one –sixth of the outer diameter/least lateral dimension of the well

in plan. Normally the depth of sump shall not exceed 3.0 m below the level

of the cutting edge unless otherwise specially permitted by the Engineer.

In case a well sinks suddenly with a jerk , the steining of the well shall be examined to the satisfaction of the Engineer to see that no damage has

occurred to it. i) In pneumatic sinking, the well shall not, at any time, be dropped to a depth greater than 500 mm by the method of “blowing down”.

Dewatering shall be avoided if sand blows are expected .Any equipment and

men working inside the well shall be brought out of the well as soon as there

are any indications of sand –blow.

Sand blowing in wells can often be minimized by keeping the level of water

inside the well higher than the water table and also by adding heavy

kentledge.

In soft strata prone to settlement/creep, the construction of the abutment

wells shall be taken up only after the approach embankment for a sufficient

distance near the abutment, has been completed.

1208.10 Tilts and Shifts

Unless otherwise the tilt of any well i.e. its inclination from the vertical, shall not exceed 1

(horizontal) in 80 (vertical). The shift of the well i.e. the horizontal displacement of the

centre of the well at the founding level from its theoretical position shall not be more than

150 mm in any resultant direction.

Tilts and shifts shall be carefully checked and recorded regularly during sinking operations

in format given in Appendix 1200/11. For the purpose of measuring the tilts along the two

axes of bridge, reduced level of the marks painted, on the surface of the staining of the well

shall be taken. For determination of shift, location of the ends of the

510 UPID


two diameters shall be precisely measured along the two axes, with reference to fixed reference points. Whenever any tilt is noticed ,adequate corrective measures like placing eccentric kentledge,

pulling, strutting, anchoring or depositing more dredged material outside the tilted face,

water/air jetting, shall be adopted before any further sinking. After correction, the dredged

material shall be removed and disposed of sufficiently away from the affected well. In case

of sinking by jack down method tilt can be controlled by suitably adjusting jack down

pressure on one side.

A pair of wells close to each other has a tendency to come closer while sinking. Timber struts may be introduced in between the steining of these wells to prevent such movement.

Tilts occurring in a well during sinking in dipping rocky strata can be controlled by suitably supporting the curb. In the event of a well developing tilt or shift beyond the specified permissible values, the

Contractor shall have to carry out, at his own cost, suitable remedial measures to the

satisfaction of the Engineer, to bring the tilt and shift within permissible values. If the resultant tilt and shift of any well exceeds 1 in 80 or 150 mm respectively the well so

sunk shall be regarded as not confirming to specification and classified as substandard work.

The Engineer in his sole discretion, may consider accepting such a well, provided:

Calculations for foundation pressures and steining stresses, accounting for the

actual tilt and shift furnished by the Contractor show that the well is safe.

remedial measures required to bring the stresses within permissible values ( such

as increase in the dimension of the well cap, provision of dummy weights on the

wall cap etc.), shall be carried out by the Contractor at his own cost.

The Contractor shall be subjected to reduction in rates as a penalty in accordance with Clause 1215(g).

In case the Engineer, in his discretion, rejects the well, the Contractor shall dismantle the

rejected well to the extent directed by the Engineer and remove the debris. Further, the

Contractor shall at his own risk and cost, complete the bridge with modified span

arrangement acceptable to Engineer.

1208.11 Seating of Wells

The well shall be uniformly seated on the foundation strata. It should be ensured by test

borings that the properties of the soil encountered at the founding level and up to a depth of

one and a half times the well diameter, is identical to that adopted in the design. The

procedure for test boring shall be in accordance with the provisions of these Specifications. In

case the soil encountered is inferior to that adopted in design, the well shall be re-designed by

the Engineer adopting the soil properties actually encountered and the founding level

intimated to the Contractor, who shall carry out the work accordingly. In case of seating of wells in hard rocky strata, where the rock profile is steeply sloping,

pneumatic methods of sinking may be adopted to seat the well evenly as directly by the

Engineer. The decision of adopting pneumatic sinking shall be taken by the Engineer. The

511 UPID


cutting edge may also be embedded for a suitable depth in the rocky strata, as decided by the Engineer keeping in view the quality of rock. A sump of depth 300 mm in hard rock or 600 in ordinary rock shall be made inside the well by chiseling or blasting as approved by

Engineer. Diameter of sump shall be 1.5 m to 2 m less than that of the dredge hole. After the

well has been evenly seated on good hard rock, arrangements shall be made to facilitate

proper inspection in dry and visible conditions before the bottom plug is laid.

1209 BOTTOM PLUG

A bottom plug of concrete shall be provided in ll wells, the top level of which shall be kept a

minimum of 300 mm above the top of the curb, as shown in IRC: 78. A suitable sump shall

be made below the level of the cutting edge. Before concreting the bottom plug, it shall be

ensured that the inside faces of curb and steining have been cleaned thoroughly. The concrete mix used in bottom plug shall have a minimum cement content of 330 kg per

cum with a slump about 150 mm, to permit easy flow of concrete through tremie to fill up all

cavities. Concrete shall be laid in one continuous operation till the dredge hole is filled to the

required height. For under water concreting, the concrete shall be placed by tremie under still

water condition and the minimum cement content shall not be less than 330 kg/m3 inclusive

of all mineral admixtures, if added. In case of grouted concrete, the grout mix shall not be leaner than 1:2. It shall be ensured that

the grout fills up all interstices upto the top of the bottom plug by suitable means such as,

controlling the rate of pumping etc. Any dewatering required, shall only be done 7 days after casting of bottom plug. The concrete production and placement equipment should be sufficient to enable under water

concreting within stipulated time. Necessary standby equipment should be available for

emergency situation. Before commencing plugging, all loose material from the bottom of the well shall be

removed. Concreting shall be done in one continuous operation till the dredge hole is filled up

to the required height and thereafter soundings shall be taken to ensure that the concrete has

been lid to the required height. Least disturbance shall be cause to the water inside the well

while laying concrete in the bottom plug. The Concrete after placing, shall not be disturbed in

any way for at least 7 days. In order to check whether there is any rise in the level of the bottom plug, soundings should be taken at the close of concreting and once every day for next 3 days. The soundness of the bottom plug may be tested by dewatering the well to a level 5 m below

the surrounding water level and checking the rise of water. For foundation subjected to

artesian pressure, the depth of dewatering by 5 m shall be measured from the still water level

created inside the well by the construction of false steining. The rate of rise shall preferably

be less than 10 cm per hour. In case the rate is higher, suitable remedial measures as directed

by the Engineer, shall be taken by the Contractor at his own cost.

1210 SAND FILLING

512 UPID


Sand filling shall commence 7 days after laying of bottom plug. The level of the top of the bottom plug shall be verified before starting sand filling. The sand shall be clean and free from earth, clay clods, roots, boulders, shingles, etc. and

shall be compacted as directed. Sand filling shall be carried out up to the level shown on the

drawing or as directed by the Engineer.

1211 TOP PLUG

After filling sand up to the required level, a top plug of 300 mm thick concrete of grade M 15, shall be provided over it as shown on the drawing or as directed by the Engineer.

1212 WELL CAP

A reinforced cement concrete well cap will be provided over the top of the steining in

accordance with the drawing. Formwork will be prepared conforming to the shape of the well

cap. In case sand filling has been carried out up to the top of the well, the concrete of the well

cap may be laid directly on it after it has been suitably levelled. Otherwise, suitable shuttering

supported on the inside of the steining, shall be provided for carrying the weight of the green

concrete of the well cap. Concreting shall be carried out in dry condition. A properly designed false steining may be provided where required, to ensure that the well cap is laid in dry condition. The bottom of the well cap shall be laid preferably as low as possible but above the LWL in

the active channel. Where the bed level is higher than the LWL, the top of the well cap may

be suitably raised and kept 1 m below existing ground level. Bond rods of steining shall be

anchored into the well cap.

1213 TOLERANCES

The permissible tilt and shift shall not exceed 1(horizontal) in 80 (vertical) and the shift at the well base shall not be more than 150 mm in any resultant direction. For the well steining and well cap, the permissible tolerances shall be as follows:

a) Variation in dimension : +50 mm, -10 mm

b) Misplacement from specified : 15 mm

position in plan

c) Surface unevenness measured with : 5 mm

3 m straight edge

d) Variation of level at the top : ± 25 mm

1214 TESTS AND STANDARDS OF ACCEPTANCE

The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.

513 UPID


1215 MEASUREMENTS FOR PAYMENT All quantities shall be measured from the drawing, or as ordered by the Engineer, excepting those required to be provided by the Contractor at his cost.

The structural steel in cutting edge shall be measured in tonnes based on the net weight of the metal used in it, as per Section 1900 of these Specifications.

The concrete in curb, well steining and well cap shall measured in cubic

metres in each of the items as per Section 1700 of these Specifications.

The steel reinforcement shall be measured in tonnes separately in each of the items, as per Section 1600 of these Specifications.

The measurement for well sinking shall be made in running metres for

different depths and in different types of strata (e.g. predominantly sand/clay

soil, ordinary rock, hard rock etc.) as specified in the contract. The depth of

sinking shall be measured from the level specified in the contract. If no level

has been specified in the Contract, sinking shall be measured from the low

water level or from the level at which the cutting edge was laid, whichever is

higher.

The quantity of concrete in bottom and top plug shall be measured in cubic metres as per Section 1700 of these Specifications.

The quantity of sand filling shall be measured in cubic metres.

Pneumatic sinking, where required, shall be paid as a separate item and shall be measured in cubic metres of material to be excavated.

1216 RATE

The contract unit rates of structural steel in cutting edge shall cover all costs of

labour, materials, tools, plant and equipment, including placing in position,

sampling and testing, and, supervision, all as per Section 1900 of these

Specifications.

The contract unit rates for concrete in curb, steining, bottom plug, top plug and

well cap, shall cover all costs of labour, material, tools, plant and equipment,

formwork and staging including placing in position, sampling and testing, and,

supervision, all as per Section 1700 of these Specifications and as described in

this Section.

The contract unit rates for reinforcement in curb, steining, and well cap, shall

cover all costs of labour, material, tools, plant and equipment, including

bending to shape, placing in position, sampling, testing, and supervision, all as

per respective Section 1600 of these Specifications and as described in this

Section.

The contract unit rates for sand filling shall cover all costs of labour, material, tools, plant and equipment, including placing in position and supervision.

The contract unit rates for sinking of well shall cover the costs of labour, tools,

and equipment and plant and for all operations and other incidentals for

sinking of well including seating except pneumatic sinking as prescribed in

514 UPID


this Section. The unit rates shall specify the strata such as types of soil, rock etc. The rate shall cover all testing and supervision required for the work.

The contract unit rate of material to be excavated by pneumatic sinking shall

cover all costs of labour, material, tools, plant and other equipment and other

incidentals and safety provisions and supervision required for pneumatic

sinking as per this Section. Reduction in contract unit rates for sinking as a penalty, as required under

Clause 1208.10.

If any well with tilt and/or shift exceeding the permissible values is accepted by the Engineer, the Contractor shall be subjected to a reduction in the rates for the sinking of well as follows:

S.No. Amount of Tilt and/or Shift Percent Reduction on the

Rate (s) for sinking of

Whole Well

1) Tilt exceeding the specified permissible value but 5 percent equal to or within 1 in 60

2) Tilt exceeding 1 in 60 but equal to or within 1 in 50 10 percent

3) Tilt exceeding 1 in 50 20 percent

4) Shift exceeding the specified permissible value but 2 percent

equal to or within 200 mm

5) Shift exceeding 200 mm but equal to or within 300 5 percent mm

6) Shift exceeding 300 mm 10 percent

For excessive tilt and shift, the reduction in rates shall be decided separately by the Engineer

13 BEARINGS

13.1 DESCRIPTION

This work shall consist of furnishing and fixing bearings in position in accordance with the details shown on the drawings, to the requirements of these Specifications or as directed by the Engineer.

13.2 GENERAL The bearings may either be supplied directly to the Engineer by the manufacturer to be

installed by the Contractor or supplied and installed by the Contractor as part of the contract. In the former case, the manufacturer shall be associated with the installation of the bearings to the full satisfaction of the Engineer, whereas in the latter case, the Contractor shall be solely responsible for the satisfactory supply and· installation of the bearing. In the detailed description of the specification, a general reference shall be made to the Contractor or manufacturer and the interpretation shall be as per terms of contract.

The Contractor shall exercise the utmost care in setting and fixing all bearings in their

correct positions and ensuring that uniformity is obtained on all bearing surfaces.

Bearings shall be handled with care and stored under cover.

515 UPID


iv.)

It shall be ensured that the bearings are set truly level and in exact position as indicated on the drawings so as to have full and even bearing on the seats. Thin mortar pads (not exceeding 12 mm .thickness) may be provided for this purpose.

v.)

It shall be ensured that the bottoms of girders to be seated on the bearings are plane at the locations of the bearings and that the bearings are not displaced while placing the girders.

vi.)

For bridges with skew angle less than 20°, the bearings shall be placed at right angles to the longitudinal axis of the bridge. For bridges with skew angle greater than 20°, very wide bridges and curved bridges, the location of bearings shall be ensured as shown on the drawings.

vii.)

Easy access to the bearing shall be made available for purposes of inspection and maintenance. Provision shall also be made for jacking up of the superstructure so as to allow repair/replacement of bearings.

13.3 ELASTOMERIC BEARINGS Elastomeric bearings shall cater for translation and/or rotation of the superstructure by elastic deformation.

13.3.1 Materials

i.)

Chloroprene Rubber(CR) only shall be used.

ii.)

Grades of raw elastomer of proven use in elastomeric bearings, with low crystallization rates and adequate shelf life viz. Neoprene WRT, Neoprene W, Bayprene 110, Bayprene 210, Skyprene B-5, Skyprene B-30, Denka S-40V and Denka M-40, shall be used.

iii.)

No reclaimed rubber or vulcaniz'ed wastes or natural rubber shall be .used.

iv.)

The polychloropene content of the compound shall not be lower than 60 per cent. The ash content shall not exceed 5 per cent of its weight. Polychloropene content shall be determined in accordance with ASTM- 0297 and ash content as per 18:3400-Part XXII.

v.)

Use of synthetic rubber-like materials such as Ethyl Propylene Dimonomer (EPDM), lsobutane Isoprene Copolymer (IIR) and Chloro- lsoprene Copolymer (CIIR) shall not be permitted.

13.3.1.1 Properties of Elastomer

The elastomer shall conform to the properties specified in Table 13.1.

Table 13.1: Properties of Elastomer

Property Unit Value of the Characteristic Test Method IS

Specified Specification

Reference

(1) (2) (3) (4)

516 UPID


1. Physical properties

1.1 Hardness

Minimum tensile Strength

- Moulded test piece MPa 17 17 17

-Test piece from bearing 14 14 14 18:3400 (Part I)

1.3 Minimum elongation at

break

- Moulded test piece

- Test piece from bearing % 400 350 250 18:3400 (Part II)

Unit Value of the Characteristic Test Method IS Property Specified Specification

Reference

(1) (2) (3) (4)

2. Maximum compression

set(%)

(24 h, 100 ± 1 °C) % < 35 IS:3400 (Part X)

3. Accelerated aging

(72 h, 100 ± 1 °C) IS:3400 (Part IV)

(Maximum change from un- aged value)

3.1 Maximum change in IRHD ±5

hardness

' ±15

3.2 Maximum change in %

tensile strength

3.3 Maximum change in % ±30

elongation

Shear modulus (G) is the apparent "conventional shear modulus" of the elastomer bearing determined by testing. At nominal temperature of 23 °C ± 2°C, the value of G shall comply with the values given in Table 13-2.

Table 13.2: Shear Modulus at Nominal Temperature

Hardness (IRHD) G (MPa) Tolerances of G (MPa)

(1) (2) (3)

50 ±5 0.7 ± 0.15

60 ± 5 0.9 ± 0.18

517 UPID


70 ± 5 1.15 ± 0.20

The adhesion strength of elastomer to steel plates determined according to IS:3400 (Part XIV) method A, shall not be less than 7 Kn/m.

For elastomeric bearings (CR) used in adverse climatic conditions, the ozone resistance of elastomer shall be proved satisfactory when assessed by test according to IS:3400 (Part XX). The testing shall be carried out for a duration of 96 hours at a temperature of 40±1°C, strain of 30 percent and ozone concentration of 100 pphm by volume.

If any cracking is detected by visual observation at the end of the test, the material shall be considered unsatisfactory. No specific tests for assessment of low temperature resistance are deemed necessary.

Note: For use of elastomer in extreme cold climates, the Engineer may specify special grade of low temperature resistant elastomer in conformity with operating ambient temperature conditions. The specifications for such special grade elastomer including the tests for low temperature resistance, shall be mutually agreed by the Engineer and the producer/ supplier and are outside the purview of these Specifications. Laminates of mild steel conforming to IS:2062/IS:1079 or equivalent international grade, shall only be permitted. The yield stress of the material shall not be less than 250 MPa. Use of any other material like fibre glass or similar fabric as laminates, shall not be permitted.

The manufacturers of elastomeric bearings shall satisfy the Engineer that they have in-house facilities for carrying out the following tests on elastomer in accordance with the relevant provisions of ASTM D-297.

a) Identification of polymers to confirm the usage of chloroprene

(Appendix X-2)

b) Ash content to determine the percentage (sub-

section 34)

c) Specific gravity (sub-section 15)

d) Polymer content (sub-section 10)

The Engineer shall invariably get the test (a) performed in his presence or in the presence of his authorized representative. In case of any dispute regarding interpretation of results, the Engineer may carry out test as per ASTM S-3452-78 (chromatography test) at the manufacturer's cost in a recognized test house. The elastomer specimen to conduct the test shall be obtained from the bearing selected at random for destructive test. The remaining part of the test bearing shall be preserved by the Engineer for any test to be done later, if required.

13.3.2 Manufacturing and Workmanship Plain pad and strip bearing shall be moulded in one piece, or comprise single pieces cut

from previously moulded strips or slabs. Cutting shall produce a smooth surface without injurious heating of the elastomer.

Bearing with steel laminates shall be moulded as a single unit in a mould and vulcanised

under heat and pressure. Moulding of elements in separate units and subsequent bonding as well as cutting from large sized cast, shall not be permitted.

518 UPID


iii.)

The moulds used shall have standard surface finish adequate from any surface blemishes.

to produce bearings free

iv.) Steel plates for laminates shall be sand/grit blasted, clean of all mill scales and shall be free from all contaminants prior to bonding by vulcanization ..Rusted plates with pitting shall not be used. The plates shall be rounded so as to be free of sharp edges.

v.) Bonding shall be carried out during vulcanisation using suitable bonding agent for bonding of elastomer to steel such that the bond peel strength is at least 7 N/mm width when tested in accordance with IS:3400 Part XIV method A.

vi.) Spacers used in mould to ensure cover and location of laminates shall be of minimum size and number practicable. Any hole at surface or in edge cover shall be filled in subsequently.

vii.)

Care shall be taken to ensure uniform vulcanizing conditions and homogeneity of elastomer through the surface and body of bearings.

viii.)

The vulcanizing equipment/press shall be such that between the platens of the press, the pressure and temperature are uniform and capable of being maintained at constant values as required for effecting a uniform vulcanization of the bearing.

ix.) The moulding dies utilized for manufacturing the bearings shall be so set inside the platen of the press that the pressure developed during vulcanization of the product is evenly distributed and the thickness maintained at all places are within acceptable tolerance limits taking into consideration the expansion/shrinkage allowance of vulcanizate (the product of vulcanization).

x.)

The raw compound which is introduced inside the metal dies for vulcanization shall be accurately weighed each time and shall be of sufficient quantity to ensure proper flow of material to every part of the die so that a homogeneous and compact bearing is produced without any sign of sponginess or deficiency of material at any place.

xi.)

Before the rubber mix of any batch is used for producing vulcanized bearings, test pieces in the form of standard slab and buttons shall be prepared in accordance with prescribed standards and salient properties tested and recorded regularly against each batch of production to monitor the quality of the products.

xii.)

Bearings of similar size to be used in a particular bridge project shall be produced by identical process and in one lot as far as practicable. Phased production may be resorted to only when the total number of bearings is large.

13.3.3 Manufacturing Tolerances The bearings shall be fabricated/manufactured with the tolerances specified in Table 13.3. Tolerances of thickness of individual layer of elastomer, dimension of laminates, and flatness of laminates are primarily meant for quality control during production. In order to measure thickness of individual layer of elastomer, dimension of laminates and flatness of laminates of a finished bearing, it is essential to cut the bearing, which may be done if agreed upon between the manufacturer and the buyer.

519 UPID


Table 13.3: Tolerances

Items Tolerances

1) Overall linear plan dimensions -3 mm, +6 mm

2) Total mean bearing -2.5%, +5% thickness

(The Bearings of similar size to be used in a

particular bridge project shall be produced by

identical process and in one lot as far as

practicable. Phased production may be resorted to

only when the total number of bearings is large

Manufacturing Tolerances

The bearings shall be abricated/manufactured ith

the tolerances specified in Table 2000-3.

Tolerances of thickness of individual layer of

elastomer, dimension of laminates, and flatness of

laminates are primarily meant for quality control

during production. In order to measure thickness

of individual layer of elastomer, dimension of

laminates and flatness of laminates of a finished

bearing, it is essential to cut the bearing, which

may be done if agreed upon between the

manufacturer and the buyer.

Table 2000-3: Tolerances

mean thickness is the arithmetic average of the

thickness measured at five points on the major

surface as indicated for various shaped bearings:

Rectangular : corners and centre

Circular :corners of inscribed square and

centre)

3) Parallelism a) Of top surface of bearing with respect to the

1 in 200 bottom surface as datum

b) Of one side surface with 1 in 100

respect to the other as

datum

4) a) Inner layer of elastomer ±12% (max of 2 mm) b) Outer layer of elastomer

+20% (max of 1 mm) c) Side cover

-0 mm, +3 mm

5) Dimension of laminates -3 mm, + 0 a) Plan dimensions of laminates

b)

Thickness of laminate

c) ±10%

Parallelism of laminate with respect to bearing base as

datum (with respect to diameter for plates circular 1 in 100 in plan and shorter side for plates rectangular in plan)

6) Flatness

Flatness shall be assessed by placing a straightedge

along the diagonal or diameter. The gap between the

straightedge and the surface shall not exceed the

tolerances specified below

520 UPID


a) Load bearing surface of the bearing 0.3% of diameter or diagonal or

2% of mean bearing thickness

which ever is higher.

b) Steel laminate 1% of diameter or diagonal

(max of 1.S.mm)

13.3.4 Acceptance Specifications

The manufacturer shall have all the test facilities required for the process and acceptance control tests installed at his plant to the. complete satisfaction of the Engineer. The test facilities and their operation shall be open to inspection by the Engineer on demand.

All acceptance and process control tests shall be conducted at the manufacturer's plant. Cost of all materials, equipment and labour shall be borne by the manufacturer unless otherwise specified or specially agreed to between the manufacturer and Engineer.

A testing programme shall be submitted by the manufacturer to the Engineer and his approval obtained before commencement of acceptance testing.

Any acceptance testing delayed 180 days beyond the date of production shall require special

approval of the Engineer and modified acceptance specification, if deemed necessary by him.

All acceptance testing shall be conducted by the Inspector with the aid of the manufacturer's personnel having adequate expertise and experience in rubber testing, working under the supervision of the Inspector and to his complete satisfaction. Inspection and acceptance shall be carried out Jot by Jot.

13.3.4.1 Acceptance Lot

A Jot under acceptance shall comprise all bearings, including the pair of extra test bearings

where applicable, of equal or near equal size produced under identical conditions of

manufacture, to be supplied for a particular project.

The size and composition of acceptance lot shall be got approved by the Engineer

For the purpose of grading levels of acceptance testing, a lot size of 24 or larger number of

bearings shall be defined as a 'large lot', while a lot'size of less than 24 number of bearings

shall be defined as a 'small lot'.

When the number of bearings of equal or near equal size for a single bridge project is large

and phased production and acceptance is permitted, the number of bearings supplied in any

single phase of supply shall comprise a lot under acceptance. When such phased supply is

made, each such lot shall be considered as a large lot for the purpose of acceptance testing.

13.3.4.2 Levels of Acceptance Testing The following two Levels of acceptance testing shall be adopted, depending on lot size :

Acceptance testing Level 1 is a higher level of inspection and testing and shall be applicable to large lots only, unless otherwise specified. This shall involve manufacture of two extra

521 UPID


bearings for each lot to be used as test bearings and eventually consumed in destructive testing.

Acceptance testing Level 2 shall be applicable to small lots only, for which one extra bearing

shall be manufactured and shall not involve destructive testing of finished bearing. Out of the

lot, one bearing shall be selected at random for carrying out material tests. This bearing shall

be excluded from the lot accepted.

Acceptance testing Level 1 may be specified for small lots also at the sole discretion of the

Engineer taking into account the special importance of a bridge project. The cost of extra

bearings, in such cases shall be borne by the user, while the cost of all other materials,

equipment and testing shall be borne by manufacturer.

13.3.4.3 Testing Acceptance testing shall comprise general inspection, test on specially moulded test pieces

and test on complete bearings or sections for measurement of various quality characteristics detailed below :

13.3.4.3.1 Acceptance Testing Level 1 General Inspection

All bearings of the lot shall be visually inspected for absence of any defects in surface finish, shape, hardness or any other discernible superficial defects.

All bearings of the lot shall be checked for tolerances for overall dimensions, mean

bearing thickness, parallelism of bearing surfaces and flatness of load bearing

surfaces as specified in Table 13.3.

The test shall be carried out on all bearings as part of the standard production process.

The temperature of the room in which the bearings are tested shall not vary more

than 10 °C. The main objective of this test is to eliminate poorly made bearings by

visual inspection in a quick and efficient way. All bearings of the lot shall be

subjected to an axial load to correspond to the design load at serviceability limit

state while visual examination is made to check for discernible defects like:

Misalignment of reinforcing plates Poor bond at laminate/steel interface Variation in elastomer layer thickness Any surface defects developed during testing

During acceptance testing, complete test data shall be furnished by the manufacturer and

one bearing per lot shall be selected at random and the same test shall be repeated.

The bearings shall then be visually inspected for defects and the stiffness shall also

be measured.

During the test, the deflection between 30 percent and 100 percent of the maximum load

for the application shall be recorded and used to check the consistency of the

stiffness value. Variation in stiffness of any individual bearing from the mean of

522 UPID


the measured values for all such bearings of the lot, shall not be larger than 20 percent of the mean value.

In case of any visual defect or unacceptable stiffness during acceptance testing, all

bearings of the lot shall be subjected to the same test again and only the bearing that

passes the test in all respects; shall be accepted.

Tests on Specially Moulded Test Pieces

Test pieces shall be moulded by the manufacturer with identical compound and underidentical vulcanising conditions as used in the manufacture of the bearings of the acceptance lot. The process shall be open to inspection by the Inspector/Engineer.

Test pieces offered for inspection shall be identified by suitable markings and duly

certified by the manufacturer.

The quality characteristics to be tested are listed below. The specification reference in

parenthesis shall define the corresponding specification for test piece, test method and criterion for acceptance.

Composition (see Note 1 below)

Hardness (Table 13.1, 1.1)

Tensile strength (Table 13-1, 1.2)

Elongation at Break (Table 1.3, 1.3)

Compression Set (Table 1.3, 2)

Accelerated Ageing (Table 1.3, 3) Adhesion

Strength (Clause 1.3.4) Ozone Resistance (see Note 2 below)

Note: The properties enumerated in Clause 13.3.1 and specific gravity of elastomer of test pieces from test bearing, shall be compared with those for corresponding specially moulded test pieces furnished by the manufacturer. The following variations shall be deemed maximum acceptable:

Specific Gravity + 02 Ash Content± 0.5 per cent (e.g., if the ash content of elastomer from test bearing is 4%, the ash content of the specially moulded test piece shall be within 3.5% to 4.5% or vice versa

Hardness (Table 13.1, 1.1)

Tensile strength (Table 13.1, 1.2)

Elongation at Break (Table 1.3, 1.3)

Compression Set (Table 1.3, 2)

Accelerated Ageing (Table 1.3, 3) Adhesion Strength (Clause 13.3.1

523 UPID


Ozone resistance test can be waived by the Engineer for bearings of CR when satisfactory results of ozone resistance tests on similar grade of elastomer may be available from process control records or development test data furnished by the manufacturer.

Where such process control data are not available or the frequency of testing not deemed adequate, ozone resistance test shall be mandatory for acceptance of bearings of CR.

However, such tests may not be insisted upon for bearings not located in adverse conditions of exposure and where the test on accelerated ageing could be considered as adequate.

Process and acceptance control tests for ozone resistance by an independent testing agency shall be acceptable.

Tests on Complete Bearings or Samples

i.) Two bearings shall be selected at random from the lot as test bearings.

The tests to be conducted are:

Test for determination of shear modulus (on a pair of bearings) and

Test for determination of compression stiffness (on one bearing out of the selected pair).

The test specifications and acceptance criteria shall conform to those given in Appendix-3 of IRC:83 Part II. The tested bearings shall be part of the lot accepted.

ii.)

Test for determination of shear modulus shall be conducted using two bearings of the lot selected at random and conforming to relevant provisions of Clause 2005.4.3.1. These bearings shall, however, be part of the lot accepted. The remaining tests stipulated in aforesaid clause shall be carried out on two bearings selected at random which shall be excluded from the lot accepted.

The test specifications and acceptance criteria shall conform to those given in Appendix-3 of IRC:83 Part II. This is a destructive test and the test bearings shall not be used in the structure.

13.3.4.4 Special Acceptance Inspection Special acceptance inspection shall comprise the following:

Acceptance testing by a NABL accredited independent external agency with separate or

supplemental test facilities provided by it for polymer identification and confirmation

about percentage of polymer content and ash content by TGA method. Acceptance testing on test pieces prepared from the surface or body of the test bearings

instead of specially moulded test pieces. Acceptance testing on cut sample from finished bearing in order to measure thickness of

individual layer of elastomer, · dimension of laminates and flatness of laminates.

524 UPID


Acceptance test at ULS condition. Bearings tested at ULS condition cannot be used in the structure as its performance at SLS condition cannot be guaranteed after such test.

v) Acceptance tests not covered by these specifications but according to the specifications laid down by the Engineer.

Special acceptance inspection may be specified under the following conditions:

a) Special contract agreement between the manufacturer and the buyer.

Cost of additional bearings to be consumed for special acceptance inspection, shall be borne by buyer.

b) Evidence of unsatisfactory process or acceptance control

13.3.4.5 Inspection Certificate A lot under inspection shall be accepted by the Inspector and so certified, when no defect is found with respect to any of the quality characteristics tested on samples drawn from the lot, according to specifications laid down to Clause 2005.4.3 covering general inspection tests on specially moulded test pieces and on complete bearings.

In case any bearing is found defective, the lot shall be rejected by the Inspector and so certified.

In case any bearing is found to be defective with respect to any quality characteristic, discerned by general inspection tests specified in Clauses 13.3.4.3.1 and 13.3.4.3.2, tests on specially moulded test pieces and complete bearings as applicable according to those Clauses, shall nevertheless be completed. If the said lot, rejected by general inspection, satisfies the acceptance criteria in respect of these other tests, the lot and individual bearings found defective shall be clearly identified in the inspection certificate.

Immediately on completion of inspection by the Inspector authorized by the Engineer, the manufacturer shall obtain an inspection certificate which shall include the details of a lot or lots accepted/rejected by him and records of all test measurements.

13.3.4.6 Quality Control Certificate

The manufacturer shall certify for each lot of bearings under acceptance that :

an adequate system of continuous quality control was operated in his plant.

the entire process remained in control during the production of the lot of bearings under acceptance, as verified from the quality control records/charts which shall be open to inspection of Engineer/Inspector on demand.

A certified copy of results of process control testing done on samples of elastomer used in the production of the lot shall be appended and shall include the following information Composition of compound- raw elastomer and ash content, the grade of raw elastomer used (including name, source, age on shelf), test results of hardness, tensile strength, elongation at break, compression set, accelerated ageing, etc. ·

A higher level certification of the process quality control shall be called for at the sole discretion of the Engineer in special cases e.g. where adequate inspection of bearings similar to those comprising the lot under inspection produced in the same plant, is not available with the Engineer or where there is any evidence of process or acceptance control being deemed

525 UPID


unsatisfactory. The higher level certification shall comprise submittal of a complete quality control report covering tests as given in Appendix 3 of IRC:83 (Part II), supplementing the quality control certificate.

13.3.4.7 Acceptance

The manufacturer shall furnish the following to Engineer for obtaining acceptance:

Quality control certificate as laid down in Clause 13.5.4.6.

Inspection certificate as laid down in Clause 13.5.4.5 .

To manufacturer shall furnish any supplementary information on the system of quality control

and/or process and acceptance control testing as may be deemed necessary by the Engineer.

In case of any evidence of process or acceptance control testing being deemed unsatisfactory by him, Engineer at his sole discretion may call for a special acceptance testing of the lot according to specifications laid down by him, without any prejudice to his right to reject the lot. The entire cost of such supplementary inspection shall be borne by the manufacturer.

The Engineer shall be the sole authority for acceptance of a lot on scrutiny of the certificates along with any supplementary evidence as mentioned in this Clause, to his complete satisfaction therewith.

In case of rejection of a lot, the Engineer shall reserve the right to call for special acceptance inspection for the succeeding lots offered for inspection, according to the specifications laid down by him. The entire cost of such tightened inspection shall be borne by the manufacturer.

13.3.5 Certification and Marking Bearings shall be transported to bridge site after final acceptance by Engineer and along with an authenticated copy of the certificate to that effect.

Each bearing shall be uniquely and individually numbered on · its external faces for identification. The identification number shall be unique and such as to enable other bearings manufactured at the same time, to be traced through the production control records, should the need arise. The manufacturer's name and unique identification number of the bearing should be vulcanized on the top or bottom of the bearing.

An information card giving the following details for the bearings, duly certified by the manufacturer, shall also be appended:

Name of manufacturer

Date of manufacture

Elastomer grade used

Bearing dimensions

Production batch no.

526 UPID


Acceptance lot no.

Date of testing

Name and specific location of bridge

Explanation of markings used on the bearing All bearings shall have suitable index markings identifying the information. The markings shall be made in indelible ink or flexible paint and if practicable, should be visible after installation. The top of the bearing and direction of installation shall be indicated.

13.3.6 Storage and Handling Each elastomeric bearing shall be clearly labelled or marked. The bearing shall be wrapped in a cover and packed in timber crates with suitable arrangement to prevent movement and to protect corners and edges.

Care shall be taken to avoid mechanical damage, contamination with oil, grease and dirt, undue exposure to sunlight and weather of the bearings during transport and handling prior to and during installation.

13.3.7 Installation Bearings shall be installed in the structure as specified or approved by the Engineer to ensure that right bearing is being installed at the right location.

Bearings must be placed between true horizontal surfaces (maximum tolerance 0.2

percent perpendicular to the load) and at true plan position . of their control lines marked on receiving surfaces (maximum tolerance

± 3 mm). Concrete surfaces shall be free from local irregularities (maximum tolerance ± 1

mm in height).

Departures from common planarity of twin or multiple bearings shall be within such

tolerance as may be specified or approved by the engineer.

Design shall be got checked for the actual inclination in seating if larger inaccuracies than those specified are permitted.

For cast in-situ concrete superstructure, where bearings are installed prior to concreting, the forms around the bearings shall be capable of easy removal. Forms shall also fit the bearings snugly and prevent any leakage of mortar/grout. Any mortar contaminating the bearings during concreting shall be completely removed before setting.

Fixing of bearing to precast concrete or steel superstructure elements, shall be done by application of epoxy resin adhesive to interface, after specified surface preparation. The specifications for adhesive material, workmanship and control shall be approved by the Engineer. Care shall be taken to guard against faulty application and consequent possibility of behaviour of the adhesive layer as a lubricant. The bonding by the adhesive shall be deemed effective only as a device for installation and shall not be deemed to secure bearings against displacement for the purpose of design.

527 UPID


Lifting of a cast in-situ post-tensioned bridge deck for relieving time dependent deformation shortly after installation of bearings, should be avoided. In case such lifting is unavoidable, the lifting arrangement, proper seating of the girder on the bearing, etc. shall be rigidly controlled to avoid any risk of misalignment.

Bulging of the rubber layer between the reinforcing steel laminates on free exposed perimeter under load, which is a normal phenomenon, shall be examined carefully for detecting any evidence of crack or bond failure.

In case seating of bearings on a non-horizontal plane is required, it shall be carried out in accordance with acceptable practice and particular specifications as may be laid out and directed by the Engineer.

As a measure of ample precaution against accidental displacement, the bearings shall be placed in a recess as shown n Fig. 9 of IRC:83 (Part II).

After installation, bearings and their surrounding areas shall be left clean. 13.3.8 Maintenance The maintenance of bearings shall be carried out according to a planned schedule. The structure should be designed and detailed in such a way that · the bearings are easily

accessible after installation for inspection and maintenance. Arrangements for insertion

of jacks to lift the bridge deck shall be made in detailing of structure.

The exposed bearing surface shall be maintained clean and free from contamination with grease, oil or other deleterious matter.

Annual routine maintenance inspection or special maintenance inspection of all bearings

shall be made to check the following aspects and results reported:

The top and bottom load bearing surfaces shall be in full contact with the plinth

(bottom supporting surface) and the soffit (top supporting surface). If there is

imperfect contact between the bearing surfaces and the soffit and plinth, the angle

between the soffit and plinth shall be checked against the design specifications.

The magnitude of the shear deflection of each bearing shall be checked to ensure that it is within the design specifications.

A visual inspection shall be made of all the accessible edges. A note shall be made of the

size and position of any cracks, splits or uneven bulges.

The plinth and soffit shall be examined for signs of displacement from original position of bearing which may be indicated by black marks left on the plinth and soffit.

Where applicable, the sliding surfaces shall be examined for cleanliness and for any

movements beyond the design range.

Where applicable, protective coating and/or dust protection shall be examined for signs of deterioration.

528 UPID


Damaged bearings shall be replaced immediately. To avoid differences in stiffness, all

adjacent bearings on the same line of support shall also be replaced.

13.4 POT BEARINGS 13.4.1 General

Pot bearings shall consist of a metal piston supported by a disc of unreinforced elastomer

confined within a metal cylinder to take care of rotation. Horizontal movement, if required,

shall be provided by sliding surfaces of PTFE pads sliding against stainless steel mating

surfaces, with a system of sealing rings. Pot bearings shall consist of cast steel assemblies or

fabricated structural steel assemblies.

13.4.2 Materials

13.4.2.1 Structural steel, mild steel, high tensile steel and steel for

forging shallconform to the requirements of Section 1009 of these

Specifications. 13.4.2.2 Cast steel shall comply with Grade 280-520W or 340-570W of IS:1030.

13.4.2.3 Stainless steel shall conform to AISI 316 Lor 02Cr17Ni12M02 of IS:6911.

13.4.2.4 PTFE

The raw material for PTFE used in bearings shall be pure polytetrafluoroethylene, free sintered without regenerated materials or fillers. The mechanical and physical properties of unfilled PTFE shall comply with Grade A of BS:3784 or equivalent. PTFE shall be either in t,he form of solid rectangular modules or large sheets with dimples formed by hot pressing or moulding. Sheet with dimples formed by machining or drilling from a solid PTFE sheet, shall

not be permitted. The surface of PTFE sheets/modules which are to be in contact with metal backing plates, shall be provided with suitable chemical treatment for proper bonding. Adhesives used for bonding PTFE to backing plates, shall produce a bond with minimum peel strength of 4 N/mm width when tested in accordance with BS:5350 (Part C9).

13.4.2.5 Elastomer The elastomer to be used for the components of bearings shall comply with provisions of Table 13.4 of this Section. The confined elastomer inside the pot shall have the properties as given in table.

Table 13.4: Properties of Confined Elastomer

S.No. Property Unit Test Method-Specification Limiting

Reference Value

1) Hardness IRHD 18:3400 (Part II) 50±5

2) Min. tensile strength MPa IS:3400 (Part I) 15.5

3) Min. elongation at break As per Table 1 of IRC:83 (Part II)

4) Max. compression set -do-

5) Accelerated aging -do-

13.4.2.6 Composite Material For guide of Pot bearings, composite material may be used for achieving lower coefficient of friction and higher strength. Such composite material shall consist of either (a) a bronze

529 UPID


backing strip and a sintered inter-locking. Pofous matrix impregnated and overlaid with a PTFE! Iead mixture or (b) a mixture of PTFE, glass fibre and graphite embedded in a bronze mesh which is bonded to a galvanized steel backing strip. 13.4.2.7 Seals

Internal seals shall be either of the following: Brass sealing ring made of metallic brass conforming to IS:410.

Poly Oxy Methylene (POM) sealing chain of proven type consisting of individual

interlocking elements made of moulded polyoxy methylene having properties as specified in Table 2 of IRC:83 (Part Ill).

External seals and wiper seals shall be made of elastomer conforming to provisions of

Clause 13.6.2.5. 13.4.2.8 Fasteners

Bolts, screws, nuts and lock nuts, shall generally conform to IS:1363, 18:1364, IS:1365, 18:2269, 18:3138, IS:6761 and 18:6639 as appropriate with mechanical properties conforming to IS:1367. Threads shall generally conform to 18:4218. Washers shall conform to IS:2016 and 18:6610 as appropriate.

13.4.3 Manufacture

The main components of a bearing shall be cast/forged as a single monolithic body. lfthey are made from mild steel,they shall be machined to the.desired shape from a single piece of mild steel free of laminations. No welding is permitted for manufacture of the main components of a bearing.

The mating surface of the piston and cylinder of Pot bearings and that of the pin and cylinder of Pin bearings, shall be metallurgically hardened. The surface hardness shall not be less than 300 BHN.

The guides shall always be monolithic with the parent component.

For cast steel bearings, surfaces which will be in contact with concrete as well as non-working external surfaces of components may be kept in as-cast condition.

For sliding components, stainless steel sheet shall be attached to the backing plate by continuous fillet welding along the edges, in such a fashion as to ensure flatness of the stainless steel sheet throughout its service life and avoid entrapment of air and prevent ingress of moisture at the interfaces. The backing plate shall extend beyond the edges of the stainless steel sheet to accommodate the weld which should not protrude above the top of the stainless steel sheet.

Suitable glue shall be used while confining the PTFE in the recesses. For large PTFE sheets sub-divided into parts, each individual part shall be confined into separate recess.

For internal seal, split rings 2 mm thick and 20 mm wide made of metallic brass shall be provided in layers with staggered split positions. For elastomeric pressure pad of up to 480 mm diameter, a minimum of 2 layers of rings shall be provided, while for that above 480 mm diameter, a minimum of 3 layers of rings shall be provided.

530 UPID


For internal seal of POM, the sealing chain made of individual interlocking elements shall be moulded as an integral part of the elastomeric pressure pad during the vulcanization process.

Pre-setting of sliding element if required shall be done in the manufacturer's workshop before dispatch.

The bearing assembly shall be"provided with temporary clamps to avoid separation of parts during transportation and installation.

All welding shall be as per IS:816 and IS:9595, with electrodes as per IS:814. Preheating and post-weld stress relieving shall be done if required.

Movement indicators shall be provided to facilitate routine inspection during service period.

All non-working surfaces as well as the surfaces to be in contact with the structure shall be suitably prepared by sand/shot blasting to SA 2% quality as per IS:9954. ·

All non-working surfaces shall be given suitable protective coating either by painting or by zinc spraying. The total dry film. thickness of protective coating shall not be less than 160 !Jm.

Painted protective coating shall comprise of two coats of epoxy primer enriched with metallic zinc, one intermediate coat of high build epoxy paint reinforced with MIO (Micaceous Iron Oxide) and one coat of high performance epoxy finish paint as per manufacturer's specification.

Bearing components to be embedded in concrete or surfaces of any component to be in contact with concrete structure, shall be given a coat of epoxy primer or any other suitable coating before dispatch, to prevent corrosion during transportation and storage at site. The protective coating shall be such that it will not affect the bond between the bearing component and the concrete.

Silicon grease shall be applied at the PTFE - stainless steel interface of Pot bearings.

The confined elastomeric pressure pad shall be lubricated with a suitable lubricant, which will not affect the material of the pad.

13.4.3.1 Manufacturing Tolerances The overall dimensions of any assembled bearing or component thereof shall not exceed the tolerance limits as given in Table 13-5:

Table 13.5: Manufacturing Tolerances Item Tolerances

1) Plandimensionofassembled bearing -0 mm to +5 mm or 0.5 percent of plan dimension whichever is higher

2) Overallheightofassembled bearing -0 mm to +3 mm or 1 percent of overall height whichever is higher

531 UPID


Parallelism of top surface of 1 in 200 assembled bearing w.r.t. the bottom surface as datum

4) Height of confined elastomeric -0 per cent to + 0.5 percent

pressure pad Thickness of any machined steel -0 mm to +1 mm

component 6) Overall dimensions of any Class 2 of IS:4897

unmachined cast steel component

7) Stainless steel sliding surface 0.0004L,whereL.=lengthindirectionof Flatness movement

Surface finish RaS0.25 !Jm as per IS:3073

The tolerance on flatness of PTFE shall be 0.2 mm where the diameter or diagonal is less than 800 mm and 0.025 per cent of the diameter or diagonal what re this dimension is greater than or equal to 800 mm. On PTFE surfaces made up of more than one piece of PTFE the above conditions shall apply to the diameter or diagonal dimension of the inscribing circle or rectangle around the PTFE. The tolerance of centre-to-centre distance of dimples, depth of dimples arid diameter of dimples for dimpled PTFE sheet shall be ±0.5 mm, ±0.5 mm and ±1.0 mm respectively.

The dimensional tolerances of confined PTFE shall be as given in Table 2000-6. The

gap between the edge of the PTFE sheet and the edge of the recess in which it is confined,

shall not anywhere exceed 0.5 mm or 0.1 per cent of the corresponding plan dimensions of

the PTFE sheet, in the direction measured, whichever is greater, but in - no case shall exceed

1 mm, The profile tolerance on the specified projection of PTFE above its confining recess

shall be as given in Table 13-6.

Table 13.6: Dimensional Tolerance of Confined PTFE and Profile Tolerance of its Projection

Maximum Dimension Tolerance on Plan Tolerance on Thickness

Tolerance on Specified of PTFE (Diameter or Projection above Dimension (mm) (mm) Diagonal) (mm) Recess (mm)

<600 ±1.0 -0 to +0.5 -0 to +0.5

>600,:!>1200 ±1.5 -0 to +0.6 -0 to +0.6

>1200,:!>1500 ±2.0 -Oto+0.7 -0 to +0.8

Tolerance of Fit

Tolerance of fit between different components of bearings shall be as follows:

For Pot bearings the tolerance of fit between the piston and cylinder shall be +0.75 mm to +1.25 mm.

For Pot bearings the tolerance of fit between the confined elastomeric pressure pad and cylinder shall not exceed 0.5 percent of the diameter of the pad or 1 mm, whichever is higher.

532 UPID


For Pin bearings the tolerance of fit between the pin and cylinder shall be+ 1.5 mm to +2 mm. Manufacturing tolerances of the contact surfaces of pin and cylinder shall be as per h11 and H11 of 18:919 respectively. The tolerance of fit between guide(s) and adjacent-component shall be +2 mm to +4 mm.

13.4.4 Inspection and Testing Inspection and testing shall consist of the following actions:

Inspection and testing of raw materials

Process inspection

Inspection and testing of finished bearings

The manufacturer shall have all test facilities required for process and acceptance control tests, installed at his plant to the complete satisfaction of the Inspector appointed by the Engineer. The test facilities and their operation shall be open for inspection by the Inspector at any time.

A testing programme shall be drawn up and submitted by the manufacturer to the Inspector and his approval obtained before commencement of testing. All tests on raw materials and finished bearings shall be carried out at the manufacturer's workshop as per procedures laid out in this Section. All the test reports duly certified by the Inspector shall be furnished by the manufacturer at the time of dispatch of the bearing from the workshop.

Routine test covering all the three items mentioned in i) above shall be carried out by the manufacturer for the bearings of each lot under acceptance. In addition, type test covering items b) and c) of i) above shall be carried out on bearings of each type and load capacity, selected at random by the Inspector, one for each lot. The size of each lot for similar type of bearings shall be 25 nos. or part thereof. Each type of bearing shall be treated as a separate lot. The Inspector may also carry out random tests on raw materials on samples drawn by the manufacturer, in which case the identification and marking of the sample will be done in the presence of the Inspector. A detailed quality control report of routine tests shall be furnished by the manufacturer to the Inspector, for each lot of bearings offered for inspection.

13.4.4.1 Tests on Raw Materials Tests on raw materials as per relevant material standards, shall be carried out by the manufacturer in accordance with stipulations in Appendix 2 of IRC:83 (Part Ill).

13.4.4.2 Process Inspection/Tests Test on welding shall consist of DP test and visual inspection as per IS:822. The hardness of all major steel components shall be tested to determine the Brinnel

Hardness Number (BHN), which shall be not less than 120 BHN for mild steel and 150

BHN for cast steel and forged steel. All major metallic components shall be ultrasonically tested as per Level 3 of IS:9565. The surface hardness of the mating interface shall be checked in Accordance with the

requirement specified in Clause 2006.3 ii).

533 UPID


Corrosion protection shall be checked in accordance with the requirement specified in Clause 2006.3 xiv).

In case any of the acceptance control tests are deemed to be unsatisfactoryby the

Inspector, complete bearing or particular component(s) of the entire lot may be

rejected, depending on the cause of rejection i.e. if the test of any material is

unsatisfactory, the component involving that material shall be rejected for the entire lot;

but if a finished bearing fails in load test, the complete bearing shall be rejected and all

the bearings of that type and load capacity, shall be load tested before acceptance. If the

result of process inspection is unsatisfactory, proper rectification measures shall have to

be adopted by the manufacturer and the acceptance tests shall be repeated.

13.4.4.3 Inspection/Test of Finished Bearings All bearings of the lot shall be visually inspected for any defects in surface finish, shape

or any other discernible superficial defects. All bearings shall be checked for overall dimensions as per manufacturing tolerances

specified in Clause 13.6.3.1. At least one or a pair of bearings of each type and different vertical load capacity,

selected at random, shall be load tested. For Pot and PTFE bearings, the test load shall

be 1.25 times the design vertical load while that for Pin and Metallic Guide Bearings, it

shall be 1.25 times the specified design horizontal load. Additionally, for testing of Pot

and PTFE bearings under a combination of loads acting in different axes, the test loads

shall be 1.1 times the respective design loads. The test load shall be applied in stages

and held for 30 minutes. For Pot bearings, the vertical deflection under sustained test

load shall not increase by more than 4% of the thickness of the confined elastomeric

pressure pad. The load shall then be removed and the bearing dismantled for visual

examination. Visual examination of the test bearing shall be carried out both during and after the test.

Any visual defects, such as physical damage, cold flow of PTFE resulting in reduction

of height by more than 0.5 mm, damage of internal seal and/or extrusion of the

confined elastomeric pressure pad for Pot bearing, defects/cracks at metal to metal

contact surfaces, shall lead to rejection of the bearing.

For bearings with sliding components, friction test shall be performed on properly lubricated

PTFE-stainless steel sliding surface at constant vertical load equal to the design vertical load

as well as the permanent vertical load. Horizontal load shall be applied till sliding occurs.

Coefficient of friction ( ) shall be determined on the basis of applied vertical and horizontal

loads and shall not exceed two-thirds of the value specified in Table 13.7, depending on the

actual average pressure on PTFE due to the applied vertical load.

534 UPID

Section VII: Works Requirements Table 13.7: Coefficient of Friction for Stainless Steel Sliding on Properly Lubricated PTFE

Average Pressure on Confined PTFE (MPa) Maximum Coefficient of Friction

5 0.08

10 0106

20 0.04

<!: 30 0.03

Rotation test shall be performed on Pot bearing with properly lubricated elastomeric pressure pad for design rotation under a constant vertical load equal to the permanent vertical load.

13.4.4.4 Certification and Marking Bearings should be transported to bridge site after final acceptance by the

Inspector/inspection agency appointed by the concerned authority, along with an authenticated copy of the certificate of acceptance. An information card listing the required bearing characteristics, duly certified by the manufacturer should also be appended with the certificate.

All bearings shall have suitable index markings in indelible ink or flexible paint, which if

practicable, shall be visible even after installation, giving the following information:

Name of manufacturer

Month and year of manufacture

Bearing designation

Type of bearing

Load and movement capacity

Centre line markings to facilitate installation

Direction of major and minor movement, if any

Preset, if any

13.4.5 Installation

13.4.5.1 General

i.) Bearings shall be so located as to avoid the accumulation of dirt and debris on

or around them. Detailing of the structure shall be such that water is prevented

from reaching the bearings.

ii.) In order to avoid contamination of moving surfaces, bearings should not

normally be dismantled after leaving the manufacturer's workshop. However,

if for any reason, a bearing is required to be dismantled, it shall be done only

under expert supervision for which the manufacturer's help may be sought.

iii.) Transfer of load from the superstructure to the bearings should not be allowed

until the bedding material has developed sufficient strength. Temporary

clamping devices should be removed at the appropriate time before the

bearings are required to accommodate movement. The holes exposed on

535 UPID


removal of temporary transit clamps should be filled with selected material. Where re-use of these fixing holes may be required, the material used for filling the holes should be capable of being easily removed without damaging the threads.

iv.)

Suitable .temporary supporting arrangements under bearing base plates should be made to accommodate thermal movement and elastic deformation of the incomplete superstructure. Such temporary supports, if provided, should be removed once the bedding material has reached its required strength. Any voids left as a consequence of their removal should be made good using the same bedding material. Steel folding wedges and rubber pads are suitable for use as temporary supports under bearing plates.

13.4.5.2 Bedding

i) The bedding material shall be selected keeping in view a number of factors such as the

type and size of bearing, construction sequence, load on the bearing, required setting

time, friction requirements, access around bearings, design and condition of surface in

the bearing area and thickness, strength and shrinkage ofbedding material.

Commonly used bedding materials are cementitious or chemical resin mortar and grout.

In some cases, it may be necessary to carry out trials to ascertain the most suitable

material. The bedding material, whether above or below the bearing, should extend over the whole

area of the bearing in order to ensure even loading. After installation, there shall be no

voids or hard spots. The top surface of any extension of the bedding beyond the bearing

shall have a downward slope away from the bearing. The bedding material shall be capable of transmitting the applied load to the structure

without being damaged. Surfaces to receive bedding mortar shall be suitably prepared

so as to be compatible with the mortar chosen.

13.4.5.2 Fixing of Bearings

i.) Bearings should be anchored in order to countervibrationand accidental impact.

Anchorage should be accurately set into recesses cast into the structure using

templates. The remaining space in the recesses should be filled with material

capable of withstanding the loads.

ii.) Bearings that are to be installed on temporary supports should be firmly fixed to

the substructure by anchorage or other means to prevent disturbance during

subsequent operations. Voids beneath the bearings should be completely filled

with bedding material using the appropriate method.

iii.) Bearings may be fixed directly to metal bedding plates that may be cast in or bedded on top of the supporting structure to the correct level and location.

iv.) If the structure is of steel, the bearings may be bolted directly onto it.

536 UPID


Care shall be taken to ensure that there is no mismatch between the bolt holes of the structure and those of the bearing.

v.)

Threaded fasteners shall be tightened uniformly to avoid overstressing of any part of the bearing.

13.4.5.4 Bearings Supporting In-situ Concrete Deck

Where bearings are installed prior to casting of an in-situ concrete deck, formwork

around bearings should be properly sealed to prevent grout leakage. It is essential that

the bearings and particularly the working surfaces are protected during concreting

operations: Sliding plates should be fully supported and care taken to prevent tilting,

displacement or distortion of the bearings under the weight of green concrete. Any

mortar contaminating the bearings should be completely removed before it sets.

For bearings supporting precast concrete or steel beams, a thin layer oL.synthetic resin

mortar should be used between bearings and the beams. Bearings shall be bolted to

anchor plates or sleeves embedded in precast concrete elements or to machined sole

plates on steel elements

13.4.5.5 Installation Tolerances Bearings shall be located so that their centre lines are within ± 3 mm of their correct position.

The level of a bearing or the mean levels of more than 1 bearing at any support, shall be

within a tolerance of± 0.0001 times the sum of the adjacent spans of a continuous girder, but

not exceeding ± 5 mm. Bearings shall be placed in a horizontal plane within a tolerance of 1

in 200 in any direction, eVen under superstructure in gradient. 13.4.6 Maintenance

Bearings shall be designed and manufactured to· make them maintenance free so as to

withstand undesirable effects caused by extreme atmosphere or aggressive

environmental conditions/ unforeseen events. Suitable easy access to the bearings shall be provided for inspection and maintenance.

Provision shall also be available for jacking up the superstructure so as to allow

repair/replacement of bearings. The area surrounding the bearings shall be kept clean and dry to avoid damage to the

bearings. The bearings shall also be periodically cleaned to remove deposits of salts,

debris, dust or other foreign material. Periodic inspection and nominal maintenance of bearings shall be carried out in order to

ensure their better performance and longer life. The bearings are required to be

inspected at intervals of one year for the first five years after installation and at intervals

of two years thereafter. The bearings shall also be examined carefully after unusual occurrences such as passage

of heavy traffic/oversized loads, earthquakes and battering by floating debris in high

floods.

537 UPID


13.5 INSPECTION AND TESTING Where any patented items are used, the manufacturer's certificate for the same with test proofs shall be submitted along with the design and got approved by the Engineer before their use in work. 13.6 MEASUREMENTS FOR PAYMENT Bearings shall be measured in numbers, according to their capacities and particular specifications given on the drawings. The quantity of elastomeric bearings shall be measured in cubic centimetres of finished dimensions. 13.7 RATE The contract unit rate of each type of bearing shall include the cost of manufacturing, supplying and fixing the bearings in position complete as specified on the drawings or as directed by the Engineer. The rate shall also include. the cost of samples and their testing as required under the specifications or as directed by the Engineer. In case of steel bearings the rate shall include the cost of all nuts, bolts and all tests prescribed in the specifications and shown on the drawings

538 UPID


14 Wearing Coat and Appurtenances

14.1 DESCRIPTION The work shall include wearing coat and bridge appurtenances such as railing, crash barrier, approach slab, drainage spout and weep holes. The work shall be executed in conformity with details shown on the drawings and these specifications or as approved by the Engineer.

14.2 WEARING COAT

14.2.1 Bituminous Wearing Coat Bituminous wearing coat shall comprise of following types: Type 1: Bituminous Concrete 50 mm thick laid in single layer

Type 2: Bituminous Concrete 40 mm thick overlaid with 25 mm thick mastic asphalt Stone

Type 3: Matrix Asphalt 50 mm thick laid in single layer

Type 4: Mastic Asphalt 50 mm thick laid in single layer

Before laying wearing coat the deck surface shall be thoroughly cleaned and tack coat shall be applied. The construction operations and bituminous mixes and tack coat shall conform to Section 500 of MORT and H Specifications.

14.2.2 Cement Concrete Wearing Coat Cement concrete wearing coat shall be laid separately over the bridge deck. The thickness of wearing coat shall be 75 mm. The concrete shall be of minimum M30 grade. Steel reinforcement of 8 mm diameter at 150 mm spacing in both directions shall be provided at the mid depth of the wearing coat. In a length of 1 m near the expansion joint additional reinforcement of 8 mm diameter bars shall be provided in both directions to make the spacing as 75 mm.

Cement concrete and steel reinforcement shall conform to Section 7.0 and Section 6.0 respectively of these Specifications.

Curing of wearing coat shall start as early as possible.

All carriageway and footpath surfaces shall have non-skid characteristics.

14.2.3 The cross slope in the deck shall be kept as 2.5 percent.

1 4.2.3 For the structures with flat deck surface, camber/super elevation in the wearing coat shall be achieved as below:

In bituminous wearing coat provide profile making course before laying wearing coat. The profile making course shall be of the same material as of wearing coat. The thickness of wearing coat at any point shall not be less than that given in Clause 2702.1 of MORT and H Specifications.

In case of cement concrete wearing coat provide profile corrective course

along with wearing coat in single layer.

539 UPID


14.2.4 Overlay on the existing wearing coat on bridge decks shall not be permitted. In case the wearing coat is damaged, it shall be repaired or replaced. The dismantling of wearing coat shall be as per Section 2800 of MORT and H Specifications.

14.3 RAILING AND CRASH BARRIER

14.3.1 General

Bridge railing/crash barrier includes the portion of the structure erected on and above the kerb.

Railing/crash barrier shall not be constructed until the centering false work for the span

has been released and the span is self-supporting.

For concrete with steel reinforcement, specifications for the items of controlled concrete

and reinforcement mentioned under relevant Sections of these Specifications shall be applicable.

The railing/crash barrier shall be carefully erected true to line and grade. Posts shall be

vertical with a tolerance not exceeding 6 mm in 3 m. The pockets left for posts shall be filled with non-shrink mortar.

The type of railing/crash barrier to be constructed shall be as shown on the drawings and

shall conform to IRC:5 and IRC:6.

Care shall be exercised in assembling expansion joints in the railing/ crash barrier to

ensure that they function properly.

The railing/crash barrier shall be of such design as to be amenable to quick repairs.

The material of metal railing/crash barder shall be handled and stored with care, so that it remains clean and free from damage. Railing/crash barrier materials shall be stored above the ground on platforms, skids, or other supports and kept free from grease, dirt and other contaminants.

Any material which is lost, stolen or damaged after delivery shall be replaced or repaired by the Contractor. Methods of repairs shall be such that they do not damage the material or protective coating.

14.3.2 Metal Railing/Crash Barrier Materials, fabrication;· transportation, erection and painting for bridge railing/crash barrier shall conform to the requirements of Section 1900 of MORT and H Specifications.

All steel railing elements, pipe terminal Sections, posts, bolts, nuts, hardware and other steel fittings shall be galvanised or painted with an approved paint.

If galvanised, all elements of the railing/crash barrier shall be free from abrasions, rough or sharp edges, and shall not be kinked, twisted or bent. If straightening is necessary, it shall be done as per method approved by the Engineer.

540 UPID


Damaged galvanised surfaces, edges of holes and ends of steel railing/crash barrier cut after galvanising shall be cleaned and re-galvanised.

The railing/crash barrier shall be carefully adjusted prior to fixing in place to ensure proper matching at abutting joints and correct alignment and camber throughout its length. Holes for field connections shall be drilled with the railing/crash barrier in place in the structure at proper grade and alignment.

Unless otherwise specified on the drawings, metal railing/crash barrier shall be given one shop coat of paint and three coats of paint after erection, if sections are not galvanised.

Railing/crash barrier shall follow the alignment of the deck. Where required as per the drawings, the rail elements shall be before erection.

14.3.3 Cast In-Situ Concrete Railing/Crash Barrier The portion of the railing/crash barrier or parapet which is to be cast in-situ shall be constructed in accordance with the requirements for Structural Concrete Section and reinforcement conforming to Sections 6.0 and 7.0 of these Specifications.

Forms shall be fabricated conforming to the shape of railing/crash barrier shown on the drawings. It shall be ensured that no form joint appears on plane surfaces. For bridges/ viaducts of length more than 500 m horizontal slip forms shall be used for casting of crash barriers.

All mouldings, panel work and bevel strips shall be constructed according to the details shown on the drawings. All corners in the finished work shall be true, sharp and clean-cut and shall be free from cracks, spalls or other defects. Castings of posts shall be done in single pour.

14.3.4 Precast Concrete Railing/Crash Barrier Precast members for railing/crash barrier shall be of reinforced cement concrete and shall conform to Sections 1600 and 1700 of these Specifications. The maximum size of the aggregate shall be limited to 12 mm and minimum concrete grade shall be M30 for railings and M40 for crash barriers. The precast members shall be removed from the moulds as soon as practicable and shall be kept damp for a period of at least 10 days, during which they shall be protected from sun and wind. Any precast member that becomes chipped, marred or cracked before or during the process of placing shall be rejected.

14.4 APPROACH SLAB Reinforced concrete approach slab with 12 mm dia bars at 150 mm c/c in each direction both at top and bottom in M30 grade of concrete covering the entire width of the roadway, shall be provided as per details given on the drawings or as approved by the Engineer. Minimum length of approach slab shall be 3.5 m and minimum thickness 300 mm

The cement concrete and reinforcement shall conform to Sections 7.0 and 6.0 respectively of these Specifications.

The approach slab shall rest on a base of 150 mm thick M15 grade concrete-or as shown on the drawings or as directed by the Engineer.

541 UPID


14.5 DRAINAGE SPOUTS Drainage along longitudinal direction shall be ensured by sufficient number of drainage fixtures embedded in the deck slab. The spouts shall be of not less than 100 mm in diameter and shall be of corrosive resistant material such as galvanised steel with suitable cleanout fixtures. The spacing of drainage spouts shall not exceed 10 m. The discharge from drainage spout shall be kept away from the deck structure by means of suitable down pipes upto 500 above High Flood Level. In case of viaducts in urban areas, the drainage spouts should be connected with suitably located runners and down pipes to discharge the surface run-off into drains provided at ground level.

14.5.1 Fabrication The drainage assembly shall be fabricat d to the dimensions shown on the drawings. All materials shall be corrosion resistant;. Steel components shall be of mild steel conforming to IS:226. The drainage assembly shall be seam welded for water tightness and then hot-dip galvanised.

14.5.2 Placement The galvanised assembly shall be given two coats of bituminous paint before placement. The whole assembly shall be placed in true position, lines and levels as shown on the drawings with necessary cutouts in the shuttering for deck slab and held In place firmly. Where the reinforcements of the deck are required to be cut, equivalent reinforcements shall be placed at the corners of the cut out.

14.5.3 Finishing After setting of the deck slab concrete, the shrinkage cracks around the assembly shall be sealed with polysulphide sealant or bituminous sealant as per 18:1834 and the excess sealant trimmed to receive the wearing coat. After the wearing coat is completed, similar sealant shall be provided to cover at least 50 mm on the wearing coat surface all round the drainage assembly.

14.6 WEEP HOLES Weep holes shall be provided on· all plain concrete, reinforced concrete, brick masonry and stone masonry structures such as, abutment, wing wall and return walls as shown on the drawings or as directed by the Engineer to permit water to flow out without building up pressure in the back fill. Weep holes shall be provided with 100 mm diameter AC/PVC/HDPE pipe for structures in plain/reinforced concrete or brick masonry. In case of stone masonry, weep holes shall be of rectangular shape 80 mmwide, 150 mm high or circular with 150 mm diameter. Weep holes shall extend through the full width of concrete/masonry with slope of about 1 vertical: 20 horizontal towards the draining face. The spacing of weep holes shall be 1 m in either direction or as shown in the drawings with the lowest at 150 mm above the low water level or ground level whichever is higher or as directed by the Engineer.

14.7 TESTS AND STANDARDS OF ACCEPTANCE The material shall be tested in accordance with these Specifications and shall meet the prescribed criteria and requirements. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.

542 UPID


14.8 MEASUREMENTS FOR PAYMENT The measurement for payment for wearing coat, railing/crash barrier, approach slab, drainage spout and weep holes shall be made as under:

i.)

Bituminous and cement concrete wearing coat shall be measured in cubic metres.

Steel reinforcement in wearing coat shall be measured in tonnes.

ii.)

Railing and metal beam crash barriers shall be measured in running metres.

iii.)

For concrete crash barriers concrete shall be measured in cubic metres and steel shall be measured in tonnes.

iv.)

Approach slab and its base shall be measured separately in cubic metres.

v.)

Drainage spouts shall be measured in numbers.

vi.)

Weep holes in concrete/brick masonry structure shall be measured in numbers. For structures in stone masonry, weep holes shall be deemed to be included in the item of stone masonry work and shall not be measured separately.

14.9 RATE The contract unit rate for wearing coat shall include the cost of all labour, material, tools and plant and other costs necessary for completion of the work as per these specifications.

The contract unit rate of railing and crash barrier shall include the cost of ail labour, material, formwork, tools and plant required for completing the work as per these Specifications.

The contract unit rate for approach slab shall include the cost of all labour, material, tools and plant required for completing the work as per these Specifications. The rate for base shall include cost of all labour, material, tools and plant required, including preparation of surface and consolidation complete in all respects.

The contract unit rate for drainage spout shall include the cost of all labour, material, tools and plant required for completing the work as per these Specifications. It shall also include the cost of providing runners and down pipes with all fixtures upto 500 mm above high flood level or up to the drains at ground, as applicable or as shown on the drawings.

The contract unit rate for weep holes shall include the cost of all labour, material, tools and plant required for completing the work as per these Specifications.

543 UPID


15 SHEET PILES

15.1 GENERAL Sheet piling be provided as cut off walls in barrage and its appurtenant works dams and canal structure as per approved drawings connection between steel sheet piles and concrete shall be make as shown on the drawing. The choice of sheet piles in preference to concrete cut off sho9uld be guided by physical condition of bed and also economy.

15.2 DRIVING SHEET PILES Sheet piles of required length and section shall be driven in the location as shown on the drawings. The pilling should be done closely to the lines shown on drawings or as per direction of Engineer-in-charge Necessary assembly frames or other suitable guide structures shall be used so that each pile is driving plumb. Mode of driving shall be such as to ensure driving of sheet piles true to line and plumb without splitting interlock or web wrinkling.

The driving of piles shall be done either by a power hammer or by manually driven monkey if the manual driving could be possible in the strata in which they are desired to be driven double piles shall be retrieved.

Sheet piles shall be cut or left at the required levels specified in the drawing. All sheet piles having a plumb deviation of more than 1/8” per foot and all sheet piles which have left their interlock or otherwise injured in diving shall be pulled out and fresh piles driven in their places. Should boulders be encountered, efforts shall be made to drive the pilling to the required depth either by moving or shattering the boulder or by deviation in the line of piling as ordered by Engineer–in-charge.

If at any time the forward edge of steel sheet piling is found to be cut of plumb the piling already assembled and partly driven shall be driven to the required depth and taper piles shall be used to bring the forward edge to plumb before the next pile is assembled and driven. The maximum taper in a single pile shall be 27mm per meter length (1/3 inch per ft of length). If work of pile driving is done by a contracting agency the sheet piles including taper piles and splice plates and bolts for making splice will be furnished by the department as per stipulation in the agreement.

15.3 PAINTING SHEET PILES The piles shall be rubbed oil all milli scales and rusts by hard wire brush or other electrically driven rust cleaner before applying paint. Approved paint of anti-corrosive nature shall then be applied uniformly with brush from one end and first coat of priming shall be allowed to dry in air for a minimum period of 24 hours. After the coat dries out, un-uniformly of the paint shall be removed by gently rubbing the prime surface with emery paper of final grit. The second coat of anti corrosive with domestic paint or any other paint approved by the Engineer-in-charge shall be applied and allowed to dry for 24 hours after which the final coat of the paint shall be applied. No paint shall be applied in the portion required to be embedded in concrete.

15.4 MODE OF DRIVING OF SHEET PILES The mode of driving of sheet piles shall be a two stage driving which gives the best result and avoid plumb deviation.

544 UPID

Section VII: Works Requirements The first stage driving or pitching of piles as it is called, shall be done by putting two bottom guides securely fixed with the ground keeping the two edges of the guide flush with the back of the piles. The guides shall be strutted at a suitable intervals before piles are pitched and should be straight enough to withstand the vibrations transmitted to it by the strokes of power hammer or the impact of the monkey falling from top driven manually.

The pitching of the piles shall proceed the driving and shall run in advance by about 60’ it minimum and the pitching driving may be done by driving atleast 4 to 5’ ft. This method remedies the large scale lateral and linear displacement of piles.

The final stage driving shall be accomplished by redriving the piles standing erect interlocked in the clutches provided for the purposed. The final stage driving shall be done by attaching plumb string in the holes provided below the top so that the deviation if any can be detected instantly and remedial measures taken to rectify the piles position.

The piles shall be provided with a cap having at least 0.8m (2’ -6”) guide at the top in order that the strokes coming on the top falls squarely on the piles and does not deviate making the pile leaning on the sides.

When driving without a frame, care must be taken to see that the envil and the hammer block remains reasonably vertical by providing pulling wires or ropes of flexible length to suit and keep the hammer vertical while going down.

15.5 PRECAUTION TO BE TAKEN IN SELECTING AND STRAIGHTENING PILES The piles before taken for driving shall invariable be tested for its true shape and for correct clutches. If the pile is not perfectly straight with its edges in perfect shape they are likely to cause rapture in the locks. A bent or blocked pile must be examined and seen that there is no deformation anywhere causing obstruction in driving and should such a deficiency be found they must be removed.

The clutches of the piles before driving must be greased after painting so that the frictional resistance to the pile being driven into them is minimized.

15.6 MAKING JUNCTION PILES AND CORNER PILES Junction piles shall be made to suit the angle of the junction provided in the drawing and similarly the angle piles shall be made out of stock by shearing the normal piles unless the required special corner pile is obtained. Since the angle of required junction piles usually are not known, they have to be manufactured locally.

15.7 WELDING OF JUNCTION AND SPECIAL PILES The shared edges of the piles must be filed or cut into double V E E or single V welding done from top while filling weld metal in the V E E so prepared, care must be taken to see that the weld metal reaches all parts thoroughly.

For angle, the web of the sheet piles shall be kept so that the slopped sheared edge of the piles conform the angle required as per drawing or direction of E/I.

Elongation of piles by welding two pieces shall be done with specific permission of the Engineer-in-charge when the driving depth is large being above 15’ ft. For shallow piles the welding may be done by cutting half V on each sheet and joining them into one.

545 UPID


15.8 EMBEDDED SHEET PILES IN CONCRETE TRENCHES Sheet piling shall be cut or left at the required levels specified in the drawings. This shall be held in position so as not to be disturbed when the concrete is placed. Anchor bars will be placed through the top portion of the sheet piling where shown on the drawings. Special care shall be taken not to disturb the piling after the concrete has been placed and during the back filling of the excavation.

15.9 MODE OF PAYMENT

Item of work of sheet pile consist of two components:

Supplying sheet pile and driving the same at site as per drawing, Technical Specification and direction of Engineer-in-charge.

15.9.1 Supplying Sheet Pile Supplying sheet pile of required specification as per drawing and direction of Engineer-in-charge, including transpiration and storage at the site. The unit for measurement for payment will be in HT. The rate will be inclusive of all cost, However, the will not include the driving the sheet pile, for which a separate rate will be provided.

The payment for supply the sheet pile will include only these components which will be actually utilized in the work in driving and embedding into concrete. Wastage will not be included.

15.9.2 Driving Sheet Pile Driving of sheet piles will be paid at the rate of each square meter driven below existing ground level only. Width of each sheet piles will be taken as the shortest distance from the center to center of the interlock unless mentioned otherwise in tender documents. No payment will be made for driving sheet piles more than the required depth and extra charge for handling sheet piles which are left over the ground level will not be allowed.

The unit rate shall include cost of handling and carriage of materials from storage yards, storing, handling, driving, cutting and splicing where required, fabrication taper piles, putting and replacing unsatisfactory and defective piles.

The portion of piles covered in concrete of capping portion will not be including in measurement of pile driving and no payment shall be made for this.

546 UPID


16 CONCRETE BLOCK PITCHING Concrete block shall be constructed over dry graded filter of specific size and thickness in accordance with drawing and specification.

All edges shall be kept vertical and gap of 50mm(2”) shall be left in between the two adjacent blocks, which shall be filled by jharries or singles of size 20mm (1/4”) and down.

Care will be taken to ensure that the mortar does not fall on the filter of jharna ballast so as to choke them. Burlap shall be invariable placed adjacent to the blocks to prevent mortar going in to the filter.

16.1 MODE OF PAYMENT The unit of measurement will be “sqr meter” of the finished area including the quantity of jharries in 50mm (2”) gaps. No separate payment shall be made for jharris and its placement.

547 UPID


17 BOULDER PITCHING Before placing boulders into position the sub grade shall be brought to the uniform level as mentioned in drawing and properly compacted and got approved by the Engineer-in-charge. The stone shall be approved by the Engineer-in-charge as to its size & shape and shall weigh between 40kg to 50kg each. It should be laid with flat surface on top and finished with even

surface. Each boulder shall be laid adjacent to the other so as to create minimum void. To create minimum void and proper packing chiseling will be used wherever necessary. Interstices in between the boulders shall be filled up the spawls properly. The top layer shall have to be leveled and hand packed so as to present an even surface to the flow. Rock

fragment and spawls shall be tightly driven to wedge the boulders in place and to close direct opening to the under lying layer. While laying the boulders attempt shall be made to break the joints as far as possible.

Incase of crated boulder pitching crates will be opened, its wire be stretched and fully straight such that it will take a perfect rectangular shape and size then boulder will be place as mentioned above as per direction of E/I. After proper placing and packing of boulder in crates, they will be closed tightly and perfectly as per direction of E/I.

17.1 MODE OF PAYMENTS The unit of payment will be cubic meter of finished work after deduction of void and rates shall include the cost of supply and placing of boulder and spawls in position and finishing the same in the manner specified.

Payment will be made after deduction of voids 5% in slope and 10% in apron in case of uncrated boulder pitching in case of crated boulder, deduction of void will be taken as 20%.

548 UPID


18 PVC WATER-STOP SEALS

18.1 MATERIAL

PVC water-stops seal shall meet the requirement specified in IS:15058 : 2002

18.2 INSTALLATION PROCEDURE: Water stoppers are tied to steel frame work through eyelets by means of small wires certain metal clamps meant to grip the water stop seal and keep it in proper position. Firstly one half of the water stop is embedded in the concrete leaving the second half extended. Second half is also embedded leaving the centre bulb free for expansion and contraction movements. The water must be installed properly to accommodate joint expansion, contraction and lateral & transverse movement.

18.3 METHODS FOR JOINTING PVC WATERSTOPS WITH HEATER BLADE Water Stoppers can be jointed on site with a simple electrical heater blade. It should be jointed in straight reaches only by are experienced personnel is consultation with the Engineer-in-charge and the manufacture.

Water Bars of same width & design should be sharply leveled at edges using a knife

Turn on the Electric Heater Bade and wait will it become hot.

Place the waterstops on both sided of heater blade & press it until it melts but without burning.

Remove the heater blade upward.

Joint the molten end quickly & hold them together firmly for approximately 20-30 seconds.

18.4 PRECAUTIONS DURING WATER STOP INSTALLATION 18.4.1 They are vulnerable to get damaged during construction. 18.4.2 Compaction of concrete around waterstop should be taken care otherwise it can

dislocate &could lead to a risk of honeycomb formation which may lead to leakage through concrete itself rather ten through joint.

18.4.3 During installation the exposed porting of water stops should be protected against

adverse weather condition.

18.5 MEASUREMENT AND PAYMENT The rate for PVC water stop seal will include supply at site including transportation, storage and handling and installation at the site. The unit rate will be per water length along the joints.

549 UPID


19 REPAIR OF STRUCTURES

19.1 Description Repair of structures shall be carried out in accordance with the repair plans and these specifications or as directed by the Engineer. Where repair work is not covered by these specifications, special specification may be framed. Implementation of repair schemes shall also conform to provisions of IRC:SP:40.

19.2 General 19.2.1 Environmental Aspect Care shall be taken to ensure suitable mitigation measures against noise and dust, pollution and damages to the environs whether temporary or permanent and shall be taken as incidental to work.

19.2.2 Phasing The sequence of work shall be in accordance with the drawings or as directed by the Engineer.

19.2.3 Management of Canal Flow and Traffic In case of canal structures, can has to be taken to see that the repair work is taken up in such a way that when canal is opened during next Kharif season for irrigation, while the work of Modernisation is not complete in all respect, the canal is safe and capable of carrying required discharge.

In case of road bridges traffic management, signage, signalling arrangement, barricading, and lighting arrangement shall be in accordance with Section 100 of MORTH Specification and with these specifications and shall be considered as incidentals to work.

19.2.4 Safety Precautions Adequate precautions shall be taken for safety of personnel, road users and existing services, which, during execution, shall be considered as incidentals to work. Persons working should wear safety helmets and rubber gloves.

19.2.5 Dismantling and Removal of Material Dismantling of any structure component and removal of materials shall conform to Sub-section 6.0 and this section and as shown on the drawings or as directed by the Engineer.

19.3 Sealing of Cracks by Injection of Epoxy Resin

19.3.1 General The work of epoxy adhesive utilising the Structural Concrete Bonding Process shall conform to these specifications.

19.3.2 The Contractor shall furnish detailed methodology of construction including sources of supply of material, tools, equipment and appliances to be used on work, details of personnel and supervision.

19.3.3 Personnel

The Contractor's personnel shall be qualified and experienced in epoxy injection process.

550 UPID


19.3.4 Material The material for injection shall be suitable two-component low viscosity epoxy resin, having the required characteristics of bonding with concrete and resistance to moisture penetration. Epoxy mortar or polysulphide resin may be used for sealing the surface.

The material for epoxy injection shall conform to the following:

The mixing ratio of resin and hardener shall generally be between 1 to 1 and 2 to 1 by volume subject 10 manufacturer's recommendation.

Neither the mixed epoxy adhesive; nor their individual components shall contain solvents

and thinners.

The component shall be free of lumps or foreign material. The viscosity of the individual

components shall not change more than +15 per cent when kepi in closed containers at 25 degrees Celsius after two weeks.

Consistency requirement.

Standard Version Low Viscosity

cps Version cps

Viscosity of Mixed Adhesive at 25(200-300)

(100-190)

degrees Celsius

PotLife of mixed1 hour ±15 minutes

v) adhesive at 25 degrees *

Celsius

vi) Set life of mixed adhesive 3 - 6 hours at 25 degrees Celsius

*In the case of two component injection system where resin and hardener gel mixed at point of injection pot life at 25 degrees Celsius shall be not greater than 15 min +10 minutes.

19.3.5 Equipment for Injection The equipment shall be portable, positive displacement type pumps with interlock to provide positive ratio control of exact proportions of the two components at nozzle. The pumps shall be generally electrically powered and shall provide in- line metering and mixing. The tolerance on mix ratio shall be 5 per cent by volume. The injection equipment shall have automatic pressure control capable of discharging mixed adhesive at any pre-set pressure within the prescribed limits and shall be additionally equipped with a manual pressure control.

The injection equipment shall be equipped with sensors on both the components A and B reservoirs that will automatically stop the machine when only one component is being pumped to the mixing head.

551 UPID


If considered appropriate, suitable compressed air operated epoxy injection gun can be used with prior approval of the Engineer for manual injection of mix when resin and hardener had been mixed in a separate unit.

19.3.6 Preparation Surfaces adjacent to cracks or other areas of application shall be cleaned of dirt, dust, grease, oil efflorescence or other foreign matter by brushing/water jetting /sand blasting. Acids and corrosives shall not be permitted for cleaning.

Entry ports shall be provided along the crack at intervals of not more than the thickness of concrete at the location.

Surface seal material shall be applied to the face of the crack between the entry ports. For through cracks, surface seal shall be applied to both faces.

Before proceeding with the injection, the surface seal material must gain adequate strength with respect to concrete strength of the member/ injection pressure.

19.3.7 Epoxy Injection Injection of epoxy adhesive shall begin at lowest entry port and continue until there is an appearance of epoxy adhesive at the next entry port adjacent to the entry port being pumped. When epoxy adhesive travel is indicated by appearance at the next adjacent port, injection shall be discontinued on the entry port being pumped and entry port shall be sealed. Thereafter, epoxy injection shall be transferred to next adjacent port where epoxy adhesive has appeared.

Epoxy adhesive injection shall be performed continuously until cracks are completely filled. If port to port travel of epoxy adhesive is not indicated, the work shall immediately be stopped. In case the volume of the injected material exceeds 2 litres for a particular entry port, the work shall be stopped and the specifications may be reviewed.

19.3.8 Precautions for Application

Unless otherwise specified, components A and B, i.e., resin and hardener shall be at a

temperature between 10 degrees Celsius and 35 degrees Celsius at the time of mixing.

b) Temperature of structural member during epoxy injection shall

be

between 10 degrees Celsius and 35 degrees Celsius unless otherwise specified.

Immediately prior to use, each component shall be thoroughly mixed -with a clean paddle. The paddle shall be of a type that does not induce air into the material. Separate clean paddle must be used for each component.

Any heating of the adhesive components shall be done by application of indirect heat in

case the work is to be done in cold climate.

Just before use, the two components shall be thoroughly mixed in the ratios specified by

the manufacturer. The length of mixing time shall be in strict accordance with

552 UPID


manufacturer's recommendations. When mined, all adhesives with different coloured components shall have a uniform colour without streaks.

The use of solvents and thinners will not be permitted except for cleaning of equipment.

19.3.9 Testing

19.3.9.1 Material Testing Prior to approval of the material, the following tests shall be carried out at site or in an authorised laboratory for each batch of resin and hardener and each combination thereof at the cost of the Contractor.

Viscosity test for resin and hardener and the mix - three specimens each.

Pot life test - three specimens each

Bond test - three specimens each.

Shear test - six specimens each, 3 after 24 hours and the other three after 72 hours of

curing Subsequent tests shall be carried out as directed by the Engineer.

Pot Life Tests

500 gm of resin formulation shall be prepared by thoroughly mixing the resin and hardener/accelerator/catalyst component in proposed proportion in a 1 kg capacity hemispheral porcelain bowl by means of a spatula or any other agitating device and note down the time and he ambient temperature.

With a clean dry 25 mm size painter's brush, the resin formulation shall be applied on a clean dry surface such as cement concrete over 15- 20 cm length, starting immediately after mixing the formulation and repeating operation every five minutes. When it becomes just difficult to spread the resin properly with the brush, the lime is noted. The time elapsed since completion of mixing of resin formulation is taken as its pot life.

One pot life test shall be performed on commencement of work and the same shall be repeated every four hours,

In case the material fails to satisfy the poi life lest it shall not be used for injection. Where the resin and hardener get mined at point of injection, the pot life is not important and no tests may be required.

Bond Test A standard 150 mm diameter and 300 mm long concrete cylinder shall be cast in 2 pieces by providing a separating media at an axis of 45 degrees Celsius to the longer axis of the cylinder (Refer relevant MORTH specification).

Three each

sets of set shall

such be

split joined

cylinders shall be with epoxy mortar

prepared at four

in advance. Two points to give a

pieces clear

of gap

553 UPID


of about 0.2 mm, which will be injected with epoxy resin at site. After epoxy

has been cured, load test is carried out on the cylinder which shall not be less

than 80 per cent of the cube strength of the concrete mix and the failure shall

not take place at the joint injected with epoxy resin.

Shear Tests

Two steel plates, minimum 3mm thick, shall be bonded with epoxy at site using

the same resin mix as used/proposed lo be used for injection. The assembly shall

be kept in mechanical clamp till epoxy is cured; A total of six specimens shall

be prepared for each batch of materials. Three test specimens shall then be

subjected to a shear force along the axis after 24 hours and the minimum shear strength before failure shall not be less than 1 MPa. (Refer relevant MORTH specification). The remaining test specimens shall be similarly tested after 72 hours of curing. The shear strength before failure shall not be less than 2.5 MPa.

19.3.9.2 Core Test If directed by the Engineer, core tests shall be conducted for the acceptance of the work. The selection of the location of cores shall be made under the direction of the Engineer in such a way that damage in critical/stressed areas of the structure is avoided. The procedure for the test shall be as under.

The Contractor shall obtain 5 cm diameter initial core samples in the first 50 linear metres.

Thereafter, frequency of core sampling shall be as specified or as agreed by the Engineer. The depth of the core shall generally be less than 20 cm. Tests and Acceptance Criteria shall be as follows: Penetration/Visual Examination - a minimum of 90 per cent of the crack shall be full of

epoxy adhesive. Bond Strength : Concrete failure before adhesive failure or 40 MPa with no failure of

either concrete “or adhesive :” If the cores taken in first 50 m length pass tests as specified above, epoxy adhesive injection work at area represented by cores will be accepted. If cores fail either by lack of penetration or bond strength, work shall not proceed further until the areas represented by the cores are rejected and retested for acceptance.

Filling of Field Control Testing Core Holes This procedure consists of using two-component bonding agent applied to surfaces of cored holes followed by application of Non-Shrink cement grout mix placed by hand trowel, thoroughly applied and tamped in place, and finished to match finish and texture of existing concrete to the satisfaction of the Engineer. Materials and procedures for filling testing core holes shall be submitted to and approved by the Engineer before proceeding with core testing work.

19.3.9.3 Test for injection equipment At all times during the course of the work the Contractor shall keep complete and accurate records and make available to the Engineer of the pressure and ratio tests specified above so that the efficacy and accuracy of the injection equipment is verified.

554 UPID


In addition, the Engineer at any time without prior intimation of the Contractor may request the Contractor to conduct the tests specified below, in the presence of the Engineer.

Pressure Test

The mixing head of the injection equipment shall be disconnected and the two

adhesive component delivery lines shall be attached to the pressure check device,

which .shall consist of two independent valved nozzles capable of sensing the

pressure. The check device shall be closed and equipment operated until the

gauge pressure in each line reads 5 MPa. The pumps shall be stopped and

the gauge pressure shall not drop below 4 MPa within 2 minutes.

The pressure test shall be run for each injection unit at the beginning and

after break of every shift.

Ratio Test The mixing head of the injection equipment shall be disconnected and the two adhesive

components shall be pumped simultaneously through the ratio check device, which shall

consist of two independent valved nozzles. There shall be a pressure gauge capable of

controlling back pressure by opening or closing valved nozzles capable of sensing the back

pressure behind each valve. The discharge pressure shall be adjusted to read 5 bar for both

adhesive components, which shall be simultaneously discharged into separate calibrated

containers during the same time period and the amounts discharged into the calibrated

containers simultaneously during the same period shall be compared to determine that the

volume/discharge conforms to the manufacturer's recommended ratio for applicable material.

19.4 Epoxy Mortar for Replacement of Spalled Concrete

19.4.1 Material

19.4.1.1 Formulation The epoxy resins for use in the mortar shall be obtained from a reputed manufacturer and the mortar shall be prepared in conformity with the manufacturer's recommendations.

They shall generally conform to the following:

Contractor shall carry out tests on the samples made out or requirements indicated above. : 90 minutes at 25 degrees Celsius 60 minutes at

Pot Life 30 degrees Celsius 45 minutes at 35 degrees

Celsius Bond Strength

: 12 MPa

Tensile Strength

: 16 MPa

The sand content in the mortar shall be in accordance with the desired consistency.

19.4.2 Proportioning and Mixing The resin and hardener shall be mixed before adding the dry filler. The mixed ready to use mortar should not contain lumps of unwanted filler and should be uniform in colour. For a total weight of 1 kg or less, hand mixing will be sufficient. For quantities in excess of 1 kg,

555 UPID


die component shall be mixed for 3 minutes with a slow speed - 400-600 rpm - electric drill with a Jiffy mixer. The stirrer shall be moved up and down and along the sides until an even streak free colour is obtained. Whipping in an excessive amount of air shall be avoided. If no power is available, a flat putty knife may be used to reach into the corners of the can and hand mixing done for at least 5 minutes.

19.4.3 Surface Preparation Surface upon which epoxy is to be placed shall be free of rust, grease, oil, paint, asphalt, loose material, unsound concrete, dust or any other deleterious material. Since cured epoxy does not provide adequate bond with any material, all overlay, whether epoxy or cement based, shall be done within pot life of the base epoxy layer.

19.4.4 Contaminants, such as oil, grease, tar, asphalt, paint, wax, curing compounds or surface impregnants like linseed oil or silicons, including laitance and weak or loose concrete shall be removed. When bonding to asphalt, the surface should be roughened so that clean aggregate is exposed. Epoxy bonding agents shall not be applied when it rains, or in standing water. The surface must be dry. Two general methods of surface preparation shall be followed:

Mechanical that includes grinding, grit blasting, water blasting and scarification,

Chemical that includes acid etching with 15 per cent by weight of hydrochloric solution,

followed by repeated flushing with high pressure stream of water.

19.4.5 Application Epoxy primer coat shall be applied with the help of stiff nylon bristle brushes or hard rubber rollers or spray gun depending upon the nature of surface and extent of work area. As far as possible, the coating shall be uniformly thick.

Before the primer coat is fully cured, epoxy mortar shall be applied by means of trowels and floats. The interval between the application of primer coat and epoxy mortar shall be approximately 15/30 minutes depending upon the ambient temperature.

Seal Coat shall be applied after 24 hours curing, after mild roughening of the surface of the mortar.

19.4.6 Coverage The coverage of resin mix would depend on the system of resin used. However, as a general guideline the coverage area shall be as under:

Primer Coat. One kg of resin-hardener mix covers an area of 3 -6 square metres per coat depending on the finish of the concrete,

b) Epoxy Mortar. One square metre of surface requires

approximately

20- 24 kg of epoxy mortar when laid to a thickness of 10mm.

Seal Coat. 4 to 6 square metres per kg of mix depending on the temperature of application.

556 UPID


19.4.7 Cleaning and Maintenance of Equipment Tools and equipment are best cleaned immediately after use since the removal of cured resin is difficult and time consuming. The bulk of resin shall be removed using a scraper and remainder washed away completely using solvents such as toluene, xylene or acetone. Equipments used for epoxy shall always be cleaned before it hardens. Solvents used for this purpose may be Acetone (flammable), Methyl Ethyl Kethone (flammable), and Methyl Chloride (non- flammable). Cured epoxies may be removed using Methylene Chloride.

19.4.8 Testing Epoxy used for making mortar shall conform to all requirements and testing procedures as laid down in Clause 19.3.9.

19.4.9 Handling Precautions Epoxy resins can cause irritation of skin in sensitive persons if incorrectly handled. The resin and hardener should not be allowed to come into direct contact with skin. The most effective protection is achieved by wearing rubber or polythene gloves. 19.4.10 Personnel and Environment Safety Any skin contact with epoxy materials, solvents and epoxy strippers should be avoided. Epoxy resins and particularly epoxy hardeners (B component) may cause a rash on the skin. The official toxicity classification on the container labels may be looked for before starting work.

Rubber gloves, with a cloth liner, and protective clothing shall be worn. Barrier creams are recommended but are not substitutes for protective clothing. Eyes shall be protected where splashing could occur while spraying or mixing. Good ventilation shall be ensured and inhalation of vapours avoided. If materials are sprayed, a respirator shall be used.

If skin contact occurs, it shall be immediately washed with a cleaner, followed by soap and water. Should eye contact occur, it shall be flushed immediately with plenty of water for 15 minutes and a doctor called for.

If contact occurs with the clothing, it shall be immediately changed to prevent further skin contact, and if the contact occurs with components A or B, the clothing shall be thrown away. Hardened epoxy is not harmful but will break the clothing.

All emptied, used buckets, rags and containers shall be removed from site. These shall be stored in waste disposal bags and suitably disposed.

19.4.11 Epoxy Bonding of New Concrete to Old Concrete Epoxy resin used for bonding shall be obtained from a reputed manufacturer. The pot life of such bonding epoxy shall not be less than 60-90 minutes at normal temperature.

The entire surface of the existing concrete member should be thoroughly cleaned by wire brush and then with compressed air to remove dust and loose particles from the surface. Any crack or spalling of concrete shall be scaled by epoxy injection/epoxy mortar/grouting as decided by the Engineer. A coating of suitable epoxy resin at the rate of 0.8 kg/sq.m. (minimum) should then be applied on the surface of the existing concrete members. Fresh concrete shall then be placed within the pot life of the resin system.

557 UPID


19.4.12 Testing

Epoxy used for bonding work shall satisfy the criteria mentioned in Clause 19.3.9 Two concrete cubes 150 mm size cast as per approved design mix shall be placed, as shown in Fig19.3 at a distance of 150 mm from each other. Epoxy resin system suggested for bonding new to old concrete shall be applied on the opposite faces of the cubes. Fresh cement concrete cube of grade as per approved design mix shall be cast with water cement ratio of 0.4 or less in the manner shown in Fig. 19.3. The assembly shall be cured in water for 28 days and steel spacer removed thereafter. The cube assembly shall .be subjected to compression load after 28 days of curing, thereby subjecting the bond to shearing load. Failure must not occur at this joint.

19.5 Cement Grouting

19.5.1 Material Grouting shall normally be performed with a mixture of ne at Portland cement and water. Other additives and admixtures may be added to improve the impermeability, strength, etc. on the approval of the Engineer. The size of the particles and the consistency of the grout must be suited to the passageways it must follow. Neat grout will not flow freely into holes smaller than about three times the largest cement particle. Except in large cavities where thick mortar can be placed, the sand should all pass the 28- mesh sieve and have a large portion passing the 50- and the 100- mesh sieves. The proportions of Ordinary Portland Cement to sand will

depend upon the size of the spaces to be filled and will vary from a neat grout to about 1:1 mix. The amount of water to be added depends upon the consistency required. Grouts with as little as 16 litres of water per bag of cement could be handled and it should 'seldom be necessary to use more than 35 to 40 litres of water per bag of cement.

Where necessary and approved by the Engineer, admixtures to Portland Cement grout mixtures may be added for delaying the setting time, increasing flow ability, minimising segregation and shrinkage.

19.5.2 Preparation

The surface shall be cleaned with wire brush and compressed air, 15 mm dia and 150 to 200 deep holes along the length of the cracks at a spacing of 500 mm may be drilled by wet drilling using rotary percussion drills and nipples, inserted in these holes.

19.5.3 Proportioning, Mixing, and Equipment for Grouting The cement grout shall be mechanically mixed using a system of power-driven paddles of high speed centrifugal pump. The grout pump to be used shall permit close control of

pressures to allow a flexible rate of injection with minimum clogging of valves and ports. The most satisfactory equipment for injecting grout is a pump of the double-acting flexible reciprocating type giving a steady flow. The grout pump shall be so placed as to reduce the waste in cleaning lines. It is preferable to add 50 per cent or more of the mixing water into the mixer before adding the dry ingredients and then the remaining water. A continuous supply of grout is preferable to an intermittent one. Consistency of the grout may be determined by trials starting with thin grout i.e. about 40 litres of water per bag of cement and progressively decreasing the water content to about 15 litres per bag of cement. Where the mixer and pump are combined in one unit, the dry material shall be screened before mixing. If the mixer and pump are in separate units, the grout shall pass through a screen before ii enters the pump.

558 UPID


19.5.4 Application Highest practical pressure within the limits 100-400 kPa should be used in order to force the surplus water from the grout. As the pressure may be distributed hydraulically over considerable areas, vigilance must be exercised to prevent damage or the needless waste of grout. Grouting is to be done by attaching a packer (consisting of expansible tube of rubber) to the end of the grout supply pump through the holes and nipples. Pressure shall be steady to ensure a continuous flow of grout. Grouting shall not be continued till the hole consumes mix at the rate of not less than 30 litres in 20 minutes or until refusal at the grouting pressure of 400 kPa at any hole until refusal. Should the grout escape from an adjacent nipple, it should be plugged or capped. Any scam, crack or joint through which grout escapes shall be caulked with epoxy mortar as soon as thick grout appears.

19.5.5 Cleaning of Equipment After completion of each grouting operation or temporary shutdown, it is advisable to force clear water through the pump until the discharge line shows no colour, after which the pump covers shall be removed and the valve chambers thoroughly cleaned. 19.5.6 Testing

Percolation test done at the end of grouting operation shall give a value of less than 2 lugions.

NOTE: For specialised treatment like polymer modified cementitious grout injection.

manufacturer's literature and specification shall be followed. 19.6 Guniting/Shotcrete 19.6.1 The gunite is a mixture of cement, sand and water. It comprises 100 parts by weight of

cement, 300 parts by weight quart/, sand, 35-50 parts by weight water and 2 parts by

weight approved quick setting compound. In general, dry mix shotcrete shall be used.

19.6.2 Ordinary Portland cement conforming to IS:269 shall be used in guniting.

19.6.3 Sand for guniting shall comply with the requirements stipulated in IS:383. In general, sand should neither be too coarse to increase the rebound nor too fine to increase the slump. Sand should preferably have moisture content between 3 to 6 per cent.

The grading of sand shall lie within the limits given below:

IS Sieve

per cent passing the sieve Designation

4. 75 mm 95 – 100

2.36 mm 65 - 90

1. 18 mm 45 - 75

600 microns 30 - 50

300 microns 10 - 22

150 microns 2 – 8

19.6.4 For thick sections it may be advantageous to incorporate coarse aggregate in the mix provided adequate guniting equipment is available. Coarse aggregate, when used, shall conform to grading given in Table I of IS:9012. The percentage of coarse aggregate may normally be kept as 20 to 40 per cent of the total aggregate and the mix shall be suitably designed.

19.6.5 Water/cement ratio for guniting shall fall within the range 0.35 to 0.50 by mass, wet enough to reduce the rebound. Drying shrinkage may be between 0.06 per cent to 0.10

559 UPID


per cent. The quick setting compound shall be added at the nozzle with water just before guniting.

19.6.6 Workmanship The cement and sand shall be batched and mixed and conveyed through a hose pipe with the help of compressed air. A separate line shall bring the water under pressure. The cement, sand and water mix shall be passed through and intimately mixed in a special manifold and then projected at high velocity to the surface being repaired. The density of gunite shall not be less than 2000 kg/cu- m. The strength of gunite shall not be less than 25 MPa, For effective guniting, the nozzle shall be kept 60 to 150 cm away from the surface, preferably normal to that surface. While enclosing reinforcement bars during repairs the nozzle shall be held closer at a slight angle and the mix shall be wetter than the normal.

19.6.7 Test panels simulating actual field conditions shall be fabricated for conducting preconstruction testing. The procedure for testing the cubes or cylinders taken from the panels stipulated in clause 6 of IS:9012 shall be followed.

19.6.8 It should be ensured from tests that strength of about 25 MPa at 28 days is available for the mortar/concrete mix. 2807.9. The defective concrete shall be cut out in the full depth till sound concrete surface is reached. Under no circumstances should the thickness of concrete to be removed be less than clear cover to the main reinforcement. No square shoulders shall be left at the perimeter of the cut-off portion and all edges shall be tapered. Thereafter, all loose and foreign materials should be removed and the surface be sandblasted to make it rough to receive shotcrete after applying a coat of bonding epoxy as per recommendation of the manufacturer @ 1.0 kg per 1.5 sq.m, of surface area.

19.6.9 The exposed reinforcement shall be thoroughly cleaned free of rust, scales etc. by wire brushing. Wherever the reinforcements have been corroded, the same shall be removed and replaced by additional reinforcement. Before application of gunite, a coat of neat cement slurry should be applied on the surface of the reinforcement.

19.6.10 Sufficient clearance shall be provided around the reinforcement to permit encasement with sound gunite. Care shall be taken to avoid sand pockets behind the reinforcement.

19.6.11A thickness of 25 to 40 mm of gunite can normally be deposited in one operation. If, for some reason, the total thickness is to be built up in successive operations, the previous layer should be allowed to set but not become hard before the application of the subsequent layer. It would always be necessary to apply guniting on a damp concrete surface.

19.6.12Where required, welded wire fabrics 5cm x 5 cm X No. 10 gauge shall be provided in the first layer of guniting. The fabric shall be tied properly. In case the damage to the concrete member is too deep, the specifications for guniting as well as requirement of placement of wire mesh has to be decided as per field conditions.

19.6.13The stipulations given in 15:9012 regarding application of gunite should be followed so as to keep the rebound to the minimum. The quality of guniting and workmanship

560 UPID


shall be such that the percentage of rebound mentioned in IS:9012 can be adhered to.

In no circumstances shall the rebound material be re-used in the work.

19.6.14 It would be desirable that green gunite is moistened for at least 7 days. Guniting work shall not be done during windy or rainy conditions.

19.6.15 Replacement/Rectification of Bearings 19.6.16 The replacement/rectification of bearings shall be carried out in accordance .with

approved repair plan or as approved by the Engineer.

19.6.17 Lifting of Superstructure spans may be carried out by jacking up from below or by lifting the span from top. Where jacks are employed, their location/number and size shall be selected in such a manner so that there are no undue stresses created in the structure. Jacks may be placed on piers/pier caps or specially erected trestles in accordance with the approved methodology for lifting of superstructure. All jacks shall be operated from one control panel by a single control lever. The system will have provision for manual over ride to control die loads of any particular jack. The jacks should be so synchronised that differential lift between individual jacks shall not exceed 1 mm.

19.6.18 Necessary repair/replacement of bearings shall be carried out as indicated in the

repair plan or as directed by the Engineer. Care shall be taken to plan the execution of repair in the shortest possible period.

19.6.19 Precautions during Lifting of Girders for Rectification of Bearings

19.6.20 Walkietalkies system or similar audio arrangements should be available for

communicating instructions regarding lifting, stopping, starting etc. The operator shall

have a clear view of the jacks and the lifting of each girder controlled by reading the

dial gauges.

19.6.21 Dismantling of Concrete Wearing Coat 19.6.22 Commencement of Dismantling

Before commencing dismantling, the nature and condition of concrete, the condition and position of reinforcement should be ascertained. The Contractor shall familiarise himself with the structural design and ensure that the overall stability of the bridge is not affected

The existing expansion joint assemblies shall remove carefully along the entire width of the carriageway. The deck slab for a width of 400 mm on either side should be removed for placing of reinforcement, anchor rods, anchor bols and other fixing assemblies for the new expansion joints and pouring of fresh concrete. The gap between the girders over the piers should be cleared of all debris A temporary platform in the gap at the end of girders shall be erected to collect the materials falling down during concreting and fixing of expansion joints

The service lines, if any, shall be disconnected/ diverted before the dismantling work

starts.

19.6.23Dismantling of concrete wearing coat shall be carried out using jack hammers or suitable manual methods as approved by the Engineer. Care should be taken to avoid

561 UPID


any damage to the existing structure including reinforcement or prestressing anchorages for cables, if any, located in the deck slab.

19.6.24 Precautions During Dismantling Work

19.6.25 For general guidelines, reference may be made to relevant IS Specification.

19.6.26 Dismantling work shall not be carried out at night, or during storm or heavy rain. A warning device shall be installed in the area to be used to warn the workers in case of mishap/ emergency.

19.6.27 Safety helmets conforming to IS:2925 shall be used by the workmen engaged in dismantling work. The sheds and tool boxes should be located away from the work site. Goggles preferably made up of celluloid and gas masks shall be worn at the time of dismantling, especially where tools like jack hammers are deployed to protect eyes from injuries from flying pieces, dirt, dust etc. Leather or rubber gloves shall be worn by the workers during the demolition of RCC work. Screens made up of GI sheets shall be placed wherever necessary to prevent the flying pieces from injuring the workers.

19.6.28 Water should be sprayed to reduce the dust while removing concrete wearing course with jack hammer. No work shall be taken up under the span when dismantling work is in progress.

562 UPID


20 DISMANTLING CANAL STRUCTURES

20.1 Scope This work shall consist of removing, as hereinafter set forth, existing Canal structures which have become un-serviceable and/or do not fit in the scheme of Modernisation project and of salvaging and disposing of the resulting materials and backfilling the resulting trenches and pits. These includes Canal structures like road bridges, canal falls, regulators, cross-drainage works etc.

Existing canal structures which are within the canal and which are designated for removal, shall be removed upto the limit and extent specified in the drawings or as indicated by the Engineer.

Dismantling and removal operations shall be carried out with such equipment and in such a manner as to leave undisturbed, adjacent, structures and any other work to be left in place.

All operations necessary for the removal of any existing structure which might endanger new construction shall be completed prior to the start of new work.

20.2 Dismantling of Structures The structures shall be dismantled carefully and the resulting materials so removed as not to cause any damage to the serviceable materials to be salvaged, the part of the structure to be retained and any other properties or structures nearby. Unless otherwise specified, the superstructure portion of structures shall be entirely removed and other parts removed below the ground level or as necessary depending upon the interference they cause to the new construction. Removal of overlying or adjacent material, if required in connection with the dismantling of the structures, shall be incidental to this item.

Where existing structures are to be extended or otherwise incorporated in the new work, only such part or parts of the existing structure shall be removed as are necessary and directed by the Engineer to provide a proper connection to the new work. The connecting edges shall be cut, chipped and trimmed to the required lines and grades without weakening or damaging any part of the structure to be retained. Due care should be taken to ensure that reinforcing bars which are to be left in place so as to project into the new work as dowels or ties are not injured during removal of concrete.

Structures involving pipes shall be carefully removed in such a manner as to avoid damage to the pipes.

Steel structures shall, unless otherwise provided, be carefully dismantled in such a manner as to avoid damage to members thereof. If specified in the drawings or directed by the Engineer that the structure is to be removed in a condition suitable for re-erection, all members shall be match-marked by the Contractor with white lead paint before dismantling; end pins, nuts, loose plates, etc. shall be similarly marked to indicate their proper location; all pins, pin holes and machined surfaces shall be painted with a mixture of white lead and tallow and all loose parts shall be securely wired to adjacent members or packed in boxes.

20.3 Dismantling Pavements and Other Structures In removing pavements, kerbs, gutters, and other structures like guard-rails, fences, manholes, catch basins, inlets, etc., where portions of the existing construction are to be left

563 UPID

Section VII: Works Requirements in the finished work, the same shall be removed to an existing joint or cut and chipped to a true line with a face perpendicular to the surface of the existing structure. Sufficient removal shall be made to provide for proper grades and connections with the new work as directed by the Engineer.

All concrete pavements, base courses in carriageway and shoulders concrete in floors of falls and regulators etc., designated for removal shall be broken to pieces whose volume shall not exceed 0.02 cu.m and stockpiled at designated locations if the material is to be used later or otherwise arranged for disposal as directed.

20.4 Back-filling Holes and depressions caused by dismantling operations shall be backfilled with excavated or other approved materials and compacted to required density as directed by the Engineer:

20.5 Disposal of Materials All materials obtained by dismantling shall be the property of Government. Unless otherwise specified, materials having any salvage value shall be placed in neat stack of like materials within the right of way, as directed by the Engineer with all lifts and up to a lead of 1000m. Pipes that are removed shall be cleaned and neatly piled on the right of way at points designated by the Engineer with all lifts and lead up to 1000m. Structural steel removed from old structures shall, unless otherwise specified or directed, be stored in a neat and presentable manner on blocks in locations suitable for loading. Structures or portions thereof, which are specified in the Contract for re-erection, shall be stored in separate piles.

All materials obtained from dismantling operations, which, in the opinion of the Engineer, cannot be used or auctioned, shall be disposed of as directed by the Engineer with all lifts and up to a lead of 1000m.

20.6 Measurements for Payment The work of dismantling structures shall be paid for in units indicated below by taking measurements before and after, as applicable:

i) Dismantling brick/stone masonry/ concrete (plain and reinforced) cu,m

ii) Dismantling flexible and cement concrete pavement cu,m

iii) Dismantling steel structures tonne

iv) Dismantling pipes, guard rails, kerbs, gutters and fencing linear meter

v) Utility services Nos.

20.7 Rates The Contract unit rates for the various items of dismantling shall be paid in full for carrying out the required operations including full compensation for all labour, materials, tools, equipment, safeguards and incidentals necessary to complete the work. These will also include excavation and backfilling where necessary to the required compaction and for handling, salvaging, piling and disposing of the dismantled materials within all lifts and up to a lead of 1000m.

564 UPID


21 OK Card System

21.1 In order to enforce the technical Specifications to promote construction quality, OK card system shall be kept In order to enforce the technical Specifications to promote construction quality, OK card system shall be kept by the department. The Executive Engineer of works is primarily responsible for executing the works as per designs and Specifications. For this Executive Engineer himself or his authorized representative Assistant Engineer/Junior Engineer will sign the OK Cards. The OK Card will be prepared and maintained in four copies. One copy each will remain with contractor, Junior Engineer, Assistant Engineer and Executive Engineer in charge of works.

The OK Card for each activity will be initiated by the contractor when he considers that all the preparations to start a particular activity are complete. The OK Card will then be given by the contractor to the concerned Junior Engineer of UPID. The Junior Engineer UPID will confirm whether all the preparations as per provisions and Specifications are complete. If the

Junior Engineer UPID finds everything in order, he will, depending upon the competency, get

the area/ works examined by the Assistant Engineer/Executive Engineer and after their approval, sign the OK Card and hand over it immediately to the contractor to commence the activity. If the JE UPID finds deficiencies in the preparations to start the activity, he will return the OK Card at the earliest, to the contractor with his remarks for rectification of the

deficiency. The activity should start only when the deficiencies are removed by the contractor and OK card is signed by the Junior Engineer, UPID. The original OK card once initiated should not be destroyed and it should have all the remarks of all the Engineers and compliance report duly entered by the contractor and final OK remarks of the Junior Engineer .While making/ releasing payments, copy of the relevant OK card will be perused by the payment authority. OK card booklet shall be arranged by the contractor according to formats provided by the Engineer.

21.2 A independent agency will be engaged as third party technical examination consultant. The consultant shall provide advisory services on quality assurance and contract management with full responsibility remaining with the consultant as far as quality control and quality of works are concerned by independent quality checking. The third party technical examination consultant‘s representative will also sign O.K. Card for important activities to the extent mentioned in their terms & conditions to ensure representative checking.

565 UPID


22 SPECIFICATION FOR INSPECTION PATH

22.1 Sub Grade: For existing bank: CBR for 500mm depth of existing soil shall be checked during construction. If a minimum CBR of 7% is achieved, in-situ soil may be used as Subgrade. Otherwise, (and for bank in filling) we have to prepare a 500mm thick subgrade having minimum CBR of 7%. For now, we will consider existing bank to be strong enough to be used as a Subgrade, and take into consideration Subgrade preparation only for areas where filling of bank is necessary. 22.2 Granular Sub Base (GSB): A GSB Layer of 150mm thickness shall be provided as a

drainage layer as per Clause 401. As the IP shall be having unidirectional camber towards countryside, GSB shall be open on one side (countryside) only. The specification of GSB shall conform to the following clauses of MORT and H specification:

Grading requirement conforming to Grading (ii) of Table 400-1

Physical Strength Requirement conforming to Table 400-2.

GSB shall be required for the entire length of IP. 22.3 Water Bound Macadam (WBM): WBM of 2 layers each having 75mm thickness shall

be provided over GSM as per Clause 404. The specification of WBM shall conform to the following clauses of MORT and H specification:

Grading requirement conforming to Table 400-9

Physical Strength Requirement conforming to Table 400-8.

WBM shall be required for the entire length of IP.

Premix Carpeting: A 20mm thick close Graded Premix Carpeting having specification

conforming to Clause 508 of MORT and H shall be used for the entire length of the IP.

566 UPID


23 Environmental and social checks/Control

For the sustainability of the work project it is important to maintain environmental and social conditions of the area with in permissible limit so that harm to human life and the land is avoided. All the work shall be carried out as per norms and as per directions of the Engineer in-charge to check any adverse effects during the construction period. all relevant acts of central and state government shall be strictly followed .

567 UPID


24 Disposal of wastes material from construction/demolition

Uncontaminated rocks, bricks, concrete, demolition debris and dirt may be left or buried on-site, or may be used off-site as fill, so long as it is not placed in vicinity of wetland or water-body. It is important to note that, such material should not be buried on-site in such a way that, usual traffic/human movement should get hindered. However, no other types of construction debris may be buried or left on-site. Some building materials can compress or decay over time such that structures built on unknown burial sites could, at some future date, be subject to subsidence.

568 UPID


Annexure – 3 B

TECHNICAL SPECIFICATIONS

(FOR GATES)

569 UPID

INTENT OF TECHNICAL SPECIFICATIONS AND SCOPE OF WORK

1.1Intent of Technical Specifications

1.1.1 Introduction: The entire work of Redesign for Rehabilitation and Modernization of Irrigation Infrastructure related to gated structure in Kanpur Branch Canal (KBC), Uttar Pradesh is covered these specifications.. These include cross-regulators on KBC, Head regulators of distributaries / minors off taking from it and escape regulators.

1.1.2 General These Specifications are part of the requirements for various items related to the Work which are to be provided according to the stipulations of the contract. Hence, the instructions given herein form an integral part of, and are applicable to the Bidding Documents issued for the Works. Addendum to these Specifications may be issued, as required, during bidding and construction phases.

These Specifications shall be read in conjunction with the Conditions of Contract, the specification Drawings and the schedule of prices and the Contractor shall comply with all provisions contained within the Bidding Documents and instructions of the Purchaser.

Certain performance requirements, materials, features, design requirements and basic arrangement for Gates, hoists and hoist support structures etc. are indicated herein. It is not the intention in these specifications to specify the complete details of the various components of the equipment. This is left to the experience and practice of Contractor who shall perform the complete design of all the equipment, structure and furnish equipment which shall meet, in all respects the specified requirements in regard to performance, durability and satisfactory operation. However, certain features, materials and design requirement are specified and are intended to establish minimum standard for the work and to enable the bidder to submit a well planned bid.

It is the intent of these specifications to establish acceptable standards of quality. Deviation from these specifications shall be considered for acceptance, provided that, in the opinion of the Engineer-in-Charge, the proposed substitutions are equal or superior in quality to those specified.

All works shall be executed according to the Technical Specifications and Specification Drawings and requirements specified by Engineer-in-Charge, in professional and diligent manner and all supplies and works shall comply with the quality requirements defined in the relevant chapters of these Specifications and other Bidding Documents. The Contractor shall endeavor to provide all such necessary efforts in order to comply with the intent of these Specifications to the satisfaction of the Engineer-in-Charge.

1.2 Scope of Work

1.2.1 General These specifications cover the requirements of design, fabrication, shop assembly, shop as well as field painting, transportation, supply, erection, testing, commissioning, (including provision for all labour, plant, material) satisfactory operation and equipment performance guarantee of the following equipment at their respective sites complete in all respects for 570 UPID

Kanpur Branch Canal, Uttar Pradesh in accordance with these Technical Specifications and Specification Drawings. The materials, workmanship, technical requirements, equipment, accessories, supplies and services required, shall be as set forth in this Technical Specifications.

The scope of work also covers unloading, stacking operation, storage and preservation of components of gates and their hoisting arrangement and hoist support structures and their accessories in the stockyards of the contractor at the project site before they are transported, installed, tested and commissioned at their respective Sites.

1.2.2 Cross-Regulator / Head Regulator / Escape Gates and their Hoists Vertical lift fixed wheel type gates are proposed for following Cross Regulators / Head Regulators / Escapes. The quantity required, size of gates, sill elevation and FSL etc. of respective Cross Regulator, Head Regulator and Escape Gates are mentioned in the Table - 1 below.

Table 3

Sl. Chainage (m)

CrossRegulators/ No. of U/S FSL (m)

Sill Level No Head Regulators Gates (m)

1 2 3 4 5 6

1

27.298

Nagariya Cross- 5

162.761

160.011

Regulator

Sl.

Clear Width Height of Gate C/C of side

C/C of tracks

of Opening including free board No seal seats (m) (m)

(m) (m)

1 7 8 9 10

1

7.5 2.90 7.65 7.90

2 7.5 2.90 7.65 7.90

3

6 2.90 6.15 6.40

4 6 2.54 6.15 6.40

5 6 2.38 6.15 6.40

6 6 2.26 6.15 6.40

7 6 2.23 6.15 6.40

8 6 2.23 6.15 6.40

9 7 2.01 7.1 7.4

571 UPID

1.2.2.1 Fixed wheel type vertical lift Gates suitable for all 9 locations and opening sizes

mentioned in Table -1 and operated by electrically operated rope drum hoist of adequate capacity complete in all respects with skin plate, vertical stiffeners, horizontal girders, end vertical girder, seal assemblies, wheel assemblies, guide shoes, seals, lifting lugs etc. and other appurtenances.

1.2.2.2 Embedded parts suitable for all 9 locations and opening sizes mentioned in Table -1 including stainless steel tracks, seal seats, sill beam, guides, bases and anchorages including latching / dogging arrangement, 1st stage anchor bolts and 2nd stage embedded parts etc. complete in all respects.

1.2.2.3 Electrically operated Rope drum hoists of adequate capacity mounted on steel trestles for operation of all Gates mentioned under paragraph 1.2.2.1 above consisting of wire ropes, drums, end reduction units, central drive units including worm reducers, DC E. M. brakes, motors, gate position indicators, arrangements for manual drive, suitable cover for the hoist equipment etc. complete in all respects.

1.2.2.4 Hoist supporting structures of adequate capacity for supporting the rope drum hoists for Head Regulator / Cross-Regulator / Escape Gates as defined at 1.2.2.3 including removable guides, trestle, ladder, railings, base plates, anchors etc. complete in all respects.

1.2.3 Gates for Distributaries, Minors and Escapes and their Hoists (for design discharge above 50 cusec)

Vertical lift slide type gates are proposed for following Distributaries, Minors and Escapes. These gates will be used for regulation of discharge. The quantity required, size of gates, sill elevation and FSL etc. of respective Gates for Distributaries, Minors and Escapes having design discharge above 50 cusec are mentioned in the Table - 2 below.

Table 4 Sl.

Sill Chainage (m) Dy/Minor No. of Gates U/S FSL (m) Level

No

(m)

1 2 3 4 5 6

1 27.096 Nagariya Dy 2 162.783 160.869

Sl.

Clear Width Height of Gate

C/C of side

of Opening C/C of tracks (m)

No including free board (m) seal seats (m)

(m)

1 7 8 9 10

1 3.4 2.07 3.5 3.64

2 2.5 1.17 2.6 2.74

3 2.5 1.62 2.6 2.74

4 2.9 1.2 3.0 3.14

572 UPID

Sl.

Clear Width Height of Gate

C/C of side

of Opening C/C of tracks (m)

No including free board (m) seal seats (m)

(m)

5 1.7 1.58 1.8 1.94

6 1.5 1.29 1.6 1.74

7 2.0 1.31 2.1 2.24

8 1.5 0.89 1.6 1.74

9 1.5 1.57 1.6 1.74

10 2.5 1.075 2.6 2.74

11 2.4 2.6 2.5 2.64

12 2.6

2.3

2.7

2.84

13 6 1.29 6.1 6.24

1.2.3.1 VerticalLift Slide Type Gates suitable for all 13 locations and opening sizes mentioned in Table -2 and operated by electrically operated screw hoist of adequate capacity complete in all respects with skin plate, vertical stiffeners, horizontal girders, end vertical girder, seal assemblies, slide blocks, guide shoes, seals, lifting lugs etc. and other appurtenances.

1.2.3.2 Embedded parts suitable for all 13 locations and opening sizes mentioned in Table -2 including stainless steel tracks, seal seats, sill beam, guides, bases and anchorages including 1st stage anchor bolts and 2nd stage embedded parts etc. complete in all respects.

1.2.3.3 Electrically operated Screw hoists of adequate capacity mounted on steel trestles for operation of all Gates mentioned under paragraph 1.2.3.1 above consisting of screw stem, end reduction units, central drive units including worm reducers, DC E. M. brakes, motors, gate position indicators, arrangements for manual drive suitable for the hoist equipment etc. complete in all respects.

1.2.3.4 Hoist supporting structures of adequate capacity for supporting the screw hoists for Gates for Distributaries, Minors and Escapes as defined at 1.2.3.3 including steel platforms, railings, base plates, anchors etc. complete in all respects.

1.2.4 Gates for Distributaries and Minors and their Hoists (for design discharge of 50 cusec and less)

Vertical lift slide type gates are proposed for following Distributaries and Minors. These gates will be used for regulation of discharge. The quantity required, size of gates, sill elevation and FSL etc. of respective Gates for Distributaries and Minors having design discharge of 50 cusec and less are mentioned in the Table - 3 below.

Table 5

573 UPID

Sl. Chainage (m)

Dy/Minor

No. of Gates

U/S FSL (m)

Sill Level No (m)

1 2 3 4 5 6

1 27.137 Pachawar Dy 2 162.779 161.311

Sl. Clear Width of Height of Gate including C/C of side C/C of tracks

No Opening (m) free board (m) seal seats (m) (m)

1 7 8 9 10

1 1.4 1.62 1.5 1.64

2

1.2 1.11

1.3

1.44

3 1.5 0.76 1.6 1.74

4 1.5 0.64 1.6 1.74

5 1.2 0.96 1.3 1.44

6 1.5 1.161 1.6 1.74

7 1.2 1.04 1.3 1.44

8 1.5 0.94 1.6 1.74

1.2.4.1 Vertical Lift Slide Type Gates suitable for all 8 locations and opening sizes mentioned in Table -3 and operated by manually operated screw hoist of adequate capacity complete in all respects with skin plate, vertical stiffeners, horizontal girders, end vertical girder, seal assemblies, Slide blocks, guide shoes, seals, lifting lugs etc. and other appurtenances.

1.2.4.2 Embedded parts suitable for all 8 locations and opening sizes mentioned in Table - 3 including stainless steel tracks, seal seats, sill beam, guides, bases and anchorages including 1st stage anchor bolts and 2nd stage embedded parts etc. complete in all respects.

1.2.4.3 Manually operated Screw hoists of adequate capacity mounted on steel bridge for operation of all Gates mentioned under paragraph 1.2.4.1 above consisting of screw stem, reduction units for the hoist equipment etc. complete in all respects.

1.2.4.4 Hoist supporting structures of adequate capacity for supporting the screw hoists for

Gates for Distributaries and Minors as defined at 1.2.4.3 including steel platform, railing, base plates, anchors etc. complete in all respects.

1.3 Conditions of Particular Application

574 UPID

1.3.1 General

Dry as well as wet tests are to be carried out for all the gates by the supplier free of cost and rectification of defects noticed during tests or during the guarantee period (not less than 12 months after commissioning and handing over) are within the scope of supply.

Shop as well as field painting is included in the scope of supply.

1st and 2nd stage concreting shall be done under supervision of gate contractor. The

responsibility of correctness and accuracy of alignments would rest with the Contractor. It has to be ensured that appropriate erection tolerances are maintained and gate and embedment match perfectly.

The design, fabrication, supply and erection of 1st stage embedded parts and 2nd stage embedded parts are included in this scope of works. The contractor when ordered in writing by the Engineer-in-Charge shall perform extra work in furnishing the items not covered in the specifications or included in the schedule but forming an inseparable part of the work contracted for. Extra work and materials will ordinarily be paid for at a lump sum or unit price agreed upon by the contractor and the Engineer-in-Charge, as stated in the orders; whenever, in the judgement of the Purchaser, it is impracticable because of nature of the work or for any other reason whatsoever, to fix the price in the order, the payment of extra works and

materials shall be made on the basis of actual cost as determined by the Engineer-in-Charge plus 10% allowance for superintendence, use of tools, tackles and shop etc.

Note: Before undertaking manufacture, exact site dimensions should be verified by the Contractor and the equipment should match with site details. Engineer-in-Charge will not be responsible for any variation whatever in the site dimensions and it will be the responsibility of Contractor for matching site dimensions at no extra cost.

1.3.2 Inspection and Quality Assurance Plan All supplies shall be subject to inspection and test by the Engineer-in-Charge to the extent practicable at all times and places. Shop tests shall also be subject to inspection and test by the Purchaser and the Purchaser shall depute Engineers for witnessing shop tests and training in works and designs as detailed in Section 5 of these specifications. Inspection shall be carried out in accordance with relevant Indian standards or equivalent International standards where Indian standards are not available or as described elsewhere in these specifications. The cost of carrying out the test / inspection and training shall be borne by the contractor and included in the price schedule for inspection and testing.

Quality Assurance system and detailed Quality Assurance plans for the manufacture and supply of all the major components and equipment submitted by the contractor shall be finalized before the award of contract.

1.3.3 Wastage of Steel The payment will be made only for the net weight of gates based on the sectional unit weight as per table of standard sections (supplied by SAIL) and used in the gates and hoists. The weight of nuts, bolts, rivets, welding etc., will not be considered in the net weight of gates.

575 UPID

All the wastage of steel section supplied by the main producer will be on the contractor’s account and the contractor should consider this aspect while quoting the rates.

1.3.4 Schedule Within 45 (Forty Five) calendar days after the date of commencement, the contractor shall submit to the Engineer-in-Charge for his approval the schedule of designs, drawings, fabrication and transportation of the equipment so as to ensure its delivery within the specified period. The schedule shall clearly state all the stages of fabrication to enable the Engineer-in-Charge to plan his inspection accordingly as stated in these specifications.

The time and the date of completion of works as stipulated in the tender document shall be

deemed to be the essence of the contract. However, certain alterations can be suggested by the bidder keeping in view the programme of erection, front availability and the completion date The contractor shall submit along with his bid a detailed programme based on the dates indicated in the tender document or alternatively his own time schedule giving shorter

delivery / erection period taking into consideration the gate by which the erection front can be made available to him. The schedule shall be within the time frame agreed above consisting of adequate number of activities covering various key phases of the work such as designs, drawings, procurement, manufacturing, shop assembly (equipment wise), sand blasting and painting, shipment, field erection and testing activities. This network shall also indicate the

interface facilities to be provided by the Engineer-in-Charge if any and the dates by which such facilities are needed. It shall also indicate the details of resources like manpower/machinery envisaged in the part and to be mobilized by the contractor for all stages of erection.

The contractor shall so organize his resources and perform his work as to complete it not later than the date agreed to by him. The time for completion of the works contracted for, shall be reckoned from the date of issue of commencement. During the performance of the contract, if in the opinion of the Engineer-in-Charge, proper progress is not maintained suitable changes shall be made in the contractor’s operation to ensure proper progress.

1.3.5 Delivery Period Time of delivery at the project site is the essence of the contract and the contractor shall abide by milestone, the time being reckoned from the commencement. Separate schedule shall be submitted for each gates and hoisting equipment.

1.3.6 Responsibilities of Contractor

The contractor shall be responsible for:

The quality of materials and workmanship in all the items of work.

Strict adherence to the dimensions of parts shown on approved drawings unless deviations

are specifically authorized in writing by the Engineer-in-Charge or Engineer-in-Charge.

Strength of all parts of gates and hoists when operated under the worst conditions of load

and under conditions of closure during periods of maximum flow/ discharge as applicable.

576 UPID

It is Contractor’s responsibility to ensure that all components supplied in accordance with

these specifications shall fit correctly to each other. In the event of any field modifications being required due to errors in shop fabrication, Contractor shall bear the full cost of such modifications. Any such changes shall be shown on the drawings and accepted in writing by Engineer-in-Charge, before being made by Contractor.

Satisfactory performance of the entire work under all operating conditions without signs of

undue strain and without damage, breakdown or deterioration of any of the parts due to faulty or incorrect or unsuitable material, workmanship or design.

Freedom from vibrations of any part or parts under the most severe operating c onditions

beyond permissible limits.

The water tightness of the gate seals.

The strength, accuracy and adequacy of all parts of gates, hoists and hoist support

structures etc. in all respects.

The contract documents and specifications do not specify in complete details the various components of the equipment and only indicate a basic arrangement for the gates, hoists and hoist support structures etc. It is the contractor’s responsibility to perform the complete design of all the equipment, structure and fabrication within the parameters laid down in the specifications. The contractor shall supply and erect all equipment in a complete shape, which will meet the requirements regarding performance, durability and satisfactory operation.

The principal parts of all the equipment are mentioned in these specifications which

outline the general features to be adopted in design. Any deviations from the specified requirements shall be done only with the approval of the Engineer-in-Charge

The contractor shall visit and carefully examine the site of the work and the adjacent premises and shall conduct necessary investigations to acquaint himself thoroughly with the facilities for handling the specified equipment at the site. A thorough investigation shall be made of potential interferences and difficulties that may be encountered in the proper and complete execution of the work specified. No plea of ignorance of existing or foreseeable conditions, that create difficulties or encumbrances in the execution of the work, will be accepted as an excuse for any failure on the part of the contractor to fulfill in every detail the requirements of the Contract Document. Furthermore, a plea of ignorance will not be accepted as a basis for any claim whatsoever.

1.4 General Requirement The contractor shall carefully study the Technical Specifications and Specification Drawings and shall intimate the Engineer-in-Charge if any error / omission is discovered. As a result of such interaction, if some corrections / modifications are required, the same shall be brought to the notice of all the contractors by the Engineer-in-Charge before the date of submission of the tender.

1.5 Atmospheric Conditions The equipment called for under these specifications shall be suitable for continuous outdoor operations in the climate at the site of Kanpur Branch Canal, UP Water Sector Restructuring 577 UPID

Project with temperature variation from minimum to maximum and humidity etc. as specified in other chapters of this document.

1.6 Warranty The contractor shall furnish warranty of the equipment for a minimum period of one year from the date of the final acceptance of equipment or commissioning or handing over to project authority whichever is later. The contractor shall guarantee among other things the following items.

Quality and strength of the materials used.

Satisfactory operation of the equipment.

Safe stresses in all parts under all conditions of operations.

Protection of equipment against vibration and corrosion.

The Contractor shall at his own expenses, correct the defects, furnish and install new parts and materials approved by the Engineer-in-Charge in all the equipment covered under para 1.2.2. to 1.2.4 within 12 months from the date of final acceptance of equipment or commissioning or handing over to project authority whichever is later. The contractor shall assume all responsibility for direct damages causing personal injury or property damage due to any manufacturing defects resulting in the failure of the equipment being supplied under these specifications.

Final acceptance of work takes place only after completion of the tests and commissioning described elsewhere in these Specifications. 578 UPID

STANDARDS AND MATERIALS

2.1Standards and Codes

General Works, design, testing, workmanship, material and supplies shall conform to the relevant Indian Standards. Wherever the Indian Standards are not existent or silent authoritative Standards and Codes like IEC or ISO Recommendations other than Indian Standards or those specified in the Bidding Documents, which ensure an equal or higher quality, may also be acceptable.

All standards and codes referred to shall be the latest current issues irrespective of the year mentioned.

When IEC or ISO Recommendations or other Standards are referred to, the edition shall be that current at the time of submittal of design.

The contractor shall supply three copies in English and one in original language of any national standards which are approved for use under the contract.

Indian Standards and Codes Throughout the duration of the contract, the materials, equipment, services, design and workmanship shall conform to the applicable Indian Codes and Standards only if not otherwise specified.

It is the Contractor’s duty to acquaint himself with all Indian Codes and Standards related to the works and he shall procure and keep at his works at the site a copy of each of such applicable documents. International Standards and Codes The International Standards / Codes may be adopted provided that: The Standards /codes proposed are at least as stringent as the equivalent Indian Standards relevant to the works or higher quality compared to those specified, and approved or if there is no applicable Indian Standards / codes for the specific item concerned, furthermore, that the Contractor submits for approval copies of the standards which he proposes to use.

2.2 Standards for General Application 2.2.1 General Standard publications issued by the following organizations of standardization are considered being approved standards for the works with a priority to use Indian Standards.

BIS : Bureau of Indian Standards

ASTM : American Society for Testing & material

ASME : American Society of Mechanical Engineers

DIN : Deutsche Industrie Norm

BSI : British Standard Institution

IEC : International Electromechanical Commission

579 UPID

ISO : The International Standard Organization

JIS : Japanese Industrial Standard

The Contractor shall state, prior to starting the works, the International Standard / code he proposes to apply, giving full identification of each of them. These proposals are subject to the approval by the Engineer-in-Charge.

2.2.2 Standards for Design & Testing The following publications of Indian Standard Specifications (latest editions) shall be followed for the basic designation only, form a part of these specifications. Latest editions of these standards shall be referred.

IS 4622

IS 5620

IS 7718

IS 800

IS 456

IS 875

IS 1855

IS 3938

IS 6938

IS 3177

IS 807

IS 1893

IS 2266

IS 2062

IS 305

IS 1030

IS 2004

IS 1875

IS 1570

(Part –II)

IS 1570

(Part –5)

IS 325

IS 1367

(Part –

II)

IS 1365

IS 1363

Recommendation of structural design of fixed wheel gates Recommendations for structural design criteria for low head slide

Gates Recommendation for inspection, testing & maintenance of fixed

wheel & slide gates (Part I – III) Code of practice for use of structural steel in general building

Construction. Code of practice for plain & reinforced concrete

Code of practice for structural safety of buildings: Loading Std.

General requirements for rubber seals for hydraulic gates

Electric wire rope hoist Code of practice for design of rope drum and chain hoists for

hydraulic gates Code of practice for electric overhead Traveling cranes other than

steel works cranes Code of practice for design manufacture erection & testing of cranes

& hoists Criteria for Earthquake resistant design of structures

Specifications for steel wire ropes for general Engineering purposes

Structural Steel (Fusion Welding Quality)

Specifications for aluminium bronze ingots and castings Specifications for carbon steel castings for general Engineering

purposes Specifications for carbon steel forgings for general Engineering

purposes Specifications for carbon steel billets, blooms, slabs and bars for

forgings -

Schedule for wrought steel (stainless and heat resisting steels) -

Schedule for wrought steel, carbon steel (unalloyed steel)

- Specification for three phase induction motors -

Technical supply conditions for threaded steel fasteners (Stainless steel threaded fasteners)

Specifications for slotted countersunk head screws

Hexagonal head bolts, screws and nuts

580 UPID

IS 2485

IS 816

IS 817

IS 2595

IS 3664

IS 7307

IS 7310

IS 7318

IS 3658

IS 3703

IS 4460

IS 2403 IS14177

Specification for drop forged sockets for wire ropes foe general

Engineer-in-Chargeing purposes Code of practice for use of metal arc welding for general construction

in mild steel Code of practice for training and testing of metal arc welders

Code of practice for radiographic testing Code of practice for ultrasonic tube echo testing by contact and

immersion methods Approval test for welding procedures (Part – I) Approval testing of welders working to approved welding procedures

(Part – I) Approval tests for welders when welding procedures approval is not

required Code of practice for liquid penetrate flow detector

Code of practice for magnetic flow detectors

Method of rating machine cut spur and helical gears

Specification for transmission steel roller chains and chain wheels

Guidelines for painting system for Hydraulic Gates and Hoists

In case of any conflict between these specifications with the above standards or codes, these specifications and drawings being part of Bidding Documents shall govern, unless otherwise directed by the Engineer-in-Charge in each particular case.

Where reference is made in the Bidding Documents to the Standards / codes of a country of origin for the supply item, it shall be a recognized national Standard / code of that country where the specific supply item is manufactured and such Standards / Codes must comply in all respects with the quality requirements of above mentioned Indian Standards / codes and to be acceptable under these Specifications and must be approved by the Engineer-in-Charge.

2.2.3 System of Units The metric system of units has been used throughout these specifications and this system of units shall be used consequently throughout the duration of contract for all technical or contractual purposes.

2.3 Material Standard

2.3.1 General

All material used for the fabrication of the equipment shall conform to latest applicable relevant Indian Standard or equivalent International Standard as DIN, ASTM or BS unless otherwise specified.

All the materials shall be of tested quality, new, unused, free from defects and of the grade / classification envisaged in the designs. The contractor shall furnish the test certificate for each lot of materials, if so required by the Engineer-in-Charge. Plates with laminations discovered during welding or during inspection shall be rejected. Materials not supplied according to the approved designs / drawings shall be rejected, removed and replaced. Approval of Engineer-in-Charge shall not relieve the contractor from the responsibility of supply of suitable materials.

581 UPID

The Contractor shall furnish a list of names of contractor(s) of the bought out complete

equipment, which are contemplated for incorporation in the work, together with performance characteristics and other pertinent information pertaining to the equipment, for the approval of the Engineer-in-Charge, samples of materials, if desired and so directed, shall be submitted for approval any equipment, materials and articles used or installed without the prior approval of the Engineer-in-Charge shall at the risk and cost of the Contractor.

If for any reason the Contractor desires to deviate from these standards, he shall submit a statement stating the exact nature of the deviations or substitution along with complete and detailed specification and test reports for the materials, which are proposed to be used. In all such cases the prior approval of the Engineer-in-Charges has to be obtained before the fabrications work is taken in hands. All the materials, supplies and articles not manufactured by the Contractors shall be produced of recognized and reputed contractors.

Defective material shall not be repaired and used in the construction of the equipment without prior approval. No peening, caulking or filling shall be permitted in repairing cracks, pinholes, or blowholes. Defects in welds shall be repaired by chipping out to sound metal and re-welding. For defects in castings, the method of repair shall be mutually agreed upon by both the seller and the Engineer-in-Charge.

Materials not listed herein may be used subject to review of their acceptability, application, and the maximum allowable design stresses established by the contractor. Material standards including grade, class or type shall be shown on the appropriate detailed drawings submitted for review. If equivalent material standards are to be used complete details of the standards shall be submitted for review including a list of materials, their Indian Standards equivalents, and the identification of components of equipment for which they are to be used.

All equipment (except customized items) and materials shall be new and shall be

essentially standard products of contractor regularly engaged in the production of the type of equipment and materials specified in the Contract Documents. Like items shall be the product of a single contractor.

The sizes, ratings, capacities, and dimensions of the various standard equipment items

listed in the Contract Documents are based on currently available standard products. Reasonable deviations will be allowed to permit supply of standard equipment. In no case shall the capacity furnished be less than that specified, unless approved.

All bolts, nuts, screws, threads, pipe, ball and roller bearings, gauges and gears shall

conform to Indian Standards or equivalent US / DIN Standards.

Equipment and materials shall contain no asbestos products (e.g. gaskets, packing, brake

pads, etc.).

Recommended materials for the components of different type of gates, hoists and cranes involved are appended below:

582 UPID

2.3.2 Vertical Lift Fixed Wheel Gates for Cross Regulators / Head Regulators / Escape

Sl. Components

Recommended Indian No. Materials Standards

1 All Structural members such as Skin Structural Steel IS 2062

plates, Stiffeners, Main horizontal

girder, vertical stiffeners, end vertical

girders, Lifting brackets etc.,

Seal bases, Track bases, seal seat

bases, seal clamps, guide shoes,

Anchor plates & anchorages, Side

guide tracks etc.

2 Seal seats Stainless steel IS 1570 (Part 5)

3 Wheel tracks Corrosion IS 1570 (Part Resistant Steel 5),Gr. 20 Cr 13

4 Wheel Cast steel / IS 1030 / IS Forged steel 2004

5 Wheel pin / Lifting pin Corrosion IS 1570 (Part Resistant Steel 5), Gr. 15 Cr

or Chrome 13, IS 2004

nickel steel with 40 micron

hard chromium

plating

6 Self aligning spherical roller bearings SKF make or

equivalent

approved make

7 Bushing Aluminum IS 305

Bronze

8 Bearing Retainers Structural Steel IS 2062

9 Sleeves for pin (distant piece) Corrosion IS 1570 (Part resistant steel 5)

hard chromium

plated mild steel

10 Seals Natural or IS 11855 synthetic rubber

a) Bottom seal a) Wedge type

rubber seal

b) Side seals b) Music note

hollow bulb

rubber seal

11 Screws / Bolts & nuts for seals Stainless Steel IS 1570 (Part

5)

15 Guide Roller Cast Steel IS 1030, Gr. 27-54 or Gr.

26-52

16 Ballast, if any Cast Steel IS 210

583 UPID

2.3.3 Vertical Lift Slide Gates for Distributaries, Minors and Escapes

Sl. Components

Recommended Indian No. Materials Standards

1 All Structural members such as Skin Structural Steel IS 2062

plates, Stiffeners, Main horizontal

girder, vertical stiffeners, end vertical

girders, Lifting brackets etc.,

Seal bases, Track bases, seal seat

bases, seal clamps, guide shoes,

Anchor plates & anchorages etc, Side

guide tracks.

2 Seal seats Stainless steel IS 1570 (Part 5)

3 Track Plates Corrosion IS 1570 (Part Resistant Steel 5), Gr. 20 Cr

13

5 Lifting pin Stainless steel IS 1570 (Part 5)

6 Slide block Structural Steel IS 2062 & IS with Aluminum 305

Bronze padding

7 Seals Natural or IS 1185

synthetic rubber

a) Bottom seal a) Wedge type

rubber seal

b) Side seals b Music note

hollow bulb

rubber seal

8 Screws / Bolts & nuts for seals Stainless Steel IS 1570 (Part

5)

2.3.4 Electrically Operated Rope Drum Hoists

Sl. Components

Recommended Indian

No.

Materials

Standards

1 Rope drum Cast steel / IS 1030 / IS

Structural Steel 2062

2 Wire rope Improved plough IS 2266

steel-fibre core

or steel core, 6 x

36, 6 x 37,

(galvanized)

3 Wire rope socket Forged steel IS 2004 / IS1875

4 Gears Cast steel / IS 1030 / IS Forged steel 2004 / IS 1875

5 Pinions Cast steel / IS 1030 / IS

Forged steel 2004

584 UPID

Sl. Components

Recommended Indian No.

Materials

Standards

6 Shafts Mild steel / IS 2062 / IS Forged steel 2004

7 Sheaves / Pulleys Mild Steel / Cast IS 2062 / IS steel 1030

8 Couplings Cast steel IS 1030

9 Bronze bushing Aluminium IS 305

bronze

10 Ball / Roller bearing S.K.F. or

equivalent

11 Plummer blocks S.K.F. or

equivalent

12 Equalizer bars, turn buckles Forged steel / IS 2004

Galvanized Steel

13 Keyways and Keys Forged Steel IS 2048 / 2291 / 2292

14 Bolts & nuts IS 1367, 1363, 2389, 1365, 3640

15 Motor IS 325 / 900 /1231 / 2223

16 All structural members for steel trestles Structural steel IS 2062

and hoist bridge etc.

17 Steel for shrunk fit gear rims Forged steel / IS 1570

Alloy steel

* (Properties)

Properties:

These properties shall apply after gears have been annealed / stress relieved / heat treated

- Carbon content: 0.25% max.

Elongation as per IS 1508:0.25% min.

- Reduction ages: 15% min.

2.3.5 Screw Hoists

Sl. Components

Recommended Indian Standards

No. Materials

1 Stem Forged Steel IS1875

2 Gears Cast steel IS1030 Carbon steel IS1875

Forged steel IS2004

3 Pinions -do- -do-

4 Shafts Forged steel IS2004 Mild steel IS2062

5 Bolts & Nuts IS1367,1363,2389,1365,3640

6 Keyways &Keys Forged steel IS2048/2291/2292

7 Bronze Bushing Aluminum Bronze IS305

8 Ball/Roller Bearing SKF or equivalent

585 UPID

Sl. Components

Recommended Indian Standards

No. Materials

9 Retainers Structural Steel IS2062

10 Plummer Blocks SKF or equivalent

11 Covers Structural Steel IS2062

12 Hoist supporting Structural Steel IS2062 structure

Properties:

These properties shall apply after gears have been annealed / stress relieved / heat treated

- Carbon content: 0.25% max.

- Elongation as per IS 1508: 0.25% min.

- Reduction ages: 15% min.

2.3.6 Hoist Bridge, Trestles, Walkway railing etc.

Sl. Recommended

Indian

No Components

Materials Standards

.

1 Base plate, anchors, bridge beams, Structural steel IS 2062/Rolled columns, stiffeners, bracings, lugs, etc. Sections IS808

2 Walkway Chequered plate Standard

3 Bridge Bearings Neoprene or IS 305 / IS 318 bronze

4 Handrails & posts Mild Steel Black IS 1239

medium duty

586 UPID

TECHNICAL DOCUMENTS

3.1Technical Documents

3.1.1 General

This Chapter specifies the general scope and gives a definition of the documents which shall be delivered by the Contractor to the Engineer-in-Charge within the periods, and in a number and quantity as specified in the Contract / Technical Specifications.

The Engineer-in-Charge reserves the right to request the Contractor for additional documents as may be required for proper understanding and definition of constructional, operational, co-ordination or other matters or may also request the Contractor not to submit some of them.

All documents to be supplied shall be submitted in accordance with the agreed program so

that any comment and change requested by the Engineer-in-Charge can be taken into account before starting of the manufacture in the workshop and / or erection or installation at the site.

If the Contractor fails to submit such documents, then the later execution of changes requested by the Engineer-in-Charge and the resulting additional cost and / or delays should be the Contractor’s responsibility. The Contractor shall not be released of his responsibility and guarantee after the Engineer-in-Charge has approved designs and drawings.

The preparation of designs, drawings or other technical documents shall not be

subcontracted by the Contractor without the written authorization of the Engineer-in-Charge. In such a case of subcontracting the Contractor shall be fully responsible for such designs, drawings and other technical documents as if he did them.

On drawings, catalogue sheets or pamphlets of standard works submitted to the Engineer-in-Charge the applicable types, paragraphs, data etc. shall either be marked distinctively or the non-applicable parts shall be crossed out. Documents not marked in such a manner will not be accepted and approved by the Engineer-in-Charge.

If required for proper understanding of the documents, additional descriptions /

explanations shall be given on these documents or on separate sheets. All symbols, marks, abbreviations etc. appearing on any document shall clearly be explained by a legend on the same document or on an attached sheet.

Each device appearing on any document (drawing, diagram, list etc.) shall clearly be designated. The abbreviation mark used for an individual device shall be identical throughout the complete documentation so as to avoid confusion. All documents shall have a uniform title block as outlined in the specification and agreed by the Engineer-in-Charge. Beginning with the very first submittal to the Engineer-in-Charge, the Contractor’s drawings shall bear a serial number corresponding to a drawing classification plan to be agreed upon by the Contractor and the Engineer-in-Charge.

Revised technical documents replacing previous submitted documents shall be marked

accordingly. Also, the revised part in the document itself shall be marked clearly. The documents, which are required to be supplied, shall be clearly marked as regard to

587 UPID

their status namely “FOR APPROAL” (A) or “FOR INFORMATION” (I) respectively.

Any comment given by the Engineer-in-Charge on an “I” type drawing shall have the same effect as if it were given on an “A” type drawing.

The Contractors shall provide to the Engineer-in-Charge at least six copies or as otherwise

specified, of all submittals as requested for in these Specifications and other Bidding Documents. They shall be complete enough to illustrate adequately the problem of the aspect concerned for the understanding of the Engineer-in-Charge.

The Contractor shall submit these documents to the Engineer-in-Charge and reasonable

time shall be given to the Engineer-in-Charge to comment or approve the submittals.

3.2 Designs & Drawings The design calculations submitted for the scrutiny shall be legible, neatly typed or written and should contain explanations of all the symbols. Calculations containing short forms duplicate symbols or output from computer programme which are not understandable shall not be

acceptable. The design calculations shall be supplemented by neat sketches, cross reference

and reference to various clauses of technical specifications and IS codes. Similarly the drawings shall also be of standard size & quality engineering drawing duly checked by the contractor in all respects. Representative of designer or designer of manufacturer / contractor will be made available during design appraisal, if required by the Engineer-in-Charge or Purchaser at no extra cost and liability for the Purchaser. Unwarranted references to past

installations for adopting a particular design will not be allowed. Compliance to various comments will have to be submitted point wise and revisions as to be marked clearly. Generally during 1st. checking whole design and drawings will be scrutinized. On subsequent scrutiny only revisions will be checked. If any change is voluntarily made by the contractor /

contractor in subsequent submissions, it should be brought in the notice of the Purchaser. Responsibility in this regard will rest fully with the contractor.

3.2.1 Drawings and data to be furnished by the Bidder along with Bid Preliminary design and drawings showing following details of all gates separately as specified earlier under the scope of work shall be furnished in quadruplicate.

3.2.1.1 Vertical Lift Wheel Gates Preliminary designs & drawings showing the following General arrangement with over all dimension, weights and materials proposed.

Sealing arrangement proposed.

Any other special features such as lifting arrangement etc.

3.2.1.2 Rope Drum Hoists for Vertical Lift Wheel Gates

Preliminary designs & drawings showing the following

General arrangement with over all dimension, Hoist capacity, weights and materials proposed.

588 UPID

Arrangement indicating the end reduction unit, gears, pinions, drive units, manual

operation and proposed tolerances. Makes and specifications of bought out items.

3.2.1.3 Hoist Support Structures Rope Drum Hoists General arrangement with over all dimension, weights and materials proposed.

Details of supports/ supporting bearings and rockers etc.

3.2.1.4 Vertical Lift Slide Type Gates

Preliminary designs & drawings showing the following General arrangement with over all dimension, weights and materials proposed.

Sealing arrangement proposed.

Any other special features such as lifting arrangement etc. 3.2.1.5 Screw Hoists for Vertical Lift Slide Type Gates

Preliminary designs & drawings showing the following General arrangement with over all dimension, Hoist capacity, weights and materials

proposed. Arrangement indicating the end reduction unit, gears, pinions, drive units, manual

operation and proposed tolerances. Makes and specifications of bought out items.

3.2.1.6 Hoist Support Structures for Screw Hoists

General arrangement with over all dimension, weights and materials proposed.

Details of supports/ supporting bearings and rockers etc.

3.2.2 Drawings and Data to be furnished by contractor after award of work Within forty five (45) days from the date of commencement of work, the contractor shall prepare and submit the detailed list of designs and drawings for different types of gates, hoists, hoist support structures and cranes etc. proposed to be prepared for the total works indicating the date of submission compatible with the work schedule.

Letterings of the drawings shall be at least 3 mm high in block capitals. Lines shall be of sufficient weight to reproduce clearly. The size of Manufacturers drawings shall conform to International Organization for Standardizations (ISO) sizes. All drawings shall bear the following heading in the block:

UP Water Sector Restructuring Project All drawings shall be drawn in accordance with Indian Standards, to scale, and shall be legible. Wordings on drawings shall be in English. Symbols shall be in accordance with Indian Standards.

All designs and drawings shall be carefully checked by the Contractor for accuracy, completeness and clarity before submission to Engineer-in-Charge for approval. The Contractor shall be responsible for correctness and adequacy of the design in relationship to the specifications.

589 UPID

The contractor shall submit the following for all equipment as soon as possible, but not

later than 90 days after the date of award of Contract and before proceeding with the fabrication work for the approval of the Engineer-in-Charge. All the documents shall be submitted separately for each gate and equipment.

Detailed design computations in 4 (four) copies for all the components and parts of the proposed equipment in accordance with design criteria, specifications to prove their adequacy supported by catalogue / technical literature of all brought out components with selection criteria and characteristic together with weights and overall dimensions. If revisions are required after a design computations has been submitted, the Manufacturer shall resubmit 4 (four) additional copies of design computations for approval after incorporating the comments.

4 (four) copies each of the carefully checked detailed drawings of gates and hoists components, hoist support structures, cranes to demonstrate fully that the equipment to be furnished shall conform to the provisions and intent of these specifications and specification drawings. If revisions are required after a drawing has been submitted, the Manufacturer shall resubmit 4 (four) additional prints for approval after incorporating the comments. Fabrication shall not commence until drawings have been approved by the Engineer-in-Charge and thereafter no change shall be made on any drawing without the approval of the Engineer-in-Charge.

Drawings and accompanying data shall show the specification for each part and the type

of heat treatment, where ever required including the following details. The drawings shall also include sufficient details of welding, welding rod specifications and inspection methods, machining and assembly tolerances and fits.

Complete list of all parts showing the dimensions, type, grade and class of material, numbers and weight etc. The material lists shall include the relevant Indian Standard or equivalent Indian Standard.

Complete details such as makes, capacity, ratings and other details of all standard items.

Speed / Torque characteristics shall be furnished for all motors covering starting and

running conditions with controls.

Machinery imposed load on concrete structure, location of anchors, ground pockets and checks in structures construction constructed by others shall be provided.

The proposed methods of installations of all anchorages and complete equipment.

For all large pieces of work which, due to their dimensions and / or weight and transport

limitations, will require special means for their transportation, the contractor shall submit binding loading drawing indicating dimensions, weights etc. of the respective pieces of work and the necessary trailer for its transportation to the site.

The design of all equipment shall be such that installation, replacements and general maintenance may be undertaken with the minimum time and expense.

590 UPID

All drawings submitted will form a part of the contract. The sequence of submission of

drawings will also form a part of the contract. The sequence of submission of all drawings shall be such that all information is available for checking of each drawing, when it is received. The Engineer-in-Charge will return a copy of each drawing to the contractor marked either ‘approved’ or ‘approved as noted’ or ‘returned for corrections/modification’. The notation ‘approved’ ‘approved as noted’ shall authorize the contractor to proceed with the manufacture of the equipment covered by such drawings subject to the corrections, if any, noted thereon. When prints of drawings have been returned for corrections / modification, the contractor shall revise / modify

the drawings as necessary and shall resubmit fresh prints for approval in the same routine as before.

Approval by the Engineer-in-Charge for the Contractor’s design and drawings shall not be

held to relieve the contractor for any part of the contractor’s obligation to meet all the requirements of the specifications or of the responsibility for the correctness and accuracy of designs, drawings, fabrication, erection, commissioning, performance and guarantee etc.

The Purchaser shall have the right to ask the Contractor to make any change in the designs

and drawings, which may be necessary in the opinion of the Purchaser to make the equipment conform to the provision and intent of those specifications without additional cost to the Purchaser.

The requirements of any such alterations requested by the Purchaser or the Engineer-in-Charge, shall not be construed to mean that the drawings have been checked in detail shall not be accepted as justification for an extension of time and shall not relieve the manufacturer from responsibility for the adequacy of the designs and correctness of the drawings.

Unless otherwise specifically provided for in the schedule and/or in the specifications and /or in the specification drawings, the contractor shall furnish all the materials accessories, tools & tackles and appurtenant parts called for in the specification or shown on the specification drawings, but not mentioned in the specifications or anything called for in the specifications but not shown on the drawings shall be treated as called for and shown on both.

Any fabrication work performed prior to the formal approval of the Engineer-in-

Charge in respect of the designs and drawings shall be at the risk and cost of the

contractor. The Engineer-in-Charge shall have the absolute right to ask the contractor to

make change(s) in the designs and drawings, which may be deemed necessary in the

opinion of the Engineer-in-Charge to make the equipment conform to the stated provisions

and intent of the specifications, without any additional cost. After designs and drawings

are completed and approved, the contractor shall supply to the Engineer-in-Charge 6 (Six)

prints of all the designs and drawings, out of which 2 (two) prints duly laminated.

However prior to completion of contract, contractor shall supply 5(Five) prints of all

approved as built drawings plus one copy in compact disc.

3.2.3 Diagrams

The Contractor shall submit the following diagrams:

591 UPID

The circuit diagrams shall show the power circuits in all phases with the main apparatus as

well as the pilot circuits (measuring and control circuits). It shall show in full the functioning of part or all installations, works or circuits with all required technical information. This shall show all technical blocks control cubicle, cable details, cable tracks etc.

Details of complete coordinated wiring of all electrical equipment along with diagrams

and catalogues shall be furnished.

Electrical wiring diagrams of hoists, hydraulic circuits, piping / cable diagrams, automatic

and manual lubrication system, performance curves, specifications and catalogue numbers of all motor control centers, control panels, motors and accessories.

Controls & indicators

3.2.4 List of Schedules

The following schedules are required to be furnished by the Contractor after the approval and commissioning of the equipment. This information is to be appended with the operation and maintenance manuals.

The Motor Lists shall be prepared according to the power distribution boards. The motors

are connected to and shall contain at least the following information / data; Works identification number

Description

Manufacture, type, rating and data of driven machine

Manufacture and type of electric motor / consumer

Rated capacity

Service factor (ratio between motor output and power requirement of

the driven machine)

Rated speed

Rated voltage

Rated current

Ratio of starting current to rated current

Ratio of pull-out torque to rated torque

Power factor at rated capacity

Efficiency at rated capacity

Power consumption at machine design loading

592 UPID

Design / enclosure / cooling (according to IEC)

Duty (continuous / intermittent / star-up)

Staring method / permissible starting frequency

Denomination of feeder

Motor protection

Applicable Standard Circuit Diagram (Category)

Maximum number and overall diameter of power cable(s)

Manufacture and type of bearing(s)

Manufacture, type and quality of lubricant, service interval

Manufacture, type, number, size, spring pressure and service interval of bushes

(if applicable)

The Motor Starter Lists shall include all starters and contactors used for motors and

contain the following technical information as a minimum.

Works identification number

Electrical design data as nominal and actual current rating, voltage rating, coil

rating, making and breaking capacity, mode of operation

Maximum power cable size

Maximum control cable size

Current transformer ratio, class and capacity

Type of protection relaying and catalogue number

Setting of protection relays and maximum continuous rating of the

protected circuit

Type and current rating of the back-up fuses / MCBs (Miniature

Circuit Breaker) for the main and control circuits

The Cable / Interconnection Lists shall include for each individual cable the following as a minimum

Cable number in accordance with identification System

Cable type

Rated voltage

Number and size of conductors

593 UPID

Overall diameter

Cable termination at each end

Connection point at each end with cubicle / works identification and terminal

number

Cable routing

Using interconnecting cubicles

Cable termination for incoming and outgoing cable

Interconnecting wing

The List of Measurements shall indicate all measurements, local as well as remote,

and shall contain at least:

Item / code number, function code

Description and denomination of measuring loop

Data of tapping point

Data of local devices (as detectors, instrument transformers, transmitters)

Data of remote devices

The Alarm Lists shall indicate all alarms and shall contain at least:

Item / code number, function code

Description and denomination of measuring loop

Data of alarm detector (contact) referring to applicable circuit diagram

Data of alarm annunciator (location and clear text labeling)

Lists of Final Control Elements shall indicate all control actuators and control

valves and shall contain at least:

Item / code number

Data of pipe and valve connections

Data of valve layout

Maximum required and rated power

Individual Workshop Test Schedules shall be prepared for Works / installations

(such as gates, pipes, cranes, hydraulic hoists, machines, cables) and shall contain

at least:

594 UPID


Manufacturer

Place of manufacture

Place of test

Date of test

Objective of test (all individual tests)

Standards applied

Certification

Inspection (by Engineer-in-Charge / independent test authority / Contractor

/ sub-contractor)

Release of shipment

Remarks

On the above schedule or on separate sheets the Test Procedure shall be specified giving for

each test item (kind of test) a description, test method / Standards, used instruments, sample /

routine test, test judgement.

Site Test Schedules:


Manufacturer

Place of manufacture

Place of test

Date of test

Objective of test (all individual tests)

Standards applied

Certification

Inspection (by Engineer-in-Charge / independent test authority / Contractor

/ sub-contractor)

Release of shipment

Remarks

595 UPID

The List of Tools and Appliances shall detail for all tools and appliances included

in the scope of supply:

Item and code number

Description

Quantity

Weight

Gross storage requirements (separate for open-air, indoor, air conditioned) and

individual component sets.

Spare Part Lists shall detail for all parts included in the scope of supply:

Item and code number

Description

Quantity

Weight

Gross storage requirements (separate for open-air, indoor, air conditioned) and

individual component sets.

List of Works Identification Numbers shall contain the used Works Identification

Numbers in alphanumeric order and for each of them a description (the defined

works denomination, for example as written on the Works label) and the location

(short definition of outdoor area and level elevation or building / room with

elevation and room number)

3.3 Progress Reports

The contractor shall also (during the course of design and fabrications) submit

monthlyprogress report four (4) copies along with photographs of fabrications done in a

formatacceptable to the Engineer-in-Charge, apprising him of the progress of equipment for

the preceding month. The report shall contain (but not be limited to) the following

information:

A general description of the works performed during the reporting period an each main activity.

The percentages of each main work activity completed during the reporting month with

reference versus the scheduled programme.

A list of activities scheduled to be started within the next period of three (3) months, with

expected staring and completion dates. Any notable problems, differences, comments

with reference to the schedule may be supported with appropriate documents. 596 UPID

Contractor shall also briefly report the manpower strength and expatriate personnel

employed, equipment etc. deployed during the reporting period.

A statement connecting potential problems and recommendations on how they could be resolved.

The time and the date of completion of works as stipulated in the tender document shall

bedeemed to be the essence of the contract. However, certain alterations can be suggested by

the bidder keeping in view the programme of erection, front availability and the completion

date The contractor shall submit along with his bid a detailed programme based on the

dates indicated in the tender document or alternatively his own time schedule giving shorter

delivery / erection period taking into consideration the gate by which the erection front can be

made available to him. The schedule shall be within the time frame agreed above consisting of

adequate number of activities covering various key phases of the work such as designs,

drawings, procurement, manufacturing, shop assembly (equipment wise), sand blasting and

painting, shipment, field erection and testing activities. This network shall also indicate the

interface facilities to be provided by the Engineer-in-Charge if any and the dates by which

such facilities are needed. It shall also indicate the details of resources like

manpower/machinery envisaged in the part and to be mobilized by the contractor for all stages

of erection. From time to time during manufacture and installation, Contractor shall photograph

theequipment to depict the actual progress by supplying minimum 3 views per location

per month, size of the print shall not be less than 18 cm x 24 cm.

3.4 Installation, Operation & Maintenance Manual

For guidance during the installation of the work and subsequently for guidance of

the plant operating and maintenance staff, contractor shall prepare and provide

manuals. The manuals shall contain following information in sufficient details to

enable the Purchaser to maintain, dismantle, reassemble, adjust and operate the

work with all its works and installation.

The manuals shall include a separate and complete section describing the normal

and emergency operating procedures for the gates and control equipment and

shall include easily read diagrammatic drawings of the equipment to facilitate

understanding of the descriptive information of the following:

Description of works & equipment

Operating principle & characteristics

Testing & adjustment

Maintenance instructions

Spare parts 597 UPID

The manuals shall describe and illustrate the procedure for assembling, adjusting,

operating and dismantling of each component and control system. The

maintenance of each component shall be described, including the recommended

frequency of inspection and lubrication.

Manuals shall also describe and illustrate procedures for installation, storage,

handling, unloading, reloading, unpacking and up-keeping of each component and

of the system.

Three (3) copies of the manuals shall be submitted in English in draft form

forapproval of Engineer-in-Charge within 3 months after the final approval of the

equipment. Five (5) suitably bound copies shall be provided to Engineer-in-

Charge not later than 30 days after receipt of approval.

If revision of the manuals becomes necessary, as a result of information gained

during installation and initial operation, Contractor shall make the necessary

revisions and furnish five (5) copies of the revised sections sheets with the

revision symbols along with the CD of the same.

The manuals shall include a complete list of all drawings prepared by contractor,

a list of spare parts and a list of parts for each component or item of equipment.

The parts list shall include contractor’s name and serial numbers The manual shall

include data, literature and catalogues of bought out items.

Contractor shall ensure that his installation supervisor has a copy of all approved drawings

and the manuals in his site office.

3.5 Inspection and Test Records For seeking owner’s approval for transportation of any equipment / materials / components, the contractor shall submit all relevant inspection and test records in quadruplicate, duly signed and accepted by contractor’s Quality Assurance Group and by representative of Kanpur Branch Canal, UP Water Sector Restructuring Project Authority whenever required to be associated.

Contractor, after final test and acceptance of equipment at site, shall submit 5 (five) completesets of abridged inspection & records for all equipment supplied. 598 UPID

DESCRIPTION AND DESIGN CRITERIA 4.1Design and Construction Requirements 4.1.1 General 4.1.2 Description of Components of Vertical Lift Gates and Embedded Parts. 4.1.2.1 Vertical Lift Fixed Wheel Gates: All the gates for Cross Regulators, Head Regulators and Escapes consist of skin plate supported on vertical stiffeners, which in turn rest on horizontal girder. The horizontal girders are mounted on end vertical girders, which transmit the hydrostatic pressure to track girders through the wheel assemblies.

The gates shall be designed in accordance with IS 4622 (latest edition) for following loads:

The full hydrostatic head on the gate corresponding to water levels mentioned under Design Parameters for respective gates. The gates, hoists and their components shall be designed for earthquake forces in accordance with IS 1893 (latest edition).

Total applied hydrostatic, hydro-dynamic, frictional and wind loads when the gates are raised and lowered with the designed water level.

The maximum permissible value of stresses shall not be greater than those specified

for normal working conditions in Annex B of IS 4622 (latest edition) shall be considered.

The gates shall also be checked for occasional forces. In these cases, the allowable stresses specified in Annex B of IS 4622 (latest edition) shall be increased by 33-1/3 % subject to maximum of 85% of yield point stress of the material used. The increase in allowable stresses in case of Bolts & nuts shall not exceed 25%. The permissible value of stresses in the welded connection shall be same as permitted for parent material.

The provisions shall be made for connection of the hoists with the gates and gate position indicator. The connection of the hoist shall be so made that the gate, in any position, shall remain in true vertical plane.

4.1.2.2 Vertical Lift Slide Gates: The Gates for Distributaries, Minors and Escapes consist of skin plate supported on vertical stiffeners, which in turn rest on horizontal girder. The horizontal girders are mounted on end vertical girders, which transmit the hydrostatic pressure to track girders through the slide blocks. The slide blocks shall be made of Aluminium Bronze conforming to IS 305. The minimum thickness of slide blocks shall not be less than 10.0 mm after machine finish and shall be fixed to the gate leaf with the help of stainless steel counter sunk head screws of suitable size to withstand the frictional forces being developed due to operation of gates under maximum water head. The head of screws shall be kept at least 1.5 mm below the surface of slide blocks. The Vertical Lift Slide Gates shall be designed in accordance with IS: 5620 (latest edition) for following loads: The full hydrostatic head on the gates corresponding to water levels mentioned under

Design Parameters. The gates, hoists and their components shall be designed for earthquake forces in accordance with IS1893 (latest edition).

599 UPID

Total applied hydrostatic, hydro-dynamic, frictional and wind loads etc. when the gates

are raised and lowered with the designed water level.

The maximum permissible value of stresses shall not be greater than those specified for normal working conditions in Annex C of IS 5620 (latest edition) shall be considered.

The gates shall also be checked for occasional forces. In these cases, the allowable stresses specified in Annex C of IS: 620 (latest edition) shall be increased by 33-1/3 % subject to maximum of 85% of yield point stress of the material used. The increase in allowable stresses in case of Bolts & nuts shall not exceed 25%. The permissible value of stresses in the welded connection shall be same as permitted for parent material.

The provisions shall be made for connection of the hoists with the Vertical Lift Slide Gates. The connection of the hoist shall be so made that the Vertical Lift Slide Gates, in any position, shall remain in true vertical plane.

4.1.2.3 Skin Plate Skin plate and stiffeners shall be designed together in a composite manner. Skin plate shall be checked for the following two conditions: In bending across the stiffeners, horizontal girders or as panels. In bending, co-acting with stiffeners and/or horizontal girders. For determining the stresses in bending as well as in panel the procedures as specified in IS 4622, 5620 etc. may be used unless otherwise precise methods are available. Provisions of IS 800 shall also be adhered to.

For or condition in (b) above the width of skin plate co-acting with stiffener / horizontal girder for panel shall be assumed as specified in relevant IS codes unless more exact method is available and the actual stresses due to beam action are calculated. Alternatively the co-acting width of skin plate in non panel fabrication shall be calculated as specified in IS 4622, 5620. Criteria for co-acting width shall also satisfy IS 800 or any other standers specified by the Engineer-in-Charge at the time of detailed design.

To take care of corrosion, the actual thickness of skin plate, as calculated, shall be increased by at least 1.5 mm. The actual stresses shall not be more than those specified in IS 4622, 5620 etc. However the minimum thickness of the skin plate shall not be less than 10.0 mm inclusive of corrosion allowance except for the web of rolled steel sections used. The thickness of rolled steel section webs shall not be less than 8.0 mm

4.1.2.4 Horizontal Girders, Stiffeners and End Vertical Girders The horizontal girders and vertical stiffeners shall be designed as a simply supported or continuous beams depending upon the framing adopted. The spacing in between the horizontal girders shall be such that the girders shall carry almost equal loads.

The end vertical girders shall be designed as continuous beam supported on wheel assemblies slide blocks as the case may be with concentrated loads coming from the horizontal girders and shall transfer the same to the adjoining concrete structure through the track plate & track bases. The actual stresses so computed shall not be more than those specified in Indian Standards.

600 UPID

The connections to the hoisting mechanism at a point other than end vertical girders shall be so made that the stress concentration particularly on the upper fibre of the web of the top girder is avoided. And the hoisting forces shall be dispersed through suitable stiffeners to one or more horizontal girders below the top one. The extra stresses, if any, arising due to this arrangement shall be combined with other stresses to ensure that the permissible limit does not exceed.

The maximum deflection for the gates shall not exceed l / 800 of the span, where span is centre to centre distance of wheel tracks or sliding tracks.

4.1.2.5 Seals The seals shall be rubber seals as shown in respective drawings for side and top sealing and wedge type rubber seals for bottom conforming to IS 11855.

Rubber seals shall be fixed to the gate leaf by means of counter sunk screws made of stainless steel/corrosion resistant steel. The screws shall be designed to take up full Shear force likely to develop during raising or lowering the gate under maximum head of water between the seal and bearing plates. The screws shall be adequately tightened to a constant torque and locked by punch mark. Minimum threaded length equivalent to one and half times the diameter of screws shall be screwed to ensure against their loosening under vibrations during operations.

The seals shall conform to the provision contained in IS 11855. The seal interference / compression for side and top seals shall be 3mm and the same for bottom seal shall be 5 mm. Suitable chamfer shall be provided at the bottom of skin plate / clamp plate to accommodate the bottom wedge seal in compressed position. Coefficient of friction between fluorocarbon and stainless steel (finished stainless steel) should be adopted as 0.5 considering the wear of fluorocarbon.

4.1.2.6 Seal Seats, Seal Bases and Sill Beams The minimum thickness of seal seats shall be 10 mm after machining. The seal seats shall be of stainless steel conforming to IS 1570 (Part 5) (latest edition). The seal seats shall be welded to the seal seat bases. The seal seat shall be finished smooth to triple delta.

The seal seat bases shall be made of either built up steel plate section or rolled steel sections in welded construction. These shall be aligned and securely fixed for embedment in 2nd stage concrete. Relative alignment of tracks, side and bottom seal seats when gate fully closed and seals are fully compressed shall be maintained.

The sill beam shall be provided with the stainless steel plate as bottom seal seat. The surface of the sill beam shall be machined smooth and made flush with the surrounding concrete.

4.1.2.7 Wheel Assembly Wheels

Wheels shall be of either forged steel or cast steel as shown on relevant drawings. Appropriate

ratio of bearing width and pin dia. shall be maintained. The minimum difference between

B.H.N. of track and wheel shall be 50, the track having higher BHN value. Arrangement of

wheel shall be such that as far as possible, equal load shall be shared by each wheel.

601 UPID

Wheel Axles The wheel axles shall be supported by end vertical girders. The axle shall be made of corrosion resistant steel (IS 1570, Pt. 5). Cast steel (IS 1030) or mild steel retainer shall be provided to retain the wheel bearing in position. Oil seals shall also be provided. Sleeves should be avoided. In case necessary the material thereof should be same as wheel axle.

Wheel Bearing SKF make or equivalent anti-friction spherical roller or self lubricating bronze bearings of reputed make and proven capabilities with proper lubricating arrangement shall be adopted. Bearing should have minimum 10000 hours of life and their static capacities should be at least 1.5 times the wheel load. However, the dynamic capacities should also not be less than the wheel load. Bearing should also be safe against axial loading. Bearings shall be fully protected from entry of the silt.

4.1.2.8 Track / Bearing Plates & Bases

Track / Bearing Plates Track / bearing plates shall be made of Corrosion Resistant steel conforming to I.S:1570(Part 5). These plates shall be mounted on the track bases by welding. The hardness of surface of the track plates shall be kept 50 points BHN higher than that of the wheel tread to reduce the wear on the track. The hardness of surface of the track plates shall be kept 250 points BHN (minimum). The thickness of track plate shall be calculated as per I.S: 4622 / 5620. However, the minimum thickness of track plate shall not be less than 10.0 mm after machining. The surface of track plates shall be finished smooth to two delta.

Track Bases The track bases shall be made of structural steel rolled or built up sections in welded construction conforming to IS 2062 (latest edition). These shall be embedded in 2nd stage concrete, which shall not be leaner than M-25 grade conforming to IS 456 (latest edition). The edge distance of the track base from the groove face shall be determined on the basis of shear strength of concrete. However, the minimum edge distance shall not be less than 150 mm.

The track base shall be designed as a beam on elastic foundation. The track base shall be checked for bending stress & shear stress and its flanges for bending .The web of the track base shall be checked for compression and the permissible stress in compression not be more than 85% of yield stress of the material .The track base shall also checked for shear stress in concrete under the base. The bearing and shear stresses for concrete shall not exceed those specified in IS 456.

The permissible stresses in track base shall not exceed those specified in IS code.

4.1.2.9 Guide Plates & Guide Shoes / Guide Rollers Guide plates for gates shall be fixed and embedded in 2nd stage concrete. The minimum thickness shall be as per the design heads for individual gates as specified in Indian Standards. The guide shall be effective in longitudinal as well as in transverse directions. The clearance between guide plate and guide shoes shall be 4.0 mm to 6.0 mm in each direction.

Guide shoes / rollers for gates shall be fixed on the end vertical girders of the gate leaves. The guide shoes shall be made of structural steel. The guide shoes / rollers shall be fixed with the

602 UPID

help of bolts /screws, which shall be designed to withstand the load encountered by them during the operation of the gates.

4.1.2.10 Ballast The gates shall be self closing type under their own dead weight. Suitable ballast, if required to make the gate self closing, may be provided in the form of dead weight. The ballast shall be in the form of cast iron / pig iron billets, concrete or any other suitable material and shall be securely placed in between the webs of horizontal girders ensuring that it does not get dislodged from its position, when the gate is in operation. The effect of dead weight of the ballast on the horizontal girders shall be analyzed. The centre of gravity of the gate shall be determined after the ballast is placed and properly secured in position. The ballast shall be provided such that its weight does not exceed 90% of the dead weight of the gate.

4.1.2.11 Lifting Arrangement The lifting arrangement to the gates shall be provided with respect to the true centre of gravity of the gates in such a manner that when the gates are hung freely shall remain in true vertical plane. In case the lifting lugs are welded on the web of the top horizontal girder the hoisting forces shall be dispersed through suitable stiffeners to one or more horizontal girders below the top one. The extra stresses, if any, arising due to this arrangement shall be combined with other stresses to ensure that the permissible limit does not exceed.

4.1.2.12 Anchor Bolts or Anchor Plates The anchorages shall be provided in the 1st stage concrete with suitable block-outs openings to hold and to align the 2nd stage embedded parts in the 2nd stage concrete. The 2nd stage anchor bolts shall have double nuts and washers and the minimum diameter shall be 16.0 mm. For alignments and adjustments purposes enlarged holes shall be provided in the 2nd stage embedded parts. Adequate numbers and suitable size dowel bars shall be provided in the 1st stage concrete and the surface of 1st stage concrete in block-outs shall be left thoroughly rough to ensure proper bond in between 1st stage and 2nd stage concrete.

4.1.2.13 Tolerances The tolerances for embedded parts and components of gates shall be as specified in relevant Indian Standards for respective gates.

4.1.3 Hoist Capacity The hoist capacity shall be determined by taking into consideration the algebraic sum of the worst combination of the following forces developed during either raising or lowering cycle of the gate. The hoist capacity thus calculated shall be increased by 20% as reserved.

Weight of gate along with all its components including wire rope of hoist etc.

Total water load acting on the gate components including buoyancy

All frictional forces comprising of

Wheel friction

Guide friction

Seal friction

603 UPID

Any hydro-dynamic forces like hydraulic down pull / uplift. The contractor will submit his

calculations for hydro-dynamic forces as per prevailing practice. However, model studies may be done by Engineer-in-Charge (if required). Contractor shall incorporate the results of studies (if considered necessary by the Engineer-in-Charge) without any additional cost to Engineer-in-Charge.

Any other load considered specific to the site.

Seating load shall be considered as specified in IS 6938 (latest revision).

4.1.3.1 Design Data for Rope Drum Hoists

Capacity : Adequate capacity for operation of Cross Regulator, Cross Regulator and Escapes

Maximum lift for : To be decided by manufacturer

Operating speed of : 0.3 - 0.5 m/min (tentative) Hoist For all Gates

Number of Hoist : One no. for each gate

Governing Indian Standard

I S Code : IS 6938, 3177, 800

4.1.3.2 Hoisting Speed The hoisting speed for Rope drum Hoist shall be between 0.3 to 0.5 m per minute (tentative).

4.1.3.3 Hoist Supporting Structure The hoist supporting structure shall be made of structural steel conforming to IS 2062 (latest edition) and shall be designed to withstand the hoisting load, wind load, seismic loads, dead weight of hoist and its all components as well as vibrations caused due to operation. Suitable anchorages for the hoist frame shall be provided to take the worst combination of all loads under which the gates and hoists are in operation. Ample walking space, ladders, railings, decking etc. should be provided for hoist platform for attending to hoist machinery. The chequred plate of hoist platform should not be less than 8 (eight) mm in thickness and should be reinforced.

4.1.4 Components of the Hoists

Each hoist shall comprise of following components:-

Central Drive Unit

Central drive unit shall be comprising of electric motor, 1st stage reduction gear box, electro-magnetic brakes, gate position indicator and manual drive unit etc.

End Gear Reduction Unit

The end gear reduction unit shall comprise of gears, pinions, Plummer blocks, shafts, pedestals, rope drums, bearings couplings and all other such accessories, which may form in-separable components for the satisfactory operations. Drum supports shall be

604 UPID

of fabricated type with adequate stiffening for carrying drum shaft reactions. Gear boxes should be sufficiently rigid and strong.

Control Equipment

The control equipment shall comprise of electric motor, switch gears, limit switches, control panel, and various electrical relays required for satisfactory operation of motors and brakes etc.

Miscellaneous Parts Miscellaneous parts like wire ropes, rope sockets, equalizers, turn buckles, pulleys/ sheaves, hoist base frames, cover boxes and hoist supporting structure etc.

4.1.4.1 Mechanical Equipment

4.1.4.2 Hoisting Ropes

General The wire ropes shall be made of special improved plough steel of 6 x 36 or 6 x 37 construction Lang’s Lay and fibre core and shall conform to I.S:2266 (latest edition). While selecting the diameter of the wire ropes the efficiency of pulleys, sheaves and drums shall be taken into account.

The wire ropes shall be provided with a device to take care of unequal stretch of rope. Wire ropes shall be guided over as few pulleys as possible. Reverse 'S' shaped bends shall be avoided as far as possible. The ends of rope shall not be subjected to undue twists and turns. The wire rope stands fastened with the rope drum should not step away under maximum load.

Breaking Strength The breaking strength of wire ropes, if not specified by the wire rope contractor, shall be taken on the basis of I.S: 2266 (latest edition)

Factor of Safety The minimum factor of safety based on breaking strength and safe working load of the wire ropes shall not be less than 6 (six) under normal conditions and 3 (three) under breakdown torque condition of electric motor selected .

4.1.4.3 Rope Drums The drums shall be strong enough to withstand the crushing as well as bending. The crushing strength of the drum shall be calculated as per para 4.3.3 of I.S:6938 latest edition). The minimum pitch diameter of the drum shall be 20 (twenty) times the diameter of the wire rope of 6x36 or 6x37 construction. In case of fabricated drum, the number of segment shall not exceed two.

The length of the drum shall be such that each lead off rope has minimum 2(two) full turns on the drum, when the gate is at its lowest i.e. closed position, and 1(one) spare groove for each lead off the drum, when the gate is at its highest position.

605 UPID

The drum may be with flanged ends. The flanges shall be projected to a height of not less than 2(two) times the rope diameter above the rope. A spur gear secured to the drum may be regarded as forming one of the flanges.

The drum shall be machine grooved and the contour at the bottom of the groove shall circular over an angle of at least 120°. The radius of the groove shall be 0.53 times the diameter of the wire rope duly rounded off to next full millimeter. The depth of the groove shall not be less than 0.35 times the diameter of the rope. The grooves of the drum shall be so pitched that there is a clearance between adjacent turns of the rope as under:-

1.50 mm for ropes up to and including 12.0 mm dia.

2.50 mm for ropes over 12.0 mm and including 30.0 mm dia.

3.00 mm for ropes over 30.0 mm dia.

The lead angle i.e. fleet angle of the rope shall not be more than 5° or 1 in 12 on either side of helix angle of the groove in the drum. The drum shall be strong enough to withstand the crushing as well as bending.

4.1.4.4 Gears

Spur Gears Spur gears of 20° full depth involute system shall be provided in end reduction units. The correction factor for peripheral speeds and the efficiency shall also be considered. The gears and pinions shall be made of two different grades of materials. The material of pinions shall be harder than that of gears and shall be free from imperfections such as chatter marks and blow holes etc. The gears shall be machine cut and shall be designed as per para 4.5.1 & 4.5.2 of I.S: 6938 (latest edition) or other relevant Indian Standards. The face width of gears shall not be less than two times of circular pitch. Duty factor of appropriate class of mechanism shall be taken into account in the design calculations. The keys in gear trains shall be tight fit and should not become loose in service.

4.1.4.5 Speed Reducers Standard worm reducers used for the 1st stage heavy reduction at the central drive unit, shall be high grade reduction unit suitable for the service intended. The proportions of all the parts, therein, shall be in accordance with the best engineering practices. Rating and efficiency of the reducers used in design calculations shall be as per the contractor’s recommendations. The whole assembly shall be housed in a dust proof casing with suitable lubrication facility. The reducers shall have self locking characteristics.

Gear boxes shall be of rigid construction fitted with inspection covers and lifting handles. Proper facilities for oil filling and drawing, connections for oil level indicator and adequate breathing shall be provided. The boxes shall be mounted on a leveled surface.

4.1.4.6 Gate Position Indicator The gate position indicators shall be provided to show the position of the gates, when these are being raised or lowered. The indicator dial shall be made of non-rusting metal or enameled plates. The markings on the dial in operating range shall have minimum readability of 1/20th of metre. The metre markings shall be very bold. The word ‘CLOSED’, ‘OPEN’ and ‘FULLY RAISED’ shall also be engraved or permanently marked. 606 UPID

The dial shall be located at a convenient place from where it can be read easily. The indicator points shall be made of non-rusting metal. Electro- plated or digital type indicator may also be provided.

4.1.4.7 Shafts

4.1.4.8 General The shafts shall be solid shafts made of Forged / Rolled steel and shall be designed for appropriate load / torque that is being transmitted by them. The shafts shall have ample strength, rigidity and adequate bearing surfaces. These shall be finished smooth and, if shouldered, shall be provided with fillets of large radius.

4.1.4.9 Dimensioning of Shafts In dimensioning of shafts, the ratio of length to diameter ≥ 50, the angle of twist and the revolutions / minute shall be taken into account, in addition to simple bending, pure torsion, or the combined effect of bending and torsion. The twist that shall be permitted is 1/4° to 1/3° per metre. The linear deflection in the shaft shall not exceed 1.0 (one) mm per metre length of shaft.

4.1.4.10 Allowable Stresses The allowable stresses for solid shafts shall be as per para 4.7.4 of I.S: 6938 (latest edition).

4.1.4.11 Sheaves or Pulleys All sheaves or pulleys shall be in true running balance and shall be provided with pressure grease arrangements. The ratio of sheaves / pulleys pitch diameter and the rope diameter shall be as per table 3 of I.S: 6938 (latest edition). Their material shall conform to cast steel of IS: 1030 (latest edition). The sheaves or pulleys shall be machine grooved to a depth of not less than 1.5 times the diameter of rope. The grooves shall be finished smooth and shall be free from the surface defects, which may injure the ropes. The contour at the bottom of the groove shall be circular over an angle of approximately 130° ± 5°. The radius of the groove shall be

0.53 times the dia. of rope .The included angle which is the angle between the straight slopes at the sides of grooves shall be approximately 52°. The diameter at the bottom of the grooves of the idler or balancing sheaves shall not be less than 62% of minimum pulley diameter. The sheaves / pulleys shall be provided with guard plates in order to retain the rope within the groove. All sheaves / pulleys should be fitted with roller bearings.

4.1.4.12 Sockets for Wire Ropes The socket ends shall be slightly stronger than the wire rope. The ends of the wire rope shall be secured against twisting. Molten zinc shall be used to socket the ropes. The material for wire rope sockets shall conform to I.S: 2485 (latest edition). Such specimen shall be subjected to destructive tensile test in which rope fail than the socket or joints.

4.1.4.13 Turn Buckles & Equalizer Bars Turn buckles shall be provided to adjust the elongation of wire ropes and equalizer bars shall be provided to ensure equal loading on both sides of the equalizer bars.

4.1.4.14 Bearings All the running shafts shall be provided with ball or roller bearings. The selection of the bearings shall be done on considerations of duty, load and speed of the shafts as recommended by the contractor. All bearings shall be weatherproof, drip proof and shall be

607 UPID

protected against the entrance of rain, dust or any other foreign matter. The bearings shall be SKF make or equivalent and shall comply with all design requirements required by the Engineer-in-Charge. The life of bearings shall be determined in accordance with the recommendations of their contractor.

If bush bearings are provided, the permissible stress shall not exceed 70 Kg per sq.cm. The thickness of bush bearings shall be calculated as per I.S: 6938 (latest edition).

The bearings shall be easily accessible for lubrication and /or replacement. Every bearing shall be provided with individual lubrication arrangement.

4.1.4.15 Couplings All couplings shall be of Forged or Cast steel and shall be designed to transmit the maximum torque that may be developed. All couplings shall be bored for tight fits on the shafts. Straight square keys shall be provided for fitting the couplings on shafts. All couplings shall fit true on shafts and shall be fitted accurately on shafts. Solid couplings shall be aligned in such away that these meet accurately. Flexible couplings shall be initially aligned with the same accuracy as in case of solid couplings. Flexible couplings shall be fitted between the motor shaft and extension shafts.

4.1.5 Electrical Equipment All electrical equipment and wiring shall meet all the requirements and shall be in accordance with IS: 6938 (latest edition) and other relevant Indian Standard Specifications unless otherwise specifically called for in the specifications. Nuts, railings, screws and other accessories which are external to the apparatus, but which may be required to meet the codes for installed equipment shall be furnished by the contractor. All electrical wiring shall meet the relevant provisions of Indian Electricity Act. The power supply shall be 3 (three) phase, A.C. 400 / 440 volts, 50 cycles. All electrical equipment shall be designed suitable for continuous operation under tropical conditions.

4.1.5.1 Efficiency of System The usual values of efficiencies adopted for the various elements of hoisting mechanism shall be adopted as given in Table 5 of I.S: 6938 (latest edition). The overall efficiency of the system, which is the product of individual efficiency of elements, shall then be worked out. The overall efficiency of the system shall be used for calculating the capacity of the electric motor. The ratio of overall running efficiency to the overall starting efficiency shall be less than the ratio of stating torque to running torque of motor.

4.1.5.2 Motors The motor shall be totally enclosed fan cooled, high staring torque, squirrel cage, 3(three) phase induction electric motor of rated capacity suitable for operation on 400/440 volts, 3 phase, 50 cycles / sec. A.C. power supply, 40% CDF, 150 starts/hr and outdoor type duty conforming to IS 325 (latest edition) or equivalent . Each motor shall be equipped with heater to prevent condensation of moisture drawn into the motor during shut down periods.

The motor shall be suitable for reversing frequent acceleration and mechanical braking. The r.p.m. of motor chosen shall not be more than 1000 but shall be capable of withstanding a maximum speed of 2.5 times the rated speed or 2000 rev / min whichever is less. The break-down torque of the motor at rated voltage shall not be less than 2 times i.e. 200% of the rated torque. During this condition, for checking the components of hoist and the hoist supporting 608 UPID

structure, the starting efficiency of the system shall be taken into account. The motors shall be braced and insulated to withstand plugging service and heavy shocks and vibrations transmitted to them by the driven machinery. The motors shall be provided with class – F insulation.

In case the stoppage of motion of the hoist occurs due to the electric braking, the motor shall be suitable to withstand this duty. Roller or Ball bearings provided with the motor shall be suitable to withstand the heavy vibrations and shocks. All bearing shall be sealed to prevent leakage of oil and lubricants and entrance of dust etc. Motor leads shall be brought out from the motor frame to terminals in the Terminal box fixed to the motor frame. The motor shall be so located that the terminals are accessible for inspection and maintenance with unrestricted ventilation’s. The contractor shall enclose the full technical particulars of each motor including the valves of the locked motor currents, breakdown torque etc. with the tender.

Motors shall be of Indian Standard or equivalent international standard & of reputed make like Siemens, Kirloskar, N.G.E.F., Crompton Greaves, Greaves Cotton, G.E.C. etc. and easily available in the market. Motors especially designed for the purpose shall not be accepted.

4.1.5.3 Electro-Magnetic Brakes The hoist shall be provided with an automatic DC electro-magnetic brake. The brake shall be mounted on the same base as the hoist motor. The electro-magnetic brakes shall be of spring set, shoe type solenoid operated and of continuously rating. These shall be equally effective in both directions of travel and shall be capable of overcoming at least 150% of the full load torque exerted by the motor.

The brake shall set automatically, when the current is cut off from the motor and shall be electrically released, when the current is applied to the motor. The terminals of the brake magnet shall be protected from accidental contact. The connections and winding shall be effectively protected from mechanical damage. The magnet shall be provided with an efficient cushioning device. In case the gearbox selected does not have self-locking characteristic, one additional electro-hydraulic Thruster brake shall be provided for safety. The additional brake shall have same rating but shall be arranged in such a way that service brake shall apply first and additional brake lag in application. The electro-magnetic brake shall be of DC type complete with rectifier equipment to convert the available AC supply. However, the electro-hydraulic thruster brakes shall be of AC type. The brake shall be equipped with a hand operated release lever and a weatherproof cover complete with heaters to prevent the condensation on moving parts. Hydraulically operated thruster brakes may also be used. 4.1.5.4 Limit Switches

General The limit switches, after being tripped, shall automatically reset themselves with a reasonable distance traveled in opposite direction. This does not prevent the use of changeover type limit switches, where resetting is achieved by moving in opposite direction. These may be mechanically driven from the shaft.

Hoist Limit Switch It is a device provided to cut off the current and to stop the motion of the hoist mechanism and to apply the brake, when the gate has risen to the pre-determined level. Limit switches shall be

609 UPID

weather proof type. An inter-locking arrangement shall be provided to isolate the power supply, when the hoist is being operated manually. Limit switches for intermediate position of travel and crack opening position if needed shall also be provided. Adequate adjustment shall also be provided to compensate for rope elongation. Control Equipment The hoist mechanism shall be complete with one control panel with push buttons, which shall be suitably labeled as ‘Raise’, ‘Stop’ and ‘Lower’. Lamps to indicate the condition of the control circuits and directions of motion may be provided.

The hoist shall be provided with all necessary relays, starters, heaters, if required, fuses, limit switches, indicating lights complete with suitable wiring so that all the functions are carried out smoothly. All the controls shall be so interlocked that the proper functioning of individual parts for the purpose is ensured. Hoist motion shall be done with the help of standard push Button type switches. The push button control voltage shall not be more than 110 volts. All push button control switches shall be capable of withstanding rough handling without being damaged and the cover shall be effectively secured. Necessary provision shall be made in the control equipment for remote indication of various parameters like open, close etc. of the hoist control and the gates position.

4.1.5.5 Wiring All wiring shall be laid in hot dipped galvanized metal conduit. All conductors for primary

power lighting and control circuit shall be insulated for not less than 1100 volts and shall have

standard moist resisting double braided covering. All conductors between the secondary of the motor conductor and resistors shall have sufficient current carrying capacity in accordance

with Indian Standard and shall be insulated with 1100 volts class asbestos. The primary conductor to the motor shall have standard continuous current carrying capacity of not less

than 100% of the rated full load primary current of the motor. Cables having conductors smaller than 2.5 sq.mm nominal equivalent copper areas of the cross section shall not be used

for the power wiring for any of the motors. For control circuits and auxiliary wiring, cables

having a sectional area smaller than 1.5 mm sq. nominal equivalent copper area of the cross section shall not be used. All cables shall be adequately protected against mechanical damage

and metal trunking may be used if desired. Electrical conduit shall comply with the relevant

Indian Standard. For outdoor hoists except where flexible unarmoured cables are essential,

cables shall be either armoured or enclosed throughout their length in galvanized trunking or conduit, either flexible or rigid. A flexible metallic tube or duct may not form an effective

earth connection and shall not be used for that purpose. Tapped and braided varnished cambric insulated cables shall not be used for outdoor duty. 4.1.6 Manual Operation The manual operation shall be provided for emergency operations of the gates in the event of power supply failure. An electric inter-lock shall be provided to prevent the operation due to restoration of power supply, when the manual operation is engaged. The manual operation should be designed in such a manner that the continuous effort per man does not exceed a crank force of 100 N with 400 mm of crank radius at a continuous rating of 24 rev./ min. The maximum number of persons shall not exceed 4(four). 4.1.7 Interlocking and Earthing 'Off' position interlocking earthing and other electrical equipment shall be provided in terms of provisions contained in IS: 3043 (latest edition).

610 UPID

4.1.8 Lubrication Oil lubrication shall be provided for all gear trains, sleeve bushings, bearings on motors, wheels etc. Lubrication for all mechanical operating points shall be done by means of high-pressure grease gun and industrial button type fittings. Lubricating nipples, pipes and adapters shall be easily accessible and wherever necessary the copper and brass pipe of ample size shall be provided to a convenient point for lubrication.

A lubrication chart shall be provided indicating all the lubricating points, type of lubrication and recommended frequency of lubrication.

4.1.9 Miscellaneous

Wrenches and Tools A suitable grease gun and a complete set of wrenches and tools in a pressed toolbox shall be furnished for the hoist. Sufficient quantity and variety of tools shall be furnished to cover all ordinary maintenance work of the hoist. Operating instructions in a suitable metal frame covered with glass shall be mounted at convenient location.

Machinery Housing A weatherproof housing, construction of structural steel sections and plates conforming to IS: 2062 (latest edition) shall be provided. The floor shall be of reinforced chequered steel plates of welded construction. The thickness of chequered plates used shall not be less than 8mm.

4.2 Hoist Supporting Structure

4.2.1 General The hoist supporting structure and trestles shall be made of structural steel (weldable) conforming to I.S 2062 (latest edition) and shall be designed to withstand the dead weight of

the hoist, hoisting load as well as vibrations coming on the hoist while in operation and in accordance with IS:800 (latest edition). Suitable anchorages for the hoist frame shall be provided to take the worst combinations of all loads under which the gates and hoists are under operation .The hoist supporting structure and trestles shall be either in riveted or welded construction. The frame shall be of the box type. Diaphragms shall be provided to distribute the loads to the sides properly. The structure shall be designed for each of the following combinations. The hoist bridge shall be provided with fixed / sliding bearings, hand railing, uncovered stairs, anchorages and all other bolts and fixtures etc. as may be required for

satisfactory operations of gates and hoists.

Dead loads plus live load, impact load, wind load @ 800 N / m² and crowed load @ 5000 N / m² on entire area of hoist bridge.

Dead load with no hoisting load plus effect of storm wind load @ 1500 N / m².

Breakdown torque equal to actual breakdown torque of the motor, as specified in the

contractor's catalogue and the permissible stresses as specified in IS:800 (latest edition) for normal operating condition, shall be increased by 33-1/3%.

The impact factor for the design of hoist bridge and trestles shall be taken as 1.1. The deflections of cross beams as well as main beams of the hoist bridge and trestles shall conform to relevant clauses of IS 800 (latest edition) in general. However, deflection of main beams shall not exceed 1/600 of effective span. 611 UPID

4.3 Screw Hoists and Their Accessories 4.3.1 Hoist Capacity

The hoist capacity shall be based on the algebraic sum of the worst combination of following

forces developed during either raising or lowering cycle of the gates. The hoist capacity thus

calculated shall be increased by 20% as reserved. Provisions of IS 6938 and IS 11228 shall

also be met in this regard.

All weights consisting of

Gate leaf along with all its components including horizontal girders vertical stiffeners, end vertical girders, diaphragm plates, wheel assemblies etc.

Effect of water load acting on the gate components.

Hydro-dynamic forces like hydraulic down-pull / uplift.

All frictional forces comprising

Wheel friction

Guide friction

Seal friction

Friction of moving parts of hoisting equipment

Silt load, if any.

Seating load

Any other consideration.

4.3.2 Hoisting Speed The hoisting speed shall be between 0.3 per minute (tentative).

4.3.3 Details of the Hoists 4.3.3.1 General

Screw hoist of adequate capacity shall be provided for the operation of all slide type gates.

The screw hoists for gates mentioned at Table - 2 shall be electrically operated and shall be

manufactured according to these specifications and the screw hoists for gates mentioned at

Table - 3 shall be manually operated.

The screw stem shall be made of forged steel conforming to IS 1875 and the lifting nut shall

be of phosphor bronze. The factor of safety for the screw stem shall be taken as 5 based on

ultimate tensile strength of the material. Square threads conforming to IS 4694 shall be

provided on the screw stem and lifting nut in accordance with the standard practice ISO

Metric screw threads conforming to IS 4218 (Part-I) shall be provided on stem for fixing to

gate. The lifting and lowering speed of the gate when manually operated shall be such that the

maximum effort exerted per man shall correspond to the value indicated in relevant para of

these specifications.

612 UPID

The bearing pressure on the threads of the phosphor bronze nut shall not exceed 70 Kg/sq. cm. unless otherwise approved by the purchaser.

The screw hoist assembly shall be mounted on a pedestal. All measures for satisfactory operation of the screw hoists shall be taken.

For stress in shafts and gears a factor of safety of 5 over the U.T.S. shall be allowed. Also

under breakdown conditions of torque, the stress shall not exceed 75 percent of the yield point

for that material.

It is proposed to operate the screw hoists electrically. However provision for manually

operating arrangement shall also be made. Suitable stools for two persons shall be provided.

Manually operating arrangement shall be such that the continuous effort per man does not

exceed a crank force of 10 Kg at a radius of 400 mm at a continuous rating of 24 RPM. 4.3.3.2 Hoist Equipment

The various components of the hoist shall be in accordance with the specifications given

below. All other accessories necessary for the satisfactory operation of the hoist and shall

conform to best engineering practice and standard. Each hoist shall comprise following components:-

Central Drive Unit

Central drive unit shall be comprising of an electric motor, 1st

stage reduction gear box, electro -magnetic brakes, gate position indicator and manual drive unit etc.

End Gear Reduction Unit

The end gear reduction unit shall comprise of gears, pinions, plummer blocks, shafts,

pedestals and all other such accessories, which may form in-separable components for

the satisfactory operations.

Control Equipment

The control equipment shall comprise of electric motor, switch gears, limit switches,

control panel, and various electrical relays required for satisfactory operation of

motors and brakes etc. 4.3.4 Mechanical Equipment

4.3.4.1 Screw Stem and Nuts:

For each gate hoist one screw stem shall be provided with square threads to match with

corresponding lifting nut. The stem shall be made of forged steel conforming to IS 1875.

Suitable intermediate supports shall be provided along with necessary embedments in the

concrete. The nuts shall be of phosphor bronze. The bearing pressure on the threads of

phosphor bronze nut shall not exceed 70 Kg/sq.cm. The lifting nut shall have a free fit on the stem. When the nut is assembled on the stem the threads of the stem shall bear evenly on the threads of the nut.

4.3.4.2 Pedestal

613 UPID

The pedestal shall be fabricated or cast and shall be mounted on the trestles/ hoist support structure. The pedestal shall withstand possible buckling due to total hoisting load.

4.3.4.3 Gears and Pinions

Gears and pinions shall be machine-cut or hobbed from cast steel blanks. The pinion shaft

may be cast integral with the pinion if possible, or may have bolted connection. The

addendum, dedendum, and back cone angle etc. shall be in accordance with the relevant IS.

Teeth on gear and pinion shall mesh properly and bear evenly when assembled.

Spur gears of 20° full depth involute system shall be provided in end reduction units. The

correction factor for peripheral speeds and the efficiency shall also be considered .The

material of pinions shall be harder than that of gears and shall be free from imperfections such

as chatter marks .The gears shall be machine cut and shall be designed as per IS 6938. 4.3.4.4 Speed Reducers

Standard worm or helical reducers, if used, for the 1st

stage heavy reduction at the central

drive unit, shall be high grade reduction unit suitable for the service intended. The proportions

of all the parts, therein, shall be in accordance with the best engineering practices. Rating and

efficiency of the reducers used in design calculations shall be as per the manufacturer’s

recommendations. The whole assembly shall be housed in a dust proof casing with suitable

lubrication facility. The reducers shall have self-locking characteristics. 4.3.4.5 Thrust Bearings

The seat of the bearing on nut shall be machined smoothly. The bearing shall have a force fit

on the nut. The bearing shall be forced by using a suitable device other than hammering. Care

should be taken while assembly of bearing that no dust or any foreign material will come in

contact with bearing. 4.3.5 Gate Position Indicator

To show the position of gate at any instant a position indicator shall be used. The needle

indicator will move along the graduated plate. pipe. The graduations shall read upto 1 cm of

lift of the gate. The graduated plate of 16 gauge & suitable width shall be attached to the pipe

by a suitable fixture as approved by the purchaser. The marking shall be embossed and

painted with a pleasant colour or enameled. 4.3.6 Keys, Nuts and Bolts Keys, nuts and bolts will be of mild steel and shall conform to the relevant Indian Standards specifications. All other mechanical equipment like clutch, brakes, shafts couplings etc. shall be standard items

and shall be made according to best engineering practice and of finest quality material.

4.3.7 Shafts

4.3.7.1 General

The shafts shall be solid shafts made of Forged / Rolled steel and shall be designed for appropriate load/ torque that is being transmitted by them. The shafts shall have ample

614 UPID

strength, rigidity and adequate bearing surfaces. These shall be finished smooth and, if shouldered, shall be provided with fillets of large radius.

4.3.7.2 Dimensioning of Shafts

In dimensioning of shafts, the ratio of length to diameter > 50, the angle of twist and the rev

/min shall be taken into account .In addition to simple bending, pure torsion, or the combined

effect of bending and torsion . The twist angle, that shall be permitted, is from 1/4° to 1/3° per

metre. The linear deflection in the shaft shall not exceed 1.0 (one) mm per metre length of

shaft. 4.3.7.3 Allowable Stresses The allowable stresses for solid shafts shall be as per IS 11228.

4.3.8 Bearings

All the running shafts shall be provided with ball or roller or bush bearings at their supports.

The selection of bearings shall be done on the consideration of duty, load and speed of the

shafts. The life of bearings shall be determined in accordance with the recommendations of

their manufacturer .The thickness of bush bearings shall be calculated as per IS 6938. The bearings shall be easily accessible for lubrication and /or replacement. Every bearing shall be provided with individual lubrication arrangement.

4.3.9 Efficiency of System

The usual values of efficiencies adopted for the various elements of hoisting mechanism shall

be adopted as given in IS 11228. The overall efficiency of the system, which is the product of

individual efficiency of elements, shall than be worked out. The overall efficiency of the

system shall be used in calculating the capacity of the electric motor. The ratio of overall

running efficiency to the overall starting efficiency shall be less than the ratio of starting

torque to running torque of motor. 4.3.10 Miscellaneous Parts Miscellaneous parts like hoist base frames, cover boxes etc. shall also be provided.

4.3.11 Electrical Equipment 4.3.11.1 Motors

The motor shall be totally enclosed fan cooled, high staring torque, squirrel cage, 3(three)

phase induction electric motor of rated capacity suitable for operation on 400/440 volts, 3

phase, 50 cycles / sec. A.C. power supply and outdoor type duty conforming to I.S: 325 or

equivalent. The motor shall be suitable for reversing frequent acceleration and mechanical

breaking. The break -down torque of the motor at rated voltage shall not be less than 2.25

times i.e. 225% of the rated torque. The motors shall be so located that the bush, gears and

terminals are readily available for inspection and maintenance with no restriction to the

ventilation. The motor chosen shall have rated speed not more than 1000 rev /min. 4.3.11.2 Electro-Magnetic Brakes

615 UPID

The electro-magnetic brakes shall be of spring set, shoe type solenoid operated and

continuously rated. These shall be effective in both directions of travel and shall be capable of

overcoming at least 150% of the full load torque exerted by the motor.

The brake shall set automatically, when the current is cut off from the motor and shall be

electrically released, when the current is applied to the motor. The brake shall be equipped

with a hand operated release lever and a weather proof cover complete with heaters to prevent

the condensation on moving parts Hydraulically operated thruster 4.3.12 Limit Switches

4.3.12.1 General

The limit switches, after being tripped, shall automatically reset themselves within a

reasonable distance travelled in opposite direction. This does not prevent the use of

changeover type limit switches, where resetting is achieved by moving in opposite direction.

These may be mechanically driven from the shaft. 4.3.12.2 Hoist Limit Switch

It is a device provided to cut off the current and to stop the motion of the hoist mechanism and

to apply the brake, when the gate has risen to the pre-determined level. Limit switches shall be

weather proof type. An inter -locking arrangements shall be provided to isolate the power

supply, when the hoist is being operated manually. Limit switches for intermediate position of

travel required for regulation of discharge shall also be provided. 4.3.12.3 Control Equipment

The hoist mechanism for both the type of gates shall be complete with one control panel with

push buttons, which shall be suitably labeled as ‘Raise’, ‘Stop’ and ‘Lower’ Lamps to indicate

the condition of the control circuits and directions of motion may be provided.

The hoist shall be provided with all necessary relays, starters, heaters, if required, fuses, limit

switches, indicating lights complete with suitable wiring so that all the functions are carried

out smoothly.

All the controls shall be so inter-locked that the proper functioning of individual parts for the

purpose is ensured. The wiring shall be as per relevant standards. However, hoist power

supply for the diversion conduit gate shall be provided as follows the hoist power supply shall

be through a festooned cable arrangement. The cable shall extend the entire span of the

monorail and be connected to supplied power outlet. All connectors, insulators, and brackets

shall be supplied with the hoist.

4.3.12.4 Inter-Locking and Earthing

All electrical equipment shall be provided with Off Position Inter-locking and earthing arrangement in terms of provisions contained in IS 3043.

616 UPID

4.4 Manual Operation

The manual operation shall be provided for emergency operations of the gates in the event of

power supply failure. An electric inter-lock shall be provided to prevent the operation due to

restoration of power supply, when the manual operation is engaged.

The manual operation should be designed in such a manner that the continuous effort per man

does not exceed a crank force of 10 Kg. with 400 mm of crank radius at a continuous rating of

24 rev. / min. The maximum number of persons shall not exceed 4(four).

4.4.1 Enclosures All hoist machinery shall be enclosed in weather-tight machinery housing.

4.5 Hoist Supporting Structure for Emergency & Irrigation Gate

The hoist supporting structure and trestle shall be made of structural steel (weldable)

conforming to IS 2062 and shall be designed to withstand the dead weight of the hoist,

hoisting load as well as vibrations coming on the hoist, while in operation. Suitable

anchorages for the hoist frame shall be provided to take the worst combinations of all loads

under which the gates and hoists are under operation. The hoist supporting structure and

trestle shall be either in riveted or welded construction. The frame shall be of the box type.

Field welding will not be accepted. Diaphragms shall be provided to distribute the loads to the

sides properly. Shop connection in the frame shall be either riveted or welded so that the

surface of the hoist including the outside of the frame, case and hoist housing and viewed

along with the intake structure will be a plane surface except for projections of rivet heads The

structure shall be designed for each of the following combinations.

Dead loads plus live load, impact load, wind load @ 50 kg / sq. m and crowed load @ 500 kg/ sq. m on entire area of walkway.

Dead load with no hoisting load plus effect of storm wind load @ 150 kg/sq. m.

Breakdown torque of the motor. The permissible stresses as specified in IS 800 for normal

operation shall be increased by 33-1/3 %. Deflection of hoist supporting girder shall not exceed 1/900 of distance between supports

617 UPID

MANUFACTURE 5.1 Manufacture 5.1.1 General Workmanship All fabrication work under this contract shall be done in accordance with the specifications which meet with the Engineer-in-Charge’s approval. All work shall be performed and completed in a thorough workman like manner as per latest practice in the manufacture and fabrication of materials of the type covered by these specifications. The work shall in all cases, be of the highest quality and carefully performed to the satisfaction of the authorized

representative of the Engineer-in-Charge. The contractor shall warrant all materials and workmanship furnished by him to be free from injurious defects. He shall replace, free of cost to the Engineer-in-Charge, any defective materials or workmanship noticed during erection and shall bear all cost of the modification in the field of any defect for which he is responsible. Workmanship shall conform to the latest standard, laid down in Indian Standards Specification.

All members shall be free of twists, bends or other deformations and all surfaces that will be in contact shall be thoroughly cleaned before assembling, parts shall be adjusted to line and fit and shall be firmly bolted or otherwise held securely together so that surfaces are in close contact before drilling, reaming or welding is commenced.

Plates with lamination discovered during cutting, welding or at any other time shall be rejected. Minor surface imperfections can be repaired wherever possible with the prior approval of the Engineer-in-Charge. Materials not supplied or workmanship not performed in accordance with approved drawings or specification shall be rejected and replaced. If the weight, limitations and transport clearances do not permit, the anchorages and miscellaneous embedded parts shall be fabricated into sub-assemblies. The contractor shall submit with his bid drawings showing the sub-assemblies into which he proposed to fabricate the gates, anchorages and miscellaneous assemblies and embedded parts for transporting them to the site.

All the parts of the gates shall be fabricated in accordance with these specifications and drawings. The contractor shall take special care in fabrication of the parts affecting strength, rigidity and water tightness of the gates. Attention is directed to the fact that rolled edged plates are not suitable for caulking. The seal bores shall be finished after the plates have been welded to the skin plates and the finished surfaces of the seal bases shall be in the same plane within a tolerance as specified in IS 4622 for wheeled gates and IS 5620 for slide gates.

The contractor may submit for the approval of the Engineer-in-Charge an alternative procedure for finishing the seal bases or for fastening them to the gates provided that the suggested method produces a water tight seal arrangement and that the final shape and size of plate meet the dimensional and tolerance requirements, shown on the drawing or stated in these specifications.

Holes for the wheel pins shall be bored and counter-bored in pairs to a common axis, after the leaf has been assembled and all the shop welding has been completed. The axis of these holes shall be in a common plane, which shall be parallel to the finished surface of the seal bases within specified tolerances. The seal rings provided in the wheel assembly shall be products of established contractors and must be perfectly watertight. All holes shall be accurately spaced,

618 UPID

cylindrical and perpendicular to the members. All counter sinking shall be true and square with holes. 5.2 Tolerances and Fits The tolerances and fits used for different components shall be according to the best modern shop practice. Due consideration shall be given to special nature of function of the parts and to the corresponding accuracy required to secure proper operation. The fits and tolerances shall generally be in accordance with the provisions contained in IS 2709. These shall be subjected to the approval of Engineer-in-Charge.

Where tolerance or fits are not specified on the drawings, the contractor shall follow the best modern shop practice for apparatus of the type covered by these specifications and drawings, due considerations being given to the special nature of function of the parts and to the corresponding accuracy required to secure proper operation.

5.2.1 Fabrication Tolerances All components shall be fabricated in accordance with the relevant IS Codes on gates and hoists except as noted below:

All dimensions under 400 mm shall be ± 0.8 mm unless otherwise specified and are non-cumulative. All other dimensions shall be ± 1.5 mm.

The machined sealed surface of the sill shall be straight within 0.5 mm and level within

1.0 mm over the whole length with a straight edge.

The roller / wheel paths / track plates below the lintel shall be straight within 0.4 mm in

any 3 m length and within 0.8 mm over the whole length and shall not deviate from a vertical line in any direction by more than 1.0 mm. Roller path faces for the same gate shall be in the same line within 1.0 mm.

The roller / wheel paths / track plates above the lintel shall not deviate from a vertical line

in any direction by more than 2 mm and shall be straight within 2 mm over the full length.

The side roller / wheel paths / guides shall be straight within 1.0 mm in any 3 m length

and within 2 mm over the full length. The side roller paths / guides shall not deviate from a vertical line in any direction by more than 2 mm.

The distance between side roller / wheel paths / guides and the main roller / wheel paths /

track plates shall not vary by more than 3 mm. Radial run out of assembled rollers / wheels shall not exceed 0.025 mm measured at the

roller / wheel thread. 5.2.2 Installation Tolerance Installation tolerances shall not exceed 1.5 times the corresponding fabrication tolerances or the tolerances specified in relevant codes on gates and hoists, whichever is more stringent. Design and fabrication of the gates, hoists, hoist support structures and embedded parts shall be suitable for the achievement of such tolerance during installation, including supply of dummy gate section to facilitate the accurate setting of guides. 5.3 Machine Finish The type of finish, unless otherwise specified shall be that most suitable for the part to which it applies and shall be smooth average or rough as defined under IS 3073. In general, a very

619 UPID

smooth finish (three delta > 0.200 to 1.6 microns) will be required for all surfaces in sliding / rolling contact, an average or commercial finish (two delta> 1.6 to 6.3 microns) for surfaces in contact where a tight joint is required and a rough finish (single delta > 6.3 microns) for all other machine surfaces where selective assembly for matching parts is required. The parts shall be ground if necessary to obtain the limiting tolerances. Machining for load bearing surfaces should be made as per IS 800 and other relevant standards.

5.4 Casting While making patterns for the castings, care shall be taken to avoid sharp corners or abrupt changes in cross-section and ample fillets shall be used. All casting shall be true to patterns and the thickness of the metal shall not vary at any point by more than 5mm from that shown in the drawings. Care shall be taken in the foundry to cool the castings properly so that they will not warp or twist. No castings will be accepted if it is warped or twisted to such an extent that machined surfaces cannot be properly finished to the dimensions shown on the drawings.

All castings shall be sound, clean, free from cracks, holes or sand holes and other defects. These shall have a workman like finish. Castings shall not be repaired, plugged or welded without the permission of the Engineer-in-Charge. Such permission shall be given only when

the defects are small and do not affect the strength, use or machinability of the castings. No welding shall be done after the castings are finally annealed. No defect shall be removed and paint or oil be applied to the surface of any casting until it has been inspected by the Engineer-in-Charge or the authorized representative. The treatment for casting involves heating slowly

up to a temperature of about 40o C above its upper critical temperature, holding it at the

temperature just only long enough for a uniform temperature to be attained throughout the casting and then allowing it to cool slowly in furnace. During the process, the requisite annealing temperature shall not exceed and overheating shall be avoided. End products shall conform to the requirements of relevant Indian Standards. All castings shall be ultrasonically

tested to ascertain soundness of casting. Acceptance criteria as required by Engineer-in-Charge shall be binding.

5.5 Forging

Forging, unless otherwise specified, shall be in accordance with IS 2004. The ingots from which the forging are made shall be cast in metal moulds. The workmanship shall be first class in every respect and the forging shall be free from all defects affecting strength and durability, including seams, pipes, flaws, cracks, scales, fins, porosity, hard spots, excessive non-metallic inclusions and segregations.

All forging shall be given such uniform heat treatment as required to produce materials

conforming to the requirements of these specifications, and shall be annealed or normalized and tempered as final heat treatment. In the case of shafts forged solid, which are required to be bored, the final heat treatment shall be performed after the forging has been rough bored.

In each heat treatment, the forging shall be held at the desired temperature for a sufficient

length of time to ensure penetration of the heat and proper grain refinement throughout the whole forging. A record of the heat treatments to which the forging have been submitted shall be supplied to Engineer-in-Charge.

620 UPID

In case of shaft forged solid which require boring the final heat treatment shall be

performed after the forging has been rough machined. The largest fillets compatible with the design shall be incorporated wherever a change in section occurs. Tool marks or tearing of the metal by the finishing tool will not be acceptable on the surface of fillets. Such marks, if they occur, shall be removed by grinding or polishing. All finished surfaces or forging shall be smooth and free from tool marks.

All important forging like gate wheels, wheel pins, gears, crane wheels etc. shall be

ultrasonically tested. The acceptance limit of ultrasonic testing of forging shall be as per SA 388 of ASME Section-5.

5.6 Fabrication of Structural Steel The contractor is expected to perform fabrication in the best possible manner to meet the requirements of design and drawings. However some specific guidelines are given herein.

Straightening of Members Before being laid off or worked in any manner, structural steel members shall be straight, without twists, bends or kinks, and if straightening is necessary, it shall be done by a method which shall not injure the metal to ensure good welding and fittings of members. All steel shall be cleaned of dirt, mill scale and rust prior to fabrication.

Shearing, Chipping and Gas Cutting Shearing, chipping and gas cutting shall be performed carefully and all portions of the work, which will be exposed to view after completion shall present a neat appearance. Finishing of sheared or cut edges of plates or shapes will not be required except as noted in these specifications.

Edges to be Welded The edges of plates and shapes to be joined by welding shall be properly formed to suit the type of welding selected. Where plates and shapes have been sheared, edges to be joined by welding shall be machined or chipped to sound metal. Plates and shapes to be field welded shall have their edges prepared in the shop for the type of weld selected.

Bent Plates and Shapes Where bending or forming of plates or shapes is required, the plates or shapes shall be bent by cold forming. Heating and hammering to correct bends will not be permitted.

5.6.1 Welding

Welding Technique Care shall be taken in designs that the welds when being made are well accessible.

Overhead welding is to be avoided, if possible and flat position is to be strived for.

Drawing should clearly indicate the joint position, shop or field welding, kind of welding,

method of welding, welding sizes, and other required points. Symbols to be shown on the drawing should conform to relevant Indian Standards.

All welding shall be done by the electric arc method or by a process which will exclude

the atmosphere from the molten metal, except where otherwise specifically

621 UPID

permitted. All welding electrodes required shall be furnished by the contractor. Correct selection of electrodes shall be done taking due care of welding method and base metals of components. The welding electrodes shall be of the heavily coated type designed for all position welding. The make, type and size of all welding electrodes shall be subject to the approval of Engineer-in-Charge.

In assembling and during welding, the component parts of built-up members shall be held in place by sufficient clamps or other adequate means to keep all parts in proper position. The surface to be welded shall be cleared of scale, slag, rust, paint, and other foreign matter, except that thin coat of linseed oil need not be removed before welding. Where weld metal is deposited in two or more layers, each layer shall be brushed with a wire brush or otherwise cleaned before the subsequent layer is deposited. In welding, precautions shall be taken to minimize stresses due to heat by using the proper sequence in welding.

Upon completion, the welds shall be brushed with wire brush and shall show uniform

section smoothness of weld metal. Edges and ends of fillets and butt joint welds shall indicate good fusion and penetration into base metals. Specific requirements for butt joints and fillet joints are given below:

Radiographic tests shall be carried out for all critical full strength butt welds. Welded

joints requiring radiographic testing shall be decided by the Engineer-in-Charge.

Butt joint In principle, butt joints should be made with back run. Should it be not possible to do the back-run, either a backing strip should be placed and welding should be so made that the melted metal fully penetrates to the backing strip or the slide butt welding should be executed so that melted metal reaches the back of the groove and a full penetration is achieved. Die-penetration test shall be carried out after each pass of the weld.

Fillet Joints All fillet welds shall be continuous. For the main members, no fillet welding should be made on members whose thickness differ substantially. Fillet weld at ‘T’ joints should be made, as a rule on each side of the joint, unless it is otherwise agreed due to some practical reasons. Radiographic test is not normally required for fillet welds. However, they shall be tested ultrasonically for soundness.

Qualification of Welding Process A specification of the welding process, that is proposed to be used, shall be established and recorded and, if required a copy of such specification together with a certified copy of report of results of tests made in accordance with the process and specifications shall be furnished.

The qualification of the welding process shall be at least equal to that required by ‘Standard Qualification Procedure’ of the India Standards and the minimum requirement of the tests shall be at least as stated in the said ‘Standard Qualification Procedure’.

Qualification of Welders The contractor shall be responsible for the quality of the work performed by his welding staff. All welders assigned to the work shall have passed qualification tests for welders. If at any time the work of any welder appears questionable, the welders shall be required to pass 622 UPID

additional qualification tests to determine his ability to perform the type of work on which he is engaged.

5.6.2 Riveting Rivets shall be driven by power riveters, employing pneumatic, hydraulic or electric power. After driving, their finished heads shall be of approximately hemispherical shape of uniform size throughout the work for the same size rivet, neatly finished and heated uniformly to a temperature not exceeding 1065o C. They shall not be driven after their temperature has fallen below 528o C. All shop driven rivets within a distance of 425 mm from a shop welded joint shall be driven after the welding is completed. Recapping and caulking of loose or defective rivets will not be permitted. While removing defective units, care shall be taken not to injure the adjacent metal and, if necessary, they shall be drilled out.

5.6.3 Turned and Fitted Bolts In cases where bolts have to be used but strength of a riveted connection is required, this can be obtained by using special bolts in special holes to a driving fit. The bolts are specially made from black round bars and turned down to the exact diameter. The inside of the head and flat face of the nut should be machined. The hole must be accurately drilled or reamed with a clearance of not more than 0.25 mm. The holes after assembly of the parts must be true throughout the thickness of all parts and perpendicular to axis of the member. Washers for turned and fitted bolts should be machined on both faces.

5.6.4 Set Screws All set screws shall be provided with case hardened cup points and shall be safety type. They shall not be used for transmitting torsion.

5.6.5 Drilling and Reaming Holes shall be accurately located and drilled or reamed perpendicular to the face of the member and, if necessary, shall be drilled to a template. Counter sinking, where required, shall be done carefully and to the full depth of head. Open holes in material of 18 mm or less in thickness, shall be sub-drilled or sub-punched before assembly and reamed during assembly. Holes in structural steel of more than 18 mm in thickness shall be drilled 3 mm smaller than the nominal diameter of the rivet or bolt before assembly and reamed to the full size during assembly. All members shall be shop assembled before reaming or drilling holes for field connections.

5.6.6 Punching For sub-punching and for punching to full size, the diameter of the punch shall be 4.5 mm smaller and 1.6 mm larger, respectively, than the nominal diameter of the rivet or bolt and holes shall be clean cut without torn or ragged edges. The diameter of the die shall not be more than 2.5 mm larger than the diameter of the punch. If any hole needed to be enlarged to admit the rivet or bolt, it shall be reamed.

5.7 Stress Relieving Stress relieving of welded parts shall be done, where required, after all the welding is completed. Machined surfaces of parts requiring stress relief shall be machined to final dimensions after the parts have been stress relieved. Localized stress relieving will not be permitted for shop welded parts. The procedure for stress relief shall conform to IS 10801, IS 10234 and IS 2825 (latest edition).

623 UPID

5.8 Painting 5.8.1 General All paints, painting materials and accessories required for the shop as well as field painting shall be supplied by the contractor and shall be included in the price bid. The paints proposed by the contractor must be approved by the Engineer-in-Charge before application of the same. The detailed analysis in respect of paint properties, paint composition and performance requirements of the proposed paints shall also be submitted by the contractor for examination and approval of the Engineer-in-Charge before the application of the paint. All paints shall be applied by skilled workers in a workman like manner in accordance with the provisions contained in I.S 14177 (latest edition) - “Guidelines for painting system for Hydraulic Gates and Hoists”.

Preparation of Surface for Painting For adherence and durability of the paint system it is extremely important to carry out suitable surface preparation. The surface preparations for painting shall be done in accordance with the following procedure:

All oil, grease and dirt shall be removed from the surface, which is to be painted, by the use of clean mineral spirits, xylol, or white gasoline etc. and clean wiping materials prior to sand blasting is done. All surfaces to be painted shall, thereafter, be cleaned by sand grit blasting to bare metal without any residual adherents in any form. Small quantities or oil may be removed by the blasting process in which case, however, the abrasive should not be re-used, if it contains sufficient oil or grease to render it unsuitable for blast cleaning purposes. The average surfaces roughness after sand blasting should not exceed 40 microns. Sand blasting should be conducted with sand / grit / shot of type approved as per IS 14177 (latest edition). After blast cleaning, the surface should be cleaned of loose dust and debris etc. with the help of air blast or blower.

0In case rust forms or the surface becomes otherwise contaminated in the interval between cleaning and painting, the re-cleaning process as stated above shall be carried out. Surfaces of stainless steel, corrosion resistant steel, nickel, bronze and machined surfaces adjacent to metal work being cleaned or painted shall be protected by masking tapes or by other suitable means during the cleaning and painting.

Precautions

All paints and coating materials shall be thoroughly mixed at the time of application.

Air temperature at the time of application of the paint must not be below 10°C and the relative humidity must not be above 90%. All surfaces shall be free of moisture at the time of application. Effective means shall be provided for removing all free oil and moisture from the supply lines of all spraying equipment.

The primer coat shall be applied by brushing or spraying immediately after cleaning the surfaces. Since the primer coat cannot be expected to last for an extensive period, it must receive the finishing coat of paint before it deteriorates. The finished surfaces, which are not to be painted, shall be suitably masked during painting.

The surface preparation shall be done as per the requirements of class B as specified in para 4.2.1.2 of IS 14177. In case the surface preparation is done manually by wire brush,

624 UPID

mechanical tools etc. instead of sand blasting all ferrous surfaces exposed to atmosphere or water shall given a coat of rust inhibitive phosphate wash by brush immediately following cleaning operation and surface shall be thoroughly wetted with rust inhibitive wash @ approximately 30 ml /sq. m and allowed to dry for 24 hours. Rinsing after applications generally not required but un-reacted residue, if any, shall be removed wiping the inhibitive surface with damp cloth within one hour of rust inhibitive wash has dried thoroughly and after removing un-reacted residue, the application of primer and finishing coats shall be carried out as indicated in the following paragraphs:

5.8.2 Painting Schedule

5.8.2.1 Gates and Embedded parts

Primer coat

After surface preparation the following coats of primer paints shall be applied:

Exposed Embedded parts Over the prepared surfaces one coat of Inorganic Zinc Silicate epoxy primer preferably with the help of airless spraying equipment giving a dry film thickness of 70 ± 5 microns should be applied. Alternatively two coats of Zinc rich primer, which should contain not less than 85% Zinc on dry film, should be applied to give a total dry film thickness of 75 ± 5 microns .

Gates Over the prepared surfaces one coat of Inorganic Zinc Silicate epoxy primer preferably with the help of airless spraying equipment giving a dry film thickness of 70 ± 5 microns should be applied. Alternatively two coats of Zinc rich primer, which should contain not less than 85% Zinc on dry film , should be applied to give a total dry film thickness of 75 ± 5 microns.

Unexposed parts All unexposed parts coming in contact with concrete should be given coating of cement latex solution of composition 1:3.

Finishing coats The following painting schedule shall be adopted for various portions of the exposed embedded parts and gates.

Exposed embedded parts Finishing coat shall consist of two coats of solvent less Coal tar epoxy paint. These shall be applied at an interval of about 24 hours. Each coat shall give a dry film thickness of at least 150 ± 5 microns. The total dry film thickness of all the coats including primer coating shall not be less than 350 microns.

Gates Finishing coat shall consist of two coats of solvent less Coal tar epoxy paint. These shall be applied at an interval of about 24 hours. Each coat shall give a dry film thickness of 150 ± 5 microns. The total dry film thickness of all the coats including primer coating shall not be less than 350 microns.

5.8.2.2 Hoists and Supporting structures

Primer Coat

625 UPID

Structural Components

Two coats of Zinc Phosphate primer shall be applied to give a dry film thickness of 40 ± 5 microns per coat.

Machinery

Except machined surfaces, all surfaces of machinery including gearings, housing, shafting, bearings and pedestal etc. shall be given one coat of Zinc Phosphate priming paint to give a minimum dry film thickness of 50 microns. Motors and other bought out items shall be painted, if necessary.

Un-machined Surfaces All un-machined surfaces shall be given one primer coat of Chlorinated rubber based Zinc Phosphate primer to give a dry film thickness of 50 ±5 microns.

5.8.2.3 Finishing Coats

Structural components The finishing coats of paint shall consist of one coat of alkyed based Micaceous Iron Oxide paint to give a dry film thickness of 65 ± 5 microns followed by two coats of synthetic Enamel paint conforming to IS 2932 (latest edition) to give a dry film thickness of 25 ± 5 microns per coat. The interval between each coat shall be 24 hours. The total dry thickness of all coats of paint including the priming coat shall not be less than 175 microns.

Machinery The finished paint shall consist of three coats of Aluminium paint conforming to IS 2339 (latest edition) or Synthetic Enamel paint conforming to IS 2932 (latest edition) to give a dry film thickness of 25 ± 5 microns per coat.

Un-machined Surfaces The un-machined surfaces of Hoists and supporting structures shall be cleaned and given three coats of Vinyl Resin / Chlorinated Rubber to give a dry film thickness of 30 ± 5 microns per coat to obtain a minimum dry film thickness of 125 microns including priming coat.

Machined Surfaces All machined surfaces of ferrous metal including screw threads, which will be exposed during shipment or installation shall be cleaned by suitable solvent and given a heavy uniform coating of gasoline soluble removable rust preventive compound or equivalent. Machined surfaces shall be protected with the adhesive tapes or other suitable means during the cleaning and painting operation of other components.

5.8.2.4 Embedded Parts in contact with concrete All surfaces of embedded parts, which are in contact with concrete shall be cleaned as given in para 4.2.1.4 of IS 14177 to meet the requirement of class D and shall be given a coating of cement Latex to prevent rusting. Exposed machined surfaces of ferrous metal, which are to be in rolling and sliding contact shall not be painted but shall be coated with heavy gasoline soluble rust preventive compound. In all exposures, where metal will be partially embedded in concrete, it is good practice to extend the protective coating on the non- embedded portion a 626 UPID

short distance into the area later to be embedded, thus eliminating problem at the junction point . 5.8.3 Surfaces not to painted The following surfaces are not to be painted unless or otherwise specified:

Machine finish or similar surfaces, however, such surfaces should be protected with a corrosion preventive compound.

The surfaces, which are in contact with concrete.

Stainless steel overlay surfaces.

Surfaces in sliding or rolling contact.

Galvanized surfaces, brass and bronze surfaces.

Aluminium alloy surfaces.

Bare electrical conductors and insulating materials.

Equipment name plates and instructions etc.

5.8.4 Colour Scheme Sl. Item Colour Scheme

No.

1 Exposed embedded parts and other components Black immersed in water

2 Super structure including columns, trestles, hoist Grey platform, staircase etc.

3 Hoist Machinery Grey

4 Handrails Black&White

(alternatively)

5.8.5 Handling of painted metal works The metal works to be transported by rail or by road transport shall be loaded so as to prevent shifting and scuffing or guaging of the coating. In loading and unloading and during insulation reasonable care and suitable handling equipment shall be employed to keep abrasion damage at a minimum.

5.8.6 Inspection and testing Inspection and testing of paint shall be carried out in accordance with the provisions laid down in IS 14177.

5.8.7 Field Painting The painted metal work shall be handled with care so as to preserve the shop coats. The area of the shop paint, which has been damaged during transportation, shall be cleaned to base metal and re-painted. Paint applied to such areas shall be of the same type as used originally in shop painting.

5.8.8 Repair of Primer and Finished Coats 627 UPID

For touching up, the same paint shall be used as for the original painting work. Repaired finish coats shall be of identical appearance with the original and no difference in the colour shall occur. The Engineer-in-Charge may require severely damaged coating to be removed and repainted.

5.9 Galvanizing Unless otherwise specified, all steel including ladders, platforms, hand rail bolts andnuts

associated with galvanized parts shall be hot-dip galvanized, electrolytically galvanized or sheradized, as may be appropriate to the particular case.

Galvanizing shall be performed in accordance with the relevant Indian Standard.

Material: For galvanizing, only original blast furnace raw zinc shall be applied, which

shall have a purity of 98.5%. The thickness of the zinc coat shall be:

For bolts and nuts, approx. 6 microns For all other parts, except for hydraulic steel structures or parts intermittently or permanently submerged in water, approx. 70 microns

-For hydraulic steel structures or parts intermittently or permanently

submerged in water, approx. 140 microns Cleaning: All material to be galvanized shall be cleaned carefully of rust, loose scale, dirt, oil, grease and other foreign matters. Particular care shall be taken to clean slag from welded areas.

Galvanizing of plates and shapes: Where pieces are of such length that they cannot be dipped in one operation, great care shall be exercised to prevent warping.

Galvanizing of hardware: Bolts, nuts, washers, locknuts and similar hardware shall be galvanized in accordance with the relevant standards. Excess spelter shall be removed by centrifugal spinning.

Straightening after galvanizing: All parts and shapes, which have been warped by the galvanizing process, shall be straightened by being re-rolled or pressed. The material shall not be hammered or otherwise straightened in a manner that will injure the protective coating. Materials that have been harmfully bent or warped in the process of fabrication or galvanizing shall be rejected.

Repair of galvanizing: Material on which galvanizing has been damaged shall be re-dipped unless the damage is local and can be repaired by soldering or by applying a galvanized repair compound; in this case, the compound shall be applied in accordance with the manufacturer’s instructions.

Soldering shall be done with a soldering iron using 50/50% solder (tin and lead). Surplus flux or acid shall be washed off promptly and the work shall be performed so as not to damage the adjacent coating or the metal itself. Any member on which the galvanizing coating become damaged after having been dipped twice shall be rejected.

628 UPID

5.10 TEST & INSPECTION: 5.10.1 General All materials offered under these specifications shall be tested prior to fabrication. After fabrications the parts shall be assembled in the shop and shop testing shall be performed to ensure accuracy in fabrications and workmanship. The contractor shall carry out such tests as may be required by the Engineer-in-Charge in order to determine that the gates, embedded parts, Hoists will fulfill the functions for which they have been designed. The contractor shall be responsible for all modifications and adjustments required for the works as a result of such tests.

5.10.2 Tests of Materials All materials, supplied parts and assemblies thereof being used in the works to be performed under these specifications shall be of tested quality and all works performed shall be subjected to inspections and no parts or supplies or articles or materials shall be dispatched until all tests, analysis and shop inspections have been completed or certified copies of reports of results and analysis have been accepted.

Certified copies in triplicate of the tests made and of the results thereof, shall be furnished as soon as possible after the tests are completed. The results of the tests shall be in such forms as to provide means of determining compliance with the applicable specifications for the materials tested. When required, tests or trials shall be made in the presence of the inspector duly authorized by Engineer-in-Charge, who shall be given sufficient notice to enable him to reach the site of the work in time. Test specimen and samples for analysis shall be plainly marked to indicate the material to which they represent and, if required, they shall be properly packed and prepared for shipment.

Cost of such tests and trials except the pay and allowances including the traveling and other expenses of the Engineer-in-Charge’s representative shall be borne by the contractor and shall be included in the bid.

All authorized representative of the Engineer-in-Charge shall have free access to the works of the contractor at all reasonable times and shall be provided with full facilities to inspect the processes of manufacture and the material used. The Engineer-in-Charge may reject any work or material that in the opinion of the Engineer-in-Charge does not conform to the specifications and may order to remove the same and replace or alter to conform to the specifications at the expenses of the contractor.

629 UPID

ELECTRICAL WORKS

6.1 General

6.1.1 Scope of Work The electrical items of works of any electrical or mechanical installation to be provided

under this Contract shall fulfill the requirements of this section.

All components shall be of an approved and reliable design. The highest extent of

uniformity and interchangeability shall be reached. The design shall facilitate maintenance and repair of the components.

The works shall be pre-assembled to the highest possible extent in the Contractor’s or

Sub-Contractor’s workshop, complete with all devices and wired up to common terminal blocks.

The power supply and control cables shall be laid up to these common terminal blocks. The

required control and protection devices, instruments etc. within the different scopes of work shall be supplied by and connected by the relevant Contractor.

Unless otherwise agreed, ratings of main electrical works (in feeds, bus-ties) as selected or proposed by the Contractor, whether originally specified or not, shall generally include a safety margin of 10% under consideration of the worst case to be met in service. Prior to approval of such basic characteristics, the Contractor shall submit all relevant information such as consumer lists, short circuit calculations, de-rating factors etc.

Short circuit calculations shall be evaluated giving full evidence that every electrical component can withstand the maximum stresses under fault conditions, for fault levels and duration’s obtained under the worst conditions, e.g., upon failure of the corresponding main protection device and time delayed fault clearing be the back-up protection device.

All works shall be suitable for the prevailing climatic conditions.

Outdoor installation shall be protected against solar radiation by means of adequate

covers, where required by the Engineer-in-Charge.

The Contractor shall ensure that all the supplied works are insensitive to any signals

emitted by wireless communication equipment.

6.1.2 Standards The design, manufacture and testing of all works and installations shall strictly comply with the latest edition of the relevant Indian Standards or equivalent IEC publications.

6.1.3 Colour Code The manufacturer’s painting systems shall be used to the maximum possible extent, but shall by all means be subject to the approval of the Engineer-in-Charge. Final coats of paint shall be matching adjacent installations, where required by the Engineer-in-Charge.

630 UPID

6.2 Electric Motors 6.2.1 General All motors shall be of approved manufacture and shall comply with the requirements if

this Chapter. Motors of the same type and size shall be fully interchangeable and shall comply with Indian Standard or equivalent IEC standard motor dimensions.

The general construction shall be stiff and rigid, no light metal alloy castings will be

accepted. All precautions shall be taken to avoid any type of corrosion.

All motors shall be fitted with approved types of lifting hooks or eye bolts as suitable.

AC motors shall have squirrel cage type rotors.

6.2.2 Rating

The rating of the motors shall be adequate to meet the requirements of its associated equipment. The service factor, being the ratio of the installed motor output to the required power at the shaft of the driven machine at its expected maximum power demand, shall be applied as follows except the equipment for which service factors have been specified in the respective sections:

Power Demand of Driven Machine Service Factor

Up to 5 kW 1.2

More than 5 kW 1.1

AC motors shall be capable of operating continuously under rated output conditions at any frequency between 95% and 105% of the rated frequency and / or with any voltage variation between 90% and 110% of the nominal voltage. A transient over voltage of 130% of the nominal voltage shall as well be sustained.

Further, the motors shall be capable of maintaining stable operation when running at 70% nominal voltage for a period of 10 seconds. The pullout torque for continuously loaded motors shall be at least 160% of the rated torque and for intermittently loaded motors 200% of the rated torque. However, the pullout torque of the motors specified in respective sections shall be considered.

6.2.3 Starting

AC motors shall be designed for direct on-line starting. They shall be capable of being switched on without damage to an infinite bus bar at 110% of the nominal voltage with

an inherent residual voltage of 100% even in phase opposition. For starting the motors from the individual main and auxiliary bus bars, a momentary voltage drop of 20% referred to nominal voltage should be taken into consideration. With 85% of the nominal voltage applied to the motor terminals, each motor shall be capable of accelerating its associated load to full speed with a minimum accelerating torque of 5% of full load torque.

The maximum starting currents (without any tolerance) shall not exceed value 5 times of rated current for motors.

631 UPID

Generally, all motors shall be able to withstand three cold starts per hour, equally spaced.

In addition, each MV motor shall be capable of enduring two successive starts with the motor initially at operating temperature. Each LV motor shall be capable of withstanding three successive starts under the same conditions or once every twenty minutes without detrimental heating.

Frequency of starts of motors has been mentioned in the respective sections. Contractor

shall state the frequency of starts in compliance with the motor design.

6.2.4 Windings and Insulation Class

The insulation of all motors shall be of class F but maintain in operation the temperature limit of class B materials. It shall be suitable for operation in damp locations, for occasional contact with corrosive gasses and vapours and for considerable fluctuations in temperature.

The stator winding shall be suitably braced to withstand the forces due to direct-on-line

starting and transfer conditions as mentioned before. The winding envelopment and tails shall be non-hygroscopic. The stator winding shall withstand the maximum fault current for the period determined by the associated protective devices.

The motor winding (if applicable) shall be designed to give trouble free continuous service

including repeated direct-on-line starting. The motor shall be capable of withstanding a maximum speed of 2.5 times the rated speed or 2000 rev / min whichever is less.

6.2.5 Ventilation and Type of Enclosure All motors shall be of the totally enclosed fan cooled type, protection class IP 54

according to IEC recommendation 144, Cable terminal boxes shall be of class IP 55.

Motors shall have a closed internal cooling air circuit re-cooled by an external cooling air

circuit drawn from the opposite side of the driving end.

Where motors are installed outdoors, a weatherproof design shall be chosen. MV motors and LV motors of IE size 132 and above shall be equipped with automatically controlled heating elements for protection against internal condensation of moisture during standstill periods. Such AC heater shall be suitably fixed inside the motor casing, the leads shall be led to a separate LV terminal box.

Motors installed outdoors and directly subjected to solar radiation shall be rated such as

not to exceed a minimum metal temperature of 85° C. Where necessary, such motors shall be provided with sun shields.

Vertical motors shall be provided with a top cover to prevent the ingress of dirt etc.

6.2.6 Bearings As far as possible, the motors shall have sealed ball or roller bearings lubricated for life.

All other motors with ratings of about 1 kW and above shall be equipped with lubricators permitting greasing while the motor is running and preventing over

632 UPID

lubrication. Additionally, the bearings shall be fitted with grease nipples permitting the use of a universal grease gun. Vertical motors shall have approved thrust bearings.

All bearings shall be easily controllable during operation or standstill without dismantling the bearings. The bearings shall further be protected and sealed against dust penetration and oil leakage.

In case of independent bearings, motor and bearing pedestals shall be fitted on a common

base plate.

For the transport of motors equipped with ball or roller bearings, special bearing inserts

shall be provided to prevent transport damage.

6.2.7 Shafts and Couplings The motors shall be provided with a free shaft extension of cylindrical shape with key and keyway according to IEC recommendation 72 – 1 and with the motor-side coupling, which shall be pressed on the motor shaft and be balanced together with it. A coupling guard shall be provided.

6.2.8 Terminal Boxes and Earthing

The terminal leads, terminals, terminal boxes and associated equipment shall be suitable for terminating the respective type of cables as specified in these Technical Specifications.

The terminal boxes shall be of ample size to enable connections to be made in a

satisfactory manner. Supports shall be provided at terminal boxes as required for proper guidance and fixing of the incoming cable.

The terminal boxes with the cables installed shall be suitable for connection to supply

systems with the short circuit current and the fault clearance time determined by the motor protective devices.

A permanently attached connection diagram shall be mounted inside the terminal box

cover. If motors are provided for only one direction or rotation, this shall be clearly indicated.

Terminal boxes shall be totally enclosed and designed to prevent the ingress of moisture

and dust. All points shall be flanged with gaskets of neoprene or similar material. For motors above 1 kW, the terminal box shall be sealed from the internal air circuit of the motor.

Depending on the size, the terminal box of LV motors shall be fitted either with an

approved cable sealing end or with a gland plate drilled as required and provided with suitable fittings for cable fixing and sealing. Such openings shall be temporarily plugged or sealed during transportation.

Terminal boxes of MV motors shall be fitted with an approved cable sealing end and a

pressure relief diaphragm suitably located. For plastic insulated and sheathed cables

633 UPID

filing with compound is not required. The three neutral ends of the windings of MV motors shall be brought out to separate terminal box.

For earthling purposes, each motor shall have adequately sized bolts with washers at the lower part of the frame. In addition, each terminal box shall contain on earthling screw.

6.2.9 Noise Level and Vibrations

nder all operating conditions, the noise level of motors shall not exceed 85 dB (A).

In order to prevent undue and harmful vibrations, all motors shall be statically and

dynamically balanced.

Vibration displacements or velocity shall be measured in accordance with DIN 45 665 for

IEC motor size 80 to 315. The results for all motors shall be within the “R” (reduced) limits.

6.2.10 Tests

Each motor shall be factory tested and shall undergo a test at Site. The following tests shall be performed under full responsibility of the Contractor.

Workshop Tests:

Measurement of winding resistance

No-load and short-circuit measurements

Measurement of starting current and torque

Efficiency measurement (type test)

Heat test run

Dielectric test

Measurement of insulating resistance

Over speed test

Site Tests:

Measurement of insulation resistance

Measurement of motor vibrations

Measurement of starting time

6.3 Auxiliary Works

6.3.1 Auxiliary Switches

Where appropriate, each item of works shall be equipped with all necessary

auxiliary switches, contactors and devices for indication, protection, metering,

control interlocking, supervision and other services. All auxiliary switches shall

be wired up to terminal blocks on the fixed position of the works.

634 UPID

All auxiliary switches and mechanisms shall be mounted in approved accessible

positions clear of the operating mechanism and are to be protected in an approved

manner. The contacts of all auxiliary switches shall be strong and shall have a

positive wiping action when closing. 6.3.2 Control Switches

Control Switches for electrically operated circuit breakers shall be of the pistol

grip or discrepancy type. They shall operate clockwise when closing the circuit

breakers and anti-clockwise when opening them. The control switches shall be so

designed as to prevent them from being operated inadvertently, and where

switches of the discrepancy type are used they shall require two independent

movements to effect operation. Control switches shall be so designed that when

released by the operator, they return automatically to the neutral position after

having been turned to the “closed” position and shall at the same time interrupt

the control voltage supply to the operating mechanism of the circuit breaker

Switches for other apparatus shall be operated by shrouded push buttons or have

handles of the spade type. The pistol grip type shall be used for circuit breaker

operation only.

Control, reversing, selector and test switches shall be mounted, constructed and

wired as to facilitate the maintenance of contacts without the necessity for

disconnecting wiring.

6.3.3 Anti-Condensation Heaters

Each individual enclosure accommodating electrical works which is liable to suffer from

internal condensation due to atmospheric or load variation shall be fitted with heating devices

suitable for electrical operation at the specified standard AC voltage, being of sufficient

capacity to raise the internal temperature by about 5° C above the ambient temperature.

Heaters in motors and similar works shall be switched on automatically upon opening of the

motor starter, and vice-versa. Heaters in switchgear / MCC cubicles, control cubicles, panels,

desks, etc. shall be controlled automatically by adjustable hydrostats (setting range about 50 –

100% relative humidity). The electrical apparatus so protected shall be of such design that the

maximum permitted temperature is not exceeded if the heaters are energized while the

apparatus is in operation. Heaters shall be equipped with a suitable terminal box. All works,

whether fitted with a heating device or not, shall be provided with suitable drainage and be

free from pockets in which moisture can collect. 6.3.4 Protection Devices

The main parts of the works shall be protected and interlocked so as to prevent

malfunctions and other fault occurrences, and to maintain safety during all

operation phases.

Electric protection relays shall be the standard product of an experienced and

reliable protection relay manufacturer. They shall be of the static or mechanic /

magnetic, tropical type and be mounted in suitable dust proof and shock

635 UPID

absorbing casings. They shall not be affected by external magnetic field or any

other influence (radio, computer, signals, impulses, etc.) consistent with the place

or method of mounting Electro-magnetic relays shall have a transparent cover

with appropriate seals.

The protection relays shall be equipped with all necessary auxiliaries such as

tripping unit, time relay, external resetting device (hand reset flag with seal in

operation). The relays shall provide easy access for testing and setting purposes.

Pre-warning alarms shall be installed as early as possible before the protection

system trips, in order to enable the operators to take precautions. Tripping of a

protection system as well as the sources of the protective action shall be indicated

and recorded as an alarm.

Unless otherwise required for special purposes, protection relays shall remain in

the tripped position until the operator resets the relay manually. The protection

and auxiliary relays shall be grouped and mounted on plug-in modules or

stationary mounted on swing frame with separate plugs and sockets to feature

easy replacement and testing. The construction shall be sturdy and such that all

parts are easily accessible for adjustment. Relays installed in switchboards shall

be arranged in compartments separated from the switchgear.

Besides the mechanically operated flag type indicator, all relays shall have

sufficient contacts and / or auxiliary relay contacts to perform all the tripping,

inter-tripping, interlocking, indication and alarm functions required. Spare

contacts (1 NO, 1 NC) shall be provided for later use. The contacts shall be silver-

plated or of the seal-in type with no main contacts adjustable. The relay contact

rating shall be for the specified standard voltage and for 200% of the nominal

passing current. The relay coil shall be able to operate properly at voltage

variations of -25% to +15%.

Relays shall be capable to withstanding at least one million operations without any defect.

Testing of the individual relays shall either be effected by stationary-mounted or

portable testing device.

6.4 Terminal Points

6.4.1 Scope of work

The Contractor shall supply all terminals, control boxes and cables in sufficient capacity,

conduits, fittings etc. from terminal points for the distribution of electric power to the

electrical equipment and its controls including lighting to be supplied under this Contract. The

power supply cables shall be designed so that the voltage drop between the terminal points

and the respective equipment shall be limited to within 2.5% of the rated voltage. The electric

service power provided by the Purchaser or the other contractors shall be as follows:

415/ 230 V, 50 Hz, three phase system with earthed neutral for feeding three phase and single phase consumers (connected between neutral).

636 UPID

230 V, 50 Hz, permanent supply, single phase earthed.

48 v DC system, isolated from earth, for the supply of electronic equipment,

telecontrol, telecommunications, etc. wherever necessary shall be provided by the

Contractor. 6.4.2 Supply Tolerances For supply tolerances system limits of the supply voltage see the following table:

Description 415 / 230 V 230 V 48 V, DC

a) Steady +5%, -10% ± 2% +10%, -15%

b) Transient ±30% ±10%

c) Limits of the frequency ±2% ±1%

6.5 Cables

6.5.1 General

The Contractor shall provide the relevant design and engineering of the relevant

cable systems and, in close co-operation with the Electro-Mechanical Equipment

Contractor, prepare the cable installation drawings with cable routing, connection

diagrams, and cable lists, details etc.

The power cables and control cables shall be of copper as per Indian Standards or

IEC publications and the power cables shall be of minimum size 2.5 mm and

control cables shall be of minimum size 1.5 mm.

All cables and accessories shall be suitable for installation under site conditions (e.g., aggressive soil condition, etc.).

The Contractor shall select the most suitable cable routes and raceways ensuring a

minimum of interference with other installations.

6.5.2 Colour Code

Live parts of electrical connections shall be colour coded as follows:

Description Coding Symbol Colour

AC Network Phase 1 L red

Phase 2

1 yellow

Phase 3

L blue

2

Neutral L

black

3

637 UPID

N

DC Network Positive L + + white

Negative L – - black

Neutral N Blue

Protective earthed Neutral PE / N green / yellow

Earth Earth E grey

ii) Colour coding for Mimic diagrams:

Mimic diagrams to be arranged on switchgear cubicles, control panels / desks etc. shall be colour coded as below:

a) 415V white

b) 110V DC violet

6.6 Earthing System

All electrical systems shall be properly earthed as per the latest ruling practice for the safety

of the equipment and operating staff as well as the system. All protection devices shall be

provided in the control equipment.

6.7 Labels and Plates

6.7.1 General

Labels and data plates shall be provided in accordance with applicable standards and as detailed hereunder:

The proposed material of the labels, size, exact label lettering and proposal for the

arrangement of the labels shall be submitted to the Engineer-in-Charge for

approval.

Where applicable, designations in the selected local language shall appear above or

to the right of the designation in the Ruling Language of the Contract. The

translations into and writing in the local language shall be submitted for approval.

6.7.2 Equipment Labels and Instruction Plates

The control panel for each gate shall be furnished with a large permanent main

nameplate affixed to the control cabinet in a conspicuous location, showing the

Engineer-in-Charge’s identification number and designation of the hoist and the

year of manufacture.

Additional nameplates shall be provided to indicate main operating instructions,

caution or warning for personnel and operational safety. In addition, each panel-

mounted instrument, pressure gauge, position indicator, pushbutton, switch, light

and other device related to the gate operation shall be identified by a permanently

affixed name plate describing the control functions. Each item of the control panel

638 UPID

and each pump, motor, relief valve, flow and directional control valve, check

valve, and so on shall be assigned a designation (to be shown on the supplier’s

control panel drawing) and labeled accordingly, clearly identifying the gate to

which it belongs. Electrical wiring and instruments including relays shall also be

labeled to correspond to the numbers assigned on the electrical control schematic.

Each major and auxiliary component of the control system shall have a name

plate permanently affixed thereto showing in a legible and durable manner the

serial number, name and address of the manufacture, rated capacity, speed,

setting, electrical characteristics, and other significant information, as applicable.

Nameplates of distributing agents only will not be acceptable.

In addition to the hoists, other items of the gate equipment shall also be provided

with nameplates containing operating instructions, warnings, or other information

essential to the proper use of the equipment.

The above general nameplate requirements are also for use in preparing

nameplate lists and drawings to be submitted for review. Drawings for

nameplates, as they will appear on the finished equipment shall be submitted for

review.

All nameplates shall be in English and shall be suitably engraved and shall be

weather resistant. All nameplates shall be permanently attached to the respective

parts, components, or equipment items in clearly visible locations. Nameplates for

control equipment shall be screw mounted laminated plastic, white with black

cores, with engraved capital letters of minimum height of 6 mm.

Cable and wire markets shall be identified with adhesive, self-laminating type

markers. The markers shall be printed with the cable designation or with the

conductor designation shown on the drawings. The clear laminate shall overlap

the lend and shall be resistant to oils, abrasion and high temperature. 6.7.3 Instruction Plates

All gauges, meters and other instruments etc, shall have dials or scales calibrated in metric

system. All name plates, instruction plates, warning signs etc, shall be in English as well as in

local language. All equipment shall be provided by a securely fastened name plate showing

the maker’s name, model, serial numbers, year of manufacture, main characteristic data of the

respective equipment and further relevant information specified in the applicable standards or

necessary for the proper identification of the equipment involved. The contractor shall supply and also install all label plates and other labeling, (of the screw-on

type) on control boards, control desks, panels and other places where required for operational

functional and safety reasons. The labeling, size of the plates and their location shall be

subject to approval by the Engineer-in-Charge. A sample of label plates (with indication of the

material used) with lettering shall be submitted for this purpose. The number and sizes of the

plates shall be optimum.

639 UPID

ERECTION

7.1 General

The equipment covered by these Specifications and Specification Drawing shall be supplied

and erected by the contractor completely at the project site. The contractor shall prepare a

complete erection procedure, which shall describe the sequence of operations to be carried

out, the method to be used, the measurements to be taken and the tolerances to be met in the

erection and alignment of the equipment. Such procedure shall have the approval of the

Engineer-in-Charge prior to the commencement of fabrication and when approved, shall form

a part of the specification furnished by the contractor.

7.2 Installation of 1st stage Embedded parts

st

All 1 stage anchorages shall be supplied and erected by the contractor in proper alignment. st

Fixing of 1 stage embedded parts, its concreting is responsibilities of contractor.

7.3 Installation of 2nd

stage Embedded Parts Gate frames, guides, tracks and seal seats etc. shall be assembled and installed, brought to

line, grade and plumb within the erection tolerances and secured in place by anchorages as

shown in the drawings or otherwise according to the best method in practice and as may be

necessary for successful functioning of these units. The erection tolerances for the frames and

guides shall be as indicated on the drawings or as per latest relevant IS code. Extreme care

shall be taken to ensure that their surfaces be in a true plane within the tolerance throughout

their entire length. The 2nd

stage anchorages shall be strong enough to hold the frames and

guides securely in position while concrete is being placed.

7.4 Installation of Gates, Hoists & Operating Mechanism

All the components of the gates, hoists and operating mechanism shall be erected perfectly

giving due cognizance to the unit and match marks on the components. All components shall

be designed and assembled to fit snugly and shall be watertight. In case of gates which are

exposed to floods it is desirable to avoid the flood period to perform erection of gate. Should it

be necessary to do so, due precautions should be taken for measures against floods, since the

gate may be submerged in water sustaining damages or the half erected gate may disturb the

water flow causing damages to the civil structure. One of the measures may be that the hoists

should be erected first, and when the flood forecast is made, the half-executed gates should be

hoisted above the flooding water.

7.5 Guidelines for Field Erection

The equipment shall be erected by the contractor in accordance with these

specifications to the satisfaction of the Engineer-in-Charge using most modern

techniques under the directions of the supervisory erection personnel to be

provided by the contractor and agreed by the Engineer-in-Charge.

Any required tool or equipment which is not normally available at the work site as well as any jigs or fixtures required for proper erection shall be furnished by the

640 UPID

contractor / contractor. A list of such tools shall be supplied by the contractor / contractor.

Erection tolerances shall conform to Indian Standards and /or those values specified by the Engineer-in-Charge.

Erection bolts, nuts, washers and other fasteners shall be furnished in the amount

of 15 % or ten bolts, nuts, washers and other fasteners whichever is greater in

excess of the nominal numbers of each size and length required for complete

installation of equipment.

Bolts in tension shall have a net section at root of thread 15 % in excess of the net section required in tension.

7.6 Placing of Concrete Concreting shall be done by the civil contractor in consultation with the hydro-mechanical

equipment manufacturer / contractor. The hydro-mechanical equipment manufacturer /

contractor shall give a detailed programme of fixing and aligning the embedded parts to the

Engineer-in-Charge for this purpose. Before placing the concrete in any one lift and between

placement of successive lifts, alignment tolerances shall be checked and remedial action taken

by the hydro-mechanical equipment manufacturer / contractor, if any displacement has

occurred. 7.7 Erection Personnel Skilled as well as unskilled personnel shall be arranged by the contractor for erection of the equipment covered in these specifications. 7.8 Erection Limitation

The contractor should visualize the accessibility for erection from civil data / drawings

provided in these Technical Specifications / Specification Drawings and should ensure that all

gates, hoists and associated equipment can be transported through the access tunnels /

galleries (if so required) available at various locations. The contractor shall be responsible for

provision of site jointing to suit access restrictions and provide for all requirements of

transportation through the access tunnels / galleries.

7.9 Notification The Engineer-in-Charge will notify the contractor thirty (30) days prior to date on which erection and installation of the equipment is to commence.

7.10 Cooperation with Other Contractors

No compensation shall be claimed by the contractor because of the modifications required to

accommodate equipment of other contractors except as is otherwise specifically provided

therein. All adjustments shall be made by the contractor without involving extra cost to the

Engineer-in-Charge. Two copies of all drawings and copies of all correspondence relating to

the drawings and specifications exchanged between contractors shall be sent to the Engineer-

in-Charge. 641 UPID

TRANSPORTATION AND STORAGE

8.1 Transportation

The contractor shall make his own survey for transportation limitation to site. The

weights and dimensions of gates, hoists and associated equipment covered under

these specifications should be taken into consideration while planning the gate /

hoist components and suitable splicing / site assembly and jointing provided to

enable transportation up to site. The contractor shall be held responsible for

damage and security of the equipment during transportation. An appropriate

period for transportation shall be considered.

The delivery dates, transportation and erection periods indicated in the Contract Documents shall be strictly adhered to.

From the time of manufacturing until commissioning all parts of the equipment

covered in these specifications shall be protected against damage of any kind.

Parts, which are damaged during transport, shall be replaced at the Contractor’s

expenses.

All the equipment covered in these specifications shall be insured for loss or damage during transit and site storage at the cost of the contractor.

The Contractor shall also be responsible for obtaining from the authorities any

permit that may be required for the transport of loads exceeding the normal

gauges.

8.2 Preparation for Dispatch

No assembly or its parts shall be shipped from the contractor’s shops until it has been

inspected or inspection has been waived off in writing by the Engineer-in-Charge on an item

basis. The Contractor shall provide the Engineer-in-Charge with complete packing lists of each performed shipment.

8.3 Weights

Before dispatch the contractor shall determine (by the most accurate means available) the net

weight of each piece of assembly that is to be shipped as a unit exclusive of boxes, crates or

kits. These copies listing the net weight shall be painted on the respective pieces of assemblies

or stated on the tags attached thereto.

8.4 Marking

Each part of the gate, hoist and embedded parts, which is to be transported as a separate piece,

shall be marked to show the unit of which it is a part and match marked to show its relative

position in the unit to facilitate assembly in the field. Unit marks and match marks shall be

made with heavy steel stamps and paint. Each piece, sub-assembly or package transported

separately shall be labeled or tagged with transport designation consisting of the specification

642 UPID

number, the marks number of such pieces and number of parts grouped of such sub-assemblies contained in package. Each shipping container shall also be clearly marked on at least two sides as follows:

Consignee

Contract No.

Port of destination

Item number (if applicable)

Packing number (in sequence)

Quantity per package

Description of works

Net and gross weight and volume

8.5 Packing

All parts shall be prepared for dispatch so that slings for handling may be attached

readily while parts are to be moved. Where it is unsafe to attach slings to the box,

parts shall be packed with slings attached to the part and slings shall project

through the box or crate so that attachment can be made easily. All parts shall be

properly secured and packed to withstand handling during transportation. All

packing shall allow for easy removal and checking at sites. Special precautions

shall be taken to prevent rusting of steel and iron parts during transit.

All parts including electrical parts shall be suitably protected against corrosion,

water, moisture, sand, heat, atmospheric conditions, shocks, impact, vibrations

etc. by packing them into high pressure polyethylene foil and shall be subject to

the prior approval of the Engineer-in-Charge.

All parts of equipment covered in these specifications shall be packed at the place

of manufacture. The packing shall be suitable for shipment by sea and for all

special requirements / limitations of the transportation to site. Where necessary,

double packing shall be used in order to prevent damage and corrosion during

transportation, unloading, reloading or during intermediate storage.

After delivery of material at site, all packing shall become property of the

Engineer-in-Charge. Notwithstanding anything stated in this clause the contractor

shall be entirely responsible for loss, damage or depreciation to the stores due to

faulty and insecure packing.

All spare parts shall be packed in such a way that they shall be preserved for

minimum five years, packing procedure for spare parts shall be got approved by

the Engineer-in-Charge in advance.

The Engineer-in-Charge reserves the right to inspect and approve the packing before the items are dispatched but the Contractor shall be entirely responsible for

643 UPID

ensuring that the packing is suitable for transit and such inspection will not

exonerate the Contractor the Contractor from any loss or damage due to faulty

packing.

8.6 Storage

The Contractor shall provide means for loading, unloading, reloading, stacking

operation, storage and preservation of all consignments of components of gates

and their hoisting arrangement and their accessories at any intermediate storage

during transportation as well as in the stockyards of the contractor at the project

site before they are transported, installed, tested and commissioned at their

respective Sites.

The Contractor shall be responsible for all Custom clearance of all consignments whether shipped by air / sea, local storage and further transportation to site.

If large parts are stored in the open air, they shall be provided with weather

resistant and fire resistant covers. Electrical parts, which are not packed in heavy-

duty polyethylene foil and those so packed but whose packing has been damaged

shall be kept insatiable places from the moment of storage to the moment of

installation.

All insulation materials which will be taken from the warehouse for installation

and which are stored temporarily in the station shall be protected from weather or

humidity. 644 UPID

Section IX . Particular Conditions of Contract

QUALITY ASSURANCE, INSPECTION, TESTING AND FINAL ACCEPTANCE

9.1 Quality Assurance

The contractor shall submit and finalize manufacturing Quality Plans for all the major

components and equipment. These Quality Plans will detail out various tests / inspections to be

carried out as per the requirement of these Specifications and standards mentioned therein and

quality practices and procedures followed by contractor’s Quality Control Organization, the

relevant reference documents and standards and acceptance norms etc, during all stages of

material procurement, manufacture, assembly and final testing / performance testing.

The contractor shall also furnish copies of the reference documents / plant standards /

acceptance norms / test and inspection procedure etc, as referred in Quality / reference

documents / standard etc. These will be subjected to Engineer-in-Charge’s approval without

which contractor shall not proceed. Engineer-in-Charge shall reserve the right to add any

inspection or test which is felt necessary for completion of the work. These approved

documents shall form a part of the contract. In these approved Quality Plans, Engineer-in-

Charge shall identify Customer Hold Points (CHP’s) i.e. testing checks which shall be carried

out in the presence of the Engineer-in-Charge’s Engineer or his authorized representative in

writing. All deviations to these Specifications, approved Quality Plans and applicable

standards must be documented and referred to Engineer-in-Charge along with technical

justification for approval and dispositioning.

The contractor shall also submit and finalize field quality plans which will detail out for all the

equipment, the quality practices and procedures etc. to be followed by the contractor’s site

Quality Control Organization during various stages of activities from receipt of material /

equipment at site. The field Quality Plans shall also be approved by the Engineer-in-Charge.

No material shall be dispatched from the contractor’s works before the same is accepted

subsequent to pre-dispatch / final inspection including verification of records of all previous

tests / inspection by Engineer-in-Charge’s Engineer or his authorized representative and duly

authorized for dispatch.

All the vendors / sub-vendors proposed by the contractor for procurement of major bought out

items including casting, forging, semi-finished and finished components / equipment, list of

which shall be drawn up by the contractor and finalized with the Engineer-in-Charge shall be

subject to Engineer-in-Charge’s approval. The contractor’s proposal shall include vendor /

sub-vendor’s facilities established at the respective works, the process capability, process

stabilization, Quality Control System followed, experience list etc. along with his own

technical evaluation of vendor / sub-vendors shall be submitted to the owner for approval.

Such approval shall not relieve the contractor from any obligation, duty or responsibility under

the contract. This action would, however, not involve Engineer-in-Charge in any

complications arising between the contractor and his sub-contractor(s)/vendor / sub-vendors or

any other liabilities. The contractor shall also obtain Quality Plans from approved vendor /

372 UPID


sub-vendors from whom he proposes to procure the material and submit these Quality Plans for Engineer-in-Charge’s approval.

Normally, no request for change of vendors / sub-vendors shall be entertained by Engineer-in-

Charge. But in the peculiar circumstances if the request for change of vendor / sub-vendors is

found reasonable and justified then the same shall be entertained and the decision of Engineer-

in-Charge in this respect shall be final and binding. The time consumed for the change of

vendor / sub-vendors shall not be excluded from the stipulated time of the completion of the

contract. This change shall not relieve the contractor from the responsibility to complete the

work within stipulated time in any manner.

Engineer-in-Charge reserves the right to carry out quality audit and quality surveillance of the

system and procedures of the contractor. The contractor shall provide all necessary assistance

to enable the Engineer-in-Charge to carry out such details and surveillance including Quality

Manuals.

For all spares and replacement items, the quality requirements as agreed for the main

equipment supply shall be applicable. Repair / rectification procedures to be adopted to make

the job acceptable shall be subjected to the approval of Engineer-in-Charge / authorized

representative.

Before sub-contracting any portion of work, the contractor will take prior approval of

Engineer-in-Charge.

All materials used or supplied shall be accompanied by valid and approved material

certificates and tests and inspection reports. These certificates and reports shall indicate the

heat numbers or other such acceptable identification numbers of the material. The material

certified shall also have the identification details stamped on it.

The contractor shall be required to submit six copies of the following quality assurance

documents at least four weeks after dispatch of the equipment:

Material mill test reports on components as specified in Quality Plan.

Sketches and drawings used for indicating the method of traceability of the

radiographs to the location on the equipment.

Non-destructive examination results reports including radiography interpretation reports.

Factory test result for testing required as per applicable codes and standards

referred in the Specifications.

Inspection reports duly signed by the authorized Engineering representative of the Engineer-in-Charge and contractor for the agreed inspection hold points.

All the accepted deviations shall be included with complete technical details.

373 UPID


9.2 Inspection, Testing and Maintenance

9.2.1 General

The guidelines / recommendations for inspection, testing and maintenance of gates and hoists

as contained in the relevant Indian Standards viz. IS 7718, IS 10096, IS 13053, IS 10341 but

not limited to, shall be applicable at different stages of the work viz. at the contractor’s stage at

the time of erection as well as after erection.

9.2.2 Place of Manufacture and Inspection

The contractor shall state in his tender the place of manufacture, testing and inspection of

various portions of the work included in the contract. Authorized representative of the

Engineer-in-Charge may be present at the time of any or all tests and the contractor shall

provide all necessary facilities for the same. Representatives of the Engineer-in-Charge shall

also be entitled to access to contractor’s / sub-contractor’s work at any time during the

manufacture of equipment and materials. All material entering into the work shall be subject

to inspection by Engineer-in-Charge or his authorized representatives and all purchase orders

for materials and supplies shall carry a notation to this effect. Copies of all purchase orders

and sub-contracts shall be submitted to Engineer-in-Charge at the time of placing the order.

Waiving of inspection by Engineer-in-Charge shall not relieve Contractor from the

responsibility of supplying material and workmanship acceptable to Engineer-in-Charge.

Contractor shall be responsible for proving quality of material and workmanship either by

records of inspection or by immediate inspection.

9.3 Inspection

All supplies (which include without limitation of raw materials, components, intermediate

assemblies and end products) shall be subject to inspection and test by the Engineer-in-Charge

or his authorized representatives to the extent practicable at all times and places. Inspection

shall be carried out in accordance with relevant Indian Standards. If any inspection or test is

made by the Engineer-in-Charge or his authorized representatives in the premises of the

contractor or sub-contractor, the contractor without additional charge shall provide all

reasonable facilities and assistance for the safety and convenience of the inspectors in the

performance of their duties. If on the request of the Engineer-in-Charge, inspection or test is

made at a point other than the premises of the contractor or sub-contractor of the contractor, it

shall be at the expenses of the Engineer-in-Charge except as otherwise provided in the

contract, provided that in case of rejection, the Engineer-in-Charge shall not be liable for any

reduction in value of sample and used in connection with such inspection and test. All

inspections and tests by the Engineer-in-Charge shall be performed in such a manner as not to

unduly delay the work. The Engineer-in-Charge reserves the right to charge the contractor any

additional cost of inspection and test when supplies are not ready at the time of such

inspections and test. Acceptance or rejection of the supplies shall be made as promptly as

practicable after delivery except as otherwise provided in the contract but failure

374 UPID


to inspect and accept or reject supplies shall not relieve the contractor of the responsibility for such supplies to be in accordance with the contract requirements.

The inspection and test by the Engineer-in-Charge or his authorized representatives of any

supplies or lots thereof does not relieve the contractor from any responsibility regarding

defects or other failure to meet the contract requirements which may be discovered prior to the

acceptance. Except as otherwise provided in the contract, acceptance shall be conclusive and

except as regards latent defects or such gross mistakes as amount to fraud.

The contractor shall provide and maintain the inspection system acceptable to the Engineer-in-

Charge covering the supplies hereunder. Records of all such inspection work shall be kept

complete by the contractor and made available to the Engineer-in-Charge during the

performance of the contract and for such longer period as may be specified elsewhere in the

contract.

9.4 Witnessing Shop Test, Inspection and Training

The Engineer-in-Charge will depute Engineers for the following purposes.

Witnessing Model Test, Minimum 8 Engineers for four inspection & Shop test weeks (Total 32 Engineers week with 8 round trips)

Training in works & Minimum 8 Engineers for four weeks (Total 32 Design Office Engineer-in-Charges week with 8 round trips).

The Engineer-in-Charge shall be free to even use third party inspection for witnessing tests and Inspection

The Engineer-in-Charge or his representative shall have free access to the software(s) used or

being utilized by the contractor for Planning and Design of Gates and Hoists both at his office

premises and at his shop premises. The Engineer-in-Charge or his representative shall be free

to check the design & drawings etc. on his software at any time.

The contractor shall have to impart training to Purchaser’s Engineers on various aspects

associated with the system and equipment to be supplied as well as on Software Programmes

used in design and preparation of drawings for the Gates and Hoists etc. of UP Water Sector

Restructuring Project so as to enable them to become familiar with the same.

The full expenditure in respect of travel, lodging and boarding of the Purchaser’s Engineers for

witnessing shop inspection and tests at the contractor’s work shall be borne by the Purchaser.

9.5 Operational Tests

9.5.1 General

375 UPID


The contractor shall carry out in the presence of project authorities, such tests on the gate

equipment to determine that the gate will fulfill the functions for which it has been designed.

Tests shall be repeated, if necessary, until successfully carried out to the satisfaction of the

Engineer-in-Charge. Leakage tests and operational tests shall be carried out after completion

of other portions of the work and when the reservoir is at its full level. The project authorities

shall have the right to carry out such tests also when the reservoir is at a level other than the

Full Supply Level.

9.5.2 Dry Test

Operational tests in dry shall be carried out as soon as possible after completion of erection

where all controls and permanent power supply have been connected. The tests shall include at

least two complete traverses from the maximum raised position to the full closed / seating

position. All adjustments, clearance, brakes etc. shall be checked for proper operation.

9.5.3 Wet Test

These tests should simulate the actual operating conditions as closely as possible. At least

two complete traverses will be made from the fully closed position to the normal raised

position as follows:

When gate is closed, raise to its normally open position in steps and observe the performance including vibration.

Lower the gate to the fully closed position in steps and observe the performance of

the gate including vibration.

Operation of filling value shall be tested.

Checkup proper operation of limit switches.

9.5.4 Leakage Tests

Leakage tests shall be carried out with the gate lowered on to the sill. Before measuring the

leakage, the gate shall be raised and lowered several times by a metre or so in order to dislodge

any debris that may have lodged in the side seal seats. The leakage shall then be measured and

recorded. The maximum permissible leakage shall not exceed 5 litres permin. per metre

length of periphery of sealing surface for all gates.

9.5.5 Non-Destructive Tests

9.5.5.1 General

The non-destructive tests shall be carried out as specified in SNT-TC-IA “Recommendedpractice for

non-destructive testing, personnel qualifications and certification” of the

American Society for Non-Destructive Tests or other similar International Standards.

All tests for soundness of welds shall be carried out as per IS 822 (latest edition) and other relevant IS codes.

376 UPID


9.5.5.2 Radiographic and Ultrasonic Inspection

Radiographic Examination

100% radiographic tests shall be carried out on all butt welds irrespective of

their position / location in all gates, embedded parts, hoists and hoist support

structures.

The radiographic examination shall also be done for all classes of castings. All

radiographic examination shall be carried out by the contractor as directed by

and to the satisfaction of the Engineer-in-Charge. The radiographic

examination shall conform to Indian Standard “Code of

Practice for Radiographic Testing (First Revision)” IS 2595

(LatestEdition) and Indian Standard “Code for Unfired Pressure Vessels

(with

Amendments No.1 to 4)” IS 2825 (Latest Edition). The quality of

buttwelding brought out by the radiographic examination shall obtain a minimum of 5 marks corresponding to International Institute of

Welding (IIW), Black Colour in accordance with IS 2825 (latest

edition).Isolated films getting lower marks may however, be accepted with the

approval of the Engineer-in-Charge in each individual case. Any retake of

radiography after rectification of defects shall also be done at no extra cost to

the Engineer-in-Charge.

Whenever dissimilar materials are butt welded together at least one x-ray

radiographic examination for each component of sub-assembly shall be carried

out at the selected points. The number of points to be taken would depend

upon the results obtained after the first series of test are carried out. Prior to

making radiographs of butt welds, the contractor shall place suitable

identification markers adjacent to the welds. Each marker shall be so designed

and located that the image will appear in the radiographs. The markers shall be

painted, stamped or fastened as directed by the Engineer-in-Charge and shall

not be removed until all welds have been accepted. All radiographs of welded

joints shall become property of the Engineer-in-Charge. The Radiographic test

shall be carried out by the qualified technician and at such time as decided by

the Engineer-in-Charge. The technician’s interpretation reports on the

radiographic examination shall be furnished by the contractor to the Engineer-

in-Charge. All precautions shall be taken to minimize radiation hazards.

Ultrasonic Examination

Ultrasonic examination shall be performed in accordance with the Article-

5 of ASME Boiler and pressure vessels code section V. The

relevantreferences from ASTM specification E-164-74 shall be also taken. The

377 UPID


ultrasonic examination shall be performed and supervised by experienced and

qualified personnel. If necessary special type of transducers and / or higher test

frequency etc. shall be adopted to improve the reliability of the test. The

equipment with recording facility shall be used for ultrasonic examination.

The records in such cases shall be furnished and the same shall be the property

of Engineer-in-Charge.

All indications which produce a response greater than 20% of the reference

level shall be investigated to the extent that the operator can determine the

shape, identity and location of all such reflectors and evaluate them in terms of

the acceptance standard given below:

Discontinuities shall be unacceptable if the amplitude exceeds the reference

level and discontinuities have length which exceeds 1/3 t where ‘t’ is the

thickness of the weld being examined.

Where discontinuities are interpreted to be crack, lack of fusion or incomplete

penetration, they shall be unacceptable regardless of discontinuity of signal

amplitude.

The marker shall not be removed until all the welds have been accepted.

Defective welds shall be gouged or chipped out, re-welded, re-x-rayed and the cycle repeated until satisfactory results are obtained.

Magnetic particle Inspection

All fillet welds joining diaphragm plates, rings, lugs, etc. shall have smooth

transactions into the sides of plates with toes of the welds made before depositing

the major bead. The surfaces shall be ground to merge smoothly into the plate

surface. The fillet joints are subjected to magnetic particle testing. The procedure of

carrying out the above test shall be as per relevant standards. Where magnetic

particle testing is not possible, dye penetration test shall be undertaken as

perAppendix – 8 of ASME Code section VII with the approval of the Engineer-

in-Charge.

Additional Examination

The Engineer-in-Charge may direct the use of visual, dye-penetration,

magnetic flux and ultrasonic methods and equipment to supplement the

radiographic examination. These additional methods will be used to ensure that

welds do not contain unacceptable defects as defined in sub-clause herein

above.

378 UPID


The contractor shall make available continuously throughout the contract,

technician and all equipment necessary for ultrasonic examination of the welds.

9.6 Shop Assembly and Tests

9.6.1 Gates

The gates shall be completely assembled in the shop for inspection and to ensure that all parts

to be connected are fitted properly and that all the dimensions, clearances, and tolerances

called for in these specifications and / or shown in the drawings have been obtained. The gates

shall be assembled in a vertical position to ensure proper alignment and holes for field

connections shall be carefully drilled or reamed while the gates are being assembled. The gates

would be carefully match marked to facilitate re-erection at site.

In the case of gates, when each wheel is carefully located on the wheel pin, a plane passing

through any wheel, perpendicular to the pin axis and intersecting the tread at mid-point, shall

coincide with similar planes through all other wheels in the same site of the gates within a

tolerance of 0.4 mm and shall be parallel to the corresponding plane through the wheels on the

other side of the gates. These planes, through the mid-point of treads, shall be perpendicular to

the finished surfaces of the seal bases and shall be rotated 3600 to ensure satisfactory

adjustment in all positions and to ensure even distribution of the bearing lubricant.

All gate frames and appurtenances shall be shop assembled so as to allow for adjustment of

various dimensions to make them conform to the designed dimensions, fit, tolerances, surface

finishes, clearances etc. In the event it is not possible to complete the gate leaf or any other

equipment / component in the shop, they will be accurately assembled in the shop using

temporary connections and various critical dimensions shall be verified. The embedded

metalwork to be furnished under these specifications shall be shop assembled to the extend

possible. Special care shall be taken in all phases of work affecting the strength and rigidity of

anchorages and embedded tie flats since the correct operation and stability of gates are largely

dependent upon the strength and accuracy of these parts. The cost of carrying out the tests, not

including the cost of inspection by the government personals shall be borne by the contractor

and included in the lump sum price bid in the schedule. However, at the discretion of the

Engineer-in-Charge the above test shall be carried out by the contractor on the shop assembled

parts and bought out items to the extent and in accordance with the instructions of the

Engineer-in-Charge. The fabricated parts and assembly of gates / gate frames and other

equipment shall be inspected and operational tests shall be observed by the Engineer-in-

Charge or his authorized representative.

9.6.2 Hoists

All the Hoists shall be shop assembled so as to allow for adjustment of various dimensions to make them conform to the designed dimensions, fits, tolerances, surface finishes, clearances

379 UPID


etc. In the event it is not possible to complete the equipment or such other components in the

shop, they will be accurately assembled in the shop using temporary connections and various

critical dimensions shall be verified. Under such test, the hoist shall run smoothly without

undue friction, noise or chatter, to the satisfaction of the Engineer-in-Charge. The cost of

carrying out the test, not including the cost of inspection by the government personnel shall be

borne by the contractor and included in the lump sum price bid in the schedule. However, at

the discretion of the Engineer-in-Charge, the above tests shall be carried out by the contractor

on the shop assembled parts and bought out items to the extent and in accordance with the

instructions of the Engineer-in-Charge.

As much permanent wiring as possible shall be completed during shop assembly. Rigid conduits shall be permanently installed and firmly supported in so far as practicable.

The hoists shall be operated for 15 to 30 minutes in slowest speed to demonstrate that the

equipment has been designed for continuous duty.

The contractor shall have to carryout the full load and 25 percent over load tests at the

contractor’s works / field for the hoisting motions of the hoists as per relevant Indian Standard.

9.6.3 Shop Assembly Tests

The equipment, after the fabrications and before preparing for dispatch, shall be assembled in

the shop for inspection and tested to ensure that all parts and components to be connected are

fitted properly and that all the dimensions, clearances and tolerances called for in these

specifications and / or shown in the drawings have been obtained.

9.7 Field Tests

9.7.1 Gates

a. Operational tests in dry

Operational tests in dry shall be carried out after completion of erections. The tests

shall include at least two complete traverses from the maximum raised position to

the fully seated position. All adjustment clearances, etc, shall be checked for proper

operations.

Operational tests with stipulated water head

The tests should stimulate the actual operating conditions as closely as possible.

At least two complete traverses will be made from the fully closed position as follows:

When the gates are closed, raise the gates to their normally open position.

Lower the gates to the fully closed position.

(iii)Operation at intermediate position as required by the Engineer-in-Charge.

380 UPID


(iv) And repeat the same process until these are carried out successfully to the satisfaction of the Engineer-in-Charge

Leakage tests

The maximum permissible leakage shall be 5 litre / min. / meter length of the seal.

Leakage tests shall be carried out with the gate lowered on the sill. Before the

observation for leakage the gates shall be raised and lowered about one meter

several times in order to dislodge any debris that might have lodged in the side and

bottom seals. The leakage then shall be measures and it should not be more than 5

litre / min. / meter length of seal run.

Tests shall be repeated, if necessary, until these are successfully carried out to the

satisfaction of the Engineer-in-Charge. Leakage tests and operational tests will be

carried out at the convenience of the Engineer-in-Charge after completion of other

portions the works and when the tail pool at maximum water level. However, the

Engineer-in-Charge shall have the right to carry out such tests when water level is

at F.S.L.or when the water is at a level lower than or above F.S.L.

9.7.2 Hoists

After the hoists have been erected, adjusted, lubricated and otherwise made ready for operation, it will be tested as follows:

The hoists shall be operated through cycles of lowering and raising the gates. The

hoists shall raise, lower, held the gates in any position at rated speed.

The hoists shall also be operated with a test load of 125% of the rated capacity. The

overload test will constitute the demonstration that the hoist can raise, lower or

hold in any position without damage or excessive deflection or vibration. The test

will be made under supervision of the contractor or his representative and

Engineer-in-Charge.

9.8 Final Acceptance

The final acceptance of the equipment shall be based on the following. a) Quality and workmanship of the equipment.

Satisfactory operation of the equipment after erection as required under these specifications.

Acceptance of various tests by the Engineer-in-Charge as mentioned at para 9.5,

9.6, and 9.7.

All tests may be witnessed by the contractor / Engineer-in-Charge or his authorized representative. On successful completion of all tests the equipment

381 UPID


shall be accepted but all the responsibility shall remain with the supplier within the guarantee period.

9.9 Guarantee

Within one year after acceptance of the equipment if any part of the gate / embedded parts,

hoists and hoist support structure are found defective because of workmanship or material or

otherwise, the contractor shall at his own expense, furnish and install new parts and materials

approved by the Engineer-in-Charge.

However, the guarantee period for all painting shall be 5 (five) years starting from the issue of

the “Completion Certificate”. This painting guarantee period shall be effective regardless of

any other guarantee periods for the project or parts of the project, or any “Defect Liability

Certificate” issued prior to the lapse of the painting guarantee period.

The Contractor shall perform requested painting repair work at no extra cost to the Purchaser if the painting quality is not met.

At the end of the painting guarantee period the anti-corrosive protection of the painted or

galvanized surfaces shall not have degree of rusting for anti-corrosive paints.

9.9.1. Failure to Meet Guarantee

Should any part of equipment fail to meet the guarantee or other requirement of the Technical

Specifications within the time covered by the guarantee, the Engineer-in-Charge may direct

the contractor to proceed at once to make alterations or furnish new part as may be found

necessary to meet the requirements. All expenses of furnishing, delivering and installing new

parts and test made necessary by failure of the equipment to meet the guarantee and other

requirements of Technical Specifications shall be borne by the contractor. If, after due notice

should the contractor refuse to correct any failure of the equipment to meet the requirement of

the Technical Specification during the guarantee period, the Engineer-in-Charge may proceed

at his own expense to correct such failure and to collect from the contractor an amount equal to

actual expenses so incurred including overheads and all other incidental expenses. The remedy

of Engineer-in-Charge is in addition to any and all other remedies provided in the Technical

Specifications or as provided by law.

382 UPID


9.9.2 Defective Equipment

In case any part of the equipment is found to be defective in materials or workmanship or

develops defects or does not otherwise meet the requirements of the specifications including

errors or omissions on the part of the contractor the following shall apply.

Defects disclosed prior to final acceptance

Any defect in materials or workmanship or other failure to meet the requirements

of these specifications including errors or omissions on the part of the contractor,

which are disclosed prior to final payment or prior to final acceptance tests,

whichever occurs at a later date, shall if so directed by the Engineer-in-Charge, be

corrected entirely at the expense of contractor.

Defects disclosed after final acceptance

Any latent defect not disclosed before date of final acceptance shall be corrected

promptly by the contractor entirely at his expense provided that the total period

during which the contractor is liable for replacement due to latent defects shallnot

exceed twelve months after date of final acceptance of the equipment.

9.9.3 Operation of Unsatisfactory Equipment

The Engineer-in-Charge shall have the right to operate all permanent equipment as soon as and

as long as it is in operating condition, whether or not such equipment is being accepted. Such

operation by the Engineer-in-Charge shall not lessen or impair any express or implied

warranties concerning such equipment. All repairs or alterations required shall be met at such

times as directed by the Engineer-in-Charge and in such a manner as will cause the minimum

interruptions in the use of the equipment by the Engineer-in-Charge. Operation of the

equipment pursuant to this section shall not relieve the contractor of his responsibilities to

supply all equipment in complete accordance with Technical Specifications. While

unsatisfactory articles can be taken out of service for correction of latent defects, errors or

omissions, the period of such operation of any use pending the correction of latent defects,

errors or omissions shall not exceed one year without mutual consent of the contractor and the

Engineer-in-Charge.

flapkbZ foHkkx] mRrj izns'k - Irrigation and Water Resources ...

Documents

Transcript of flapkbZ foHkkx] mRrj izns'k - Irrigation and Water Resources ...