Comprehensive Operation, Maintenance and Repair of Civil & Electromechanical assets such as Sump, Pump house, Intake Channel, Approach Road, Security Cabin, Staff quarters, Compound Wall, Bulk transmission pipeline, Valves, Pumping machinery & electrical equipment etc. for the Maliya to Bhachau – NC-09 Project, execution of required civil and electro-mechanical scheme strengthening works, including proper supply of water as per demand and maintaining complete and accurate records of all operation and maintenance activities, for a total period of 60 months, Dist.: Kutch.

Estimated Cost: Rs.

TECHNICAL SPECIFICATION CIVIL

Chief General Manager (Project)

Gujarat Water Infrastructure Limited

1st floor Block – 1, Jivraj Mehta Bhavan, Sector-10 Gandhinagar,

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

Comprehensive Operation, Maintenance and Repair of Civil & Electromechanical

assets such as Sump, Pump house, Intake Channel, Approach Road, Security

Cabin, Staff quarters, Compound Wall, Bulk transmission pipeline, Valves,

Pumping machinery & electrical equipment etc. for the Maliya to Bhachau – NC-09

Project, execution of required civil and electro-mechanical scheme strengthening

works, including proper supply of water as per demand and maintaining complete

and accurate records of all operation and maintenance activities, for a total

period of 60 months, Dist.: Kutch.

TECHNICAL SPECIFICATION

SECTION:2 SURVEY & GEOTECHNICAL INVESTIGATION FOR DESIGN ...................

SECTION – 5 STRUCTURAL STEEL WORK ....................................................

SECTION -6 WATER SUPPLY AND SANITARY WORKS ......................................

SECTION 8 : ITEMWISE SPECIFICATIONS ................................................

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

SECTION: 1 GENERAL AND MATERIAL

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

GENERAL AND MATERIAL

1.0 Employer’s Drawings:

The drawings listed in the Tender document are the Employer’s conceptual drawings

and are to be got approved prior to start of the works with actual site conditions & level

in consultation with EIC.

2.0 Drawing Sheet Format:

 All drawings provided by the Contractor shall be on standard size sheets, prepared on

computer with AutoCAD and shall show the following particulars in a title block

located in the lower right hand corner, in addition to the name of Contractor and

equipment manufacturer, date, scale, drawing number, revision number (R0 for

drawings submitted initially, R1, R2, etc. for drawings submitted subsequently) and

 Senior Manager ……,GWIL

 Project name: -

 A blank space of 90 mm x 100 mm shall be provided for the Engineer’s approval stamp

and provision shall be made for details of revisions to be recorded.

 All drawings submitted by the Tenderer/Contractor shall use the English language and

SI units. All drawings shall be clearly and fully cross-referenced to the other drawings

3.0 Tender / Contract Drawings:

 Drawings submitted by the Tenderer shall show all the essential items of the Plant

offered together with sufficient details to enable the general arrangement of the Plant

to be determined.

 The drawings and documents to be provided by the Tenderer / Contractor shall be as

per the schedules of price but shall not be limited to those listed:

4.0 Submissions and Approval of Drawings:

 The following shall be the procedure for submission and approval of drawings:

 The Contractor shall submit minimum 6 copies of the drawings to the Employer. All the

drawings are to be signed by the Contractor or his authorized representatives.

 The Engineer’s Representative will review the drawings and, if found fit for approval,

the Employer will return 2 copies to the Contractor duly approved.

 In case the drawings/documents are not fit for approval but worth for review, the

Engineer’s Representative will mark the comments on the drawings and return 2 copies

to the Contractor. In such case, the Contractor shall resubmit the revised drawings

within two weeks as per above and the same shall be repeated till the drawings are

finally approved as per sub-clause above.

 If the submitted drawings/documents are not worth for review, the Contractor will be

informed accordingly.

 On receipt of the approved drawings as per sub-clause above, the Contractor shall

submit CD/Pen-Drive, Soft Copy and documents to the employer as and when

 After tests on completion, the Contractor shall submit, within 15 days of the conclusion

of the tests, CDs/Pen-Drive, Soft Copy, Hard Copy of the “As Built Drawings” to the

 When the drawings are received by the Engineer’s Representative after revision by the

Contractor, he will only review the revision made and hence the Contractor shall

carefully identify all the revised details / dimensions and also describe the revisions in

the revision block.

 No drawings, with corrections made after taking the prints, will be accepted.

 Approval of drawings by the Engineer shall not relieve the Contractor of his

responsibility in terms of the Contract.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

5.0 Delivery, Unloading and Storing at Site:

 The Contractor shall be responsible for checking all materials delivered to Site and

shall keep the Engineer’s Representative fully informed of the state of deliveries. The

Contractor shall carry out, at his cost, all instructions of Engineer or his

Representative for proper unloading, preservation, maintenance, storage and security

of materials delivered to Site until he fulfills all his obligations under the Contract.

 The Contractor shall erect and maintain on the Site any temporary storage facility as

required and approved by the Engineer.

 Multiple handling and movement of materials during storage and retrieval shall be

6.0 Spare Parts:

 Spare Parts required after the taking over the Plant shall be filled up by the bidder in

 Spares during pre-commissioning trials, commissioning tests/maintenance, guarantee

etc. shall be provided by the Contractor. The necessary spares shall be brought by the

Contractor prior to the pre-commissioning test so as to avoid the downtime of

equipment due to non-availability of them. All these spares have to be provided as

required, by Contractor free of cost.

 All spare parts shall be new, unused and strictly interchangeable with the parts for

which they are intended to be replacements and shall be treated and packed for long

storage under the climatic conditions prevailing at the site. Each spare part shall be

clearly marked or labeled on the outside of its packing with its description, number

and purpose. When more than one spare is packed in a single case or other container,

a general description of its contents shall be shown on the outside of such case or

container and a detailed list enclosed. All cases, containers and other packages shall

be marked and numbered in an approved manner for the purpose of identification.

Spares shall be delivered to Site after the completion of erection but before start of

commissioning of Plant along with technical leaflets and details. Spare parts shall be

indicated in the assembly drawing showing clearly the part numbers.

 All cases, containers or other packages are liable to be opened for such examination as

the Engineer’s Representative may require and packing shall be designed to facilitate

opening and thereafter re-packing. In the event of some specific spares offered in the

Contract being withdrawn from manufacture owing to changes in design of equipment

or similar reasons viz., model being obsolete etc., the Contractor shall inform the

Employer before such withdrawal so that the Employer can take timely alternative

 Tools shall be delivered to site just prior to Tests on Completion.

 The specified tools shall not be used for the erection of the Plant being supplied and

except that the Engineer may call upon the Contractor to demonstrate their use or

effectiveness, they must be handed over to the Employer in a completely new and

unused condition. Should the Contractor require any such tools at site for erection, he

shall provide his own.

 The test equipment shall include special purpose items essential to the testing or re-

calibration of related items of Facilities.

MATERIALS AND WORKMANSHIP:

1.0 Introduction:

 This part of the Specification sets out the general standards of materials to be supplied

and the workmanship required to be ensured by the Contractor. All component parts of

the works shall, unless otherwise specified, comply with the provisions of employer’s

requirement or be subject to the approval of the Employer.

 Particular attention shall be paid to a neat, orderly and well-arranged installation carried

out in a methodical competent manner.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

2.0 Reference Specifications and Standards:

 Where reference is made in the Specification to a British Standard Specification

(hereinafter abbreviated to `B.S’) issued by the British Standards Institution of 2, Park

street, London W.I., or to an Indian Standard Specification (I.S.) issued by the Bureau of

Indian Standards, (earlier known as Indian Standard Institution), Manak Bhavan,

Bahadur shah Zafar Marg, New Delhi 110 002, or American Society for Testing and

materials (ASTM) issued by ASTM 1916 Race Street, Philadelphia, P.A., 19103, U.S.A. or

American national Standards Institute (ANSI) issued by ANSI 1430, Broadway, New York,

N.Y., 10018, U.S.A. or Japanese Industrial Standards (JIS) issued by Japanese Standards

Association, 4-1-24, Alaska, Minato-Ku, Tokyo 107, Japan or to any other equivalent

Standard it shall be to the latest revision of that Standard on the Tender opening date.

 The Contractor may propose at no extra cost to the Employer, the use of any relevant

authoritative internationally recognized Reference Standard.

 All details, materials and utensils supplied and workmanship performed shall comply

with the specified Standards. If Tenderer offers equipment to other Standards, the

equipment/material should be equal or superior to those specified and full details of the

difference shall be supplied.

 In the event of conflict between this Specification and the Codes for equipment,

provisions of this Specification shall govern. Certain specifications issued by national or

other widely recognized bodies are referred to in this Specification. In referring to the

Standard Specifications the following abbreviations are used:

IS: Indian Standard

ANSI: American National Standards Institute

API: American Petroleum Institute

ASME: American Society of Mechanical Engineers

ASTM: American Society of Testing and Materials

AWS: American Welding Society

AWWA: American Water Works Association

ISO: International Organization for Standardization

DIN: Deutsches Institute fur Normung

BS: British Standard

IEC: International Electro technical Commission

IEE: Institution of Electrical Engineers

IEEE: Institute of Electrical and Electronic Engineers

NEMA: National Electrical Manufacturers Association

AGMA: American Gear Manufacturer’s Association

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

3.0 Materials – General:

 All materials incorporated in the Works shall be the most suitable for the duty

concerned and shall be new and of reputed make/approved quality, free from

imperfections and selected for long life and minimum maintenance. Non-destructive

tests, if called for in the specification, shall be carried out. All submerged moving parts

of the Plant, or shafts and spindles or faces etc. in contact with them shall be of

corrosion resistant materials. All parts in direct contact with various chemicals, shall be

completely resistant to corrosion, or abrasion by these chemicals, and shall maintain

their properties without aging due to the passages of time, exposure to light or any

4.0 Workmanship – General:

 Workmanship and general finish shall be of first-class quality and in accordance with

best workshop practice.

 All similar items of the Plant and their component parts shall be completely

interchangeable. Spare parts shall be manufactured from the same materials as the

originals and shall fit all similar items.

 All parts, which can be worn or damaged by dust, shall be totally enclosed in dust

proof housings. All materials incorporated in the Works shall be the most suitable for

the duty concerned, free from imperfections and selected for long life and minimum

maintenance. All necessary accessories required for satisfactory and safe operation of

the Plant shall be supplied by the Contractor unless it is specifically excluded from his

scope. Suitable provision by means of eyebolts or other means are to be provided to

facilitate handling of all items that are too heavy or bulky for lifting and carrying by

 Welding shall comply with the latest revision of the BS 5135 Code.

 Welders shall be qualified in accordance with the requirement of the appropriate

section of BS 4871. The Engineer shall have the right to call for further qualification

from time to time from any welder who in the opinion of the Engineer does not produce

weld in accordance with the qualification. Each welder shall be assigned a number and

letter. Each welding elements shall clearly be identified as to its welder marking the

welder’s Code adjacent to the welds. A record chart shall be maintained for each

welder showing the procedures, for which he has qualified, the date of such

qualification, the type of defects produced and their frequency. The Engineer shall

disqualify the welder whose Work requires a disproportionate amount of repairs. All

procedures where required shall be qualified as per BS EN 283-3.

 Inspection and quality of surveillance shall not be limited to the examination of finished

welds. The techniques employed shall be based on methods which are known to produce

good results and which have been verified at Site by actual demonstration.

 Haphazard striking of the electrodes for establishing an arc shall not be permitted. The

arc shall be struck either on the joint or on a starting tag. The starting tag shall be of

the same material or a material compatible with the base metal being welded. In case

of any inadvertent strike on place other than the welding, the area affected shall be

ground flushed and examined by liquid penetration method.

 Generally, a stringer bead technique shall be used with a slight oscillation of necessary

to avoid slag and to minimize the number of beads needed to fill exceed 3 times the

wire diameter. Vertical welds shall be made in upward direction. For all pipes above

300 mm dia., welding shall be done whenever possible, by 2 welders working

simultaneously along both sides of the pipe.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 The root pass shall have less than 1.5 mm internal reinforcement. Defects like icicles,

burn through and excessive “such back”, etc. shall be cause for rejection of welds.

 Final welds shall be suitable for appropriate fabrication of the non-destructive

examination of the weld. If grinding is necessary, the weld shall be blended into the

parent metal without gouging or thinning of the parent metal in any way. Uneven and

excessive grinding may be a cause for rejection. Fillet weld shall preferably be convex

and free from undercutting and overlap at the toe of weld. Convexity and concavity

shall not exceed 1.5 mm. The leg lengths shall not exceed the specified size by more

 All attachments such as lugs, brackets and other non-pressure parts shall also be done

by qualified welders in accordance with the design details and materials specifications.

Temporary attachments shall be removed in a manner that will not damage the parent

metal. Areas of temporary attachments shall be dressed smooth and examined by

ultrasonic or liquid penetration methods.

 All tack welds shall be made using qualified procedure and welders, the number of sizes

of tack welds shall be kept as small as to consist of adequate strength and joint

alignments. All tack welds shall be examined visually for defects and if found defective

shall be completely removed. As welding proceeds, tack welds shall be either removed

completely or shall be properly prepared by grinding or filling their starting ends so that

they may be satisfactorily incorporated in the welds. Unacceptable defects shall be

removed by grinding machine or chipping or gouge. Flame gouging may be permitted

provided gouged surfaces are ground at least by 1.0 mm below the deepest indentation.

 All weld repairs shall be carried out using the approved welding procedures and

welders. Re-welded areas shall be re-examined by the methods specified for the original

welds and the Engineer’s Representative shall duly qualify repair procedures.

6.0 Pre-heating and Post-Heating Treatment:

 Pre-heating and post heating treatment shall conform to the relevant application

Codes. Pre-heating not exceeding 121 deg. C for all carbon steel construction above

mm thickness would be mandatory. Such pre-heating would be maintained during

flame cutting, flame or arc gouging, welding and repairs and may be done by gas

heating by gas torches/gas rings with neutral flame. The temperature shall be checked

by temperature indicating crayons. However, such pre-heating will not be necessary

for welds less than 6 mm size. In large diameter pipe fabricated out of plate materials,

production control test plates in accordance with the BS 4870-part 1 Table 6 to

represent 30% of the long seams and each welder’s performance would be mandatory.

7.0 Electrodes:

 All electrodes shall be stored in their original sealed containers under dry conditions.

Electrodes shall remain identified until consumed. All electrodes shall be dried before

use. Drying ovens shall be provided in Work areas for drying purposes. Electrodes

withdrawn from oven shall be promptly used and excess unused electrodes shall be

promptly returned to oven.

8.0 Examination/NDT/Radiography

 The various stages of examination and types shall be as stipulated in the respective

fabrication Codes. Radiographic examination shall be carried out as per provisions of

BS 2600 or BS 2910; Ultrasonic tests where called for shall be carried out as per

provisions of BS 3926; magnetic particle tests shall be carried out as per BS

Liquid penetration tests shall be carried out as per BS

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

9.0 Stainless Steel Welding:

 All welding consumable such as electrodes, filler weirs, argon gas for shielding and

purging shall be of high quality and the proposed brand shall be furnished for approval

of the Engineer. Weld deposits shall have similar or higher physical properties and

similar chemical composition to the members joined.

 All electrodes shall be purchased in sealed containers only and stored in their packing

intact. The packets opened shall be consumed as early as possible. The electrodes

removed from the containers shall be kept in holding ovens at temperatures

recommended by electrode manufacturer. Special care shall be taken in avoiding

mixing of electrodes in the oven. The electrodes and filling wires shall be free from

rust, oil, grease, earth and other foreign matter.

 Argon gas with purity 99.5% shall be used for shielding and purging. The purity of gas

shall be certified by the gas manufacturers.

 Non-destructive examination of the welds shall be carried out to ensure quality of

 The electric current for welding shall be direct current, straight polarity (electrode

negative). The welding current shall be kept minimum possible to ensure minimum

heat affected zone in the parent material. Other side of the weld joint shall be

periodically flushed with argon gas.

 Cast iron shall be of standard grey close-grained quality. The structure of the castings

shall be homogeneous and free from non-metallic inclusions and other injurious

defects. All surfaces of castings, which are not machined, shall be smooth and shall be

carefully fettled to remove all foundry irregularities.

 Minor defects in depth not exceeding 12.5 percent of total metal thickness and which

will not ultimately affect the strength and serviceability of the casting may be

repaired by approved welding techniques. The Engineer shall be notified of large

defects and no repair welding of such defects shall be carried out without prior

approval of the Engineer. If the removal of metal for repair should reduce the stress

resisting cross section of the casting by more than 25 percent, or to such an extent

that the computed stress in the remaining metal exceeds the allowable stress by more

than 25 percent, then casting shall be rejected. Test coupons cast simultaneously with

the main castings shall be identified to check physical, chemical analysis of casting.

Major defects on casting are not acceptable. Castings repaired by welding for minor

defects shall be stress-relieved after such welding. Non-destructive tests as directed

by the Engineer will be required for any casting containing defects whose extent

cannot otherwise be judged, or to determine where repair welds have been properly

 All major stress-bearing forging shall be made to a Standard Specification. Forging

shall be subjected to magnetic particle testing or dye penetration test at the areas of

fillets and change in section. The testing shall be conducted after rough machining (10

microns). Any defect, which will not machine out during the final machining, will be

gouged out fully, inspected by dye penetration or magnetic particle inspection to

ensure that the defect is fully removed and repaired using an approved repair

procedure. Any indication, which proves to penetrate deeper than 2.5% of the finished

thickness of the component, shall be reported to the Engineer giving the details like

location, length, width and depth. For the magnetic particle inspection, the choice of

wet or dry particles shall be at the Contractor’s discretion.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 All forging shall be demagnetized after test and shall be heat-treated for the relief of

residual stresses.

12.0 Design Life:

 The Works as a whole shall be new, of sound workmanship, robustly designed for a

long reliable operating life and shall be capable of 24 hours per day continuous

operation for prolonged period in the climatic and working conditions prevailing at the

site, and with the minimum of maintenance. Particular attention shall be given to

temperature changes, the stability of paint finish for high temperatures, the rating of

engines, electrical machinery, thermal overload services, cooling systems and the

choice of lubricants for possible high and prolonged operating temperatures. The

Contractor shall be called upon to demonstrate this for any component part either by

service records, or evidence of similar equipment already installed elsewhere or

relevant type tests. Routine maintenance and repair shall as far as possible not

requires the services of highly skilled personnel.

 The Plant shall be designed to provide easy access to and replacement of component

parts, which are subject to wear, without the need to replace whole units. No parts in

contact with water shall have a life from new to replacement or repair of less than

 Design features shall include the protection of Plant against damage caused by vermin,

dirt, dust and dampness and to reduce risk of fire. Plant shall operate without undue

vibration, and parts shall be designed to withstand the maximum stresses under the

most severe condition of normal service. Materials shall have a high resistance to

change in their properties due to the passage of time, exposure to light, temperature

and any other cause, which may have a detrimental effect upon the performance or

life of the Works.

 Plant located outside lockable areas/building shall have additional features to prevent

un-authorized operation.

 Design shall be carried out as per following:

RCC footings: Limit state method of design

RCC columns: Limit state method of design

RCC beams and slabs: Limit state method of design

Retaining wall: Limit state method of design with limiting crack width of 0.2mm as per

Also provide the seismic design calculation of RCC Water retaining structures as per

IS:1893 (Part – II, Draft Code).

Steel Structures: Limit state/Working Stress method of design.

RCC water retaining structure shall be designed as per Working Stress Method as per IS :

Seismic Zone for Civil Structures as per IS 1893 :

RCC structures shall be designed as per IS 456 and reinforcement details shall be done as

per IS : 13920 (Ductile detailing).

 Foundation shall be designed to carry all the loads from equipment or super structure,

which they support in accordance with the relevant codes.

Net safe bearing capacity of soil & Ground water table: As per geo-technical report

Type of foundation.

For buildings and structures: As per geo-technical report

Allowable increase in soil bearing capacity in event of storm(wind) 25%, Earthquake

25%,factor of safety as per IS 1904 against overturning 1.5, Sliding 1.5, and buoyancy

As a general rule following features will be adopted, unless decided otherwise in a

specific or exceptional case:

Top of footing will be horizontal and flat/Trapezoidal as case.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

Minimum depth of foundation is considered as per latest geotechnical report for

locations of the proposed structure.

Foundation plinth for structural columns and equipment supports shall extend not less

than 5 mm from the edge of base plate.

The clear distance between a standard mild-steel anchor bolt or anchor sleeve and the

face of the foundation shall be not less than 75 mm.

Minimum thickness of lean concrete layer shall be 100 mm for building and 150 mm for

retaining structure, also extend 75 mm beyond the foundation edge.

For heavier loads and restricted settlements pile foundation may be considered as an

alternative as per IS

Wherever columns are very near pedestals of footing are considered combined to take

unbalance loading. Sufficient reinforcement is provided to take care of unbalancing

Centre of footing and combined loading is match to nullify eccentricity in load.

Where stresses due to wind (or seismic) and temperature are combined with those due

to other loads, the allowable stresses in concrete and reinforcement steel shall be

increased by 33.33% in case of working stress design. However steels having definite

yield stress, stress limited to yield stress, for steels without definite yield point, the

stress will be limited to 80 percentage of ultimate strength or 0.2 percent proof stress

whichever is smaller.

All building shall have a minimum 1.0 m wide, 100 mm thick plinth protection paving

grade concrete or stone slabs/tiles. All plinth protection shall be supported on well

compacted strata.

HFL of nearby dam & NGL shall be checked before finalizing the uplift pressure.

Contractor shall take HFL data from concerned authority & FGL shall be considered as

1.0 mt. above HFL.

If the compound wall is in contact with HFL/ FSL/ permanent water logged area than

RCC compound wall shall be designed as Retaining wall.

 All underground or partly underground liquid containing structures shall be designed

for the following conditions:

Liquid depth to be considered up to full height of wall and no relief due to soil pressure

from the other side to be considered.

i. RCC water retaining structures like storage tanks shall be leak proof and designed by

working stress method. (Stress in steel limited to 130 N/mm2) or limit state method

with limiting crack width 0.1 mm.

ii. Structure empty condition (i.e., empty of liquid, any material, etc.) : full earth

with saturation and surcharge pressure wherever applicable, to be considered.

iii. Partition wall between dry sump and wet sump: to be designed for full liquid depth

full height of wall.

iv. Partition wall between two compartments: to be designed as one compartment

and the other full for both the directions.

v. Structures shall be designed for uplift in empty conditions with no live load with the

water table as per Geotechnical report or high flood level or rock level, whichever is

maximum. If uplift pressure is more than 2000 Kg/m2, use of pressure relief valves to

reduce uplift pressure due to ground water table shall be allowed. In this case

minimum thickness of raft shall with provision of under drainage arrangement (as per IS

4558) be kept as per below para viii.

vi. Walls shall be designed under operating conditions to resist earthquake forces from

earth pressure mobilization and dynamic water loads.

vii. Underground or partially underground structures shall also be checked against

stresses developed due to any combination of full and empty compartments with

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

appropriate ground/uplift pressures from below to base slab. A minimum factor of

shall be ensured against uplift or floatation and due to other loads shall be 1.5.

 The minimum clear cover to reinforcement in all R.C.C structures shall be as per IS:

456/IS: 3370 (Part –II), except as mentioned for following:

1. The following minimum clear cover shall be provided for RCC (non-Water retaining)

2. Face in contact with earth 50 mm

3. Free face 50 mm

id retaining structures

4. Face in contact with liquid 50 mm

5. Away from liquid but in contact with earth 50 mm

6. Sides and top 50 mm

7. Bottom 60 mm

13.0 Name Plate:

 Each item of the Plant shall have permanently attached to it in a conspicuous position,

a nameplate and rating plate. Upon these shall be engraved or stamped, the

manufacturer’s name, type and serial number of Plant, details of the loading and duty

at which the item of Plant has been designed to operate, and such diagrams as may be

required by the Engineer. All indicating and operating devices shall have securely

attached to them or marked upon them designations as to their function and proper

 Nameplates, rating plates and labels shall be of a non-flame propagating material,

either non-hygroscopic or transparent plastic with engraved lettering of a contrasting

colour. Fixing shall be by means of non-corrosive screws; drive rivets or adhesives shall

 Warning labels shall be provided where necessary to warn of dangerous circumstances

or substances. Inscriptions or graphic symbols shall be black on a yellow background

circumstances or substances. Inscriptions or graphic symbols shall be black on a yellow

 Instruction labels shall be provided where safety procedures such as wearing of

protective clothing are essential to protect personnel from hazardous or potentially

hazardous conditions. These labels shall have inscriptions or graphic symbols in white

on a blue background.

14.0 Nuts, Bolts, Studs and Washers:

 Nuts, bolts, studs and washers for incorporation in the Plant shall conform to the

requirements of the appropriate standard. Nuts and bolts shall be of the best quality

of specified grade, machined on the shank and under the head and nut.

 Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the

screwed portion of such a diameter that it will not be damaged in driving and shall be

marked in a conspicuous position to ensure correct assembly at Site.

 Washers, locking devices and anti-vibration arrangements shall be provided where

necessary Jointing hardware for the entire Plant shall be provided with sufficient

spares to cater for site losses.

 Where bolts pass through structural members taper washers shall be fitted, where

necessary, to ensure that no bending stress is caused in the bolt. Where there is a risk

of corrosion, bolts, nuts and studs shall be designed so that the maximum stress does

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

not exceed half the yield stress of the material under any conditions. All bolts, nuts

and washers that are subject to frequent adjustment or removal in the course of

maintenance and repair shall be made of nickel-bearing stainless steel.

 The Contractor shall supply all holding down, alignment and leveling bolts complete

with anchorages, nuts, washers and packing required to attach the Plant to its

foundations, and all bed plates, frames and other structural parts necessary to spread

the loads transmitted by the Plant to concrete foundations without exceeding the

design stresses.

15.0 Allowances for Wastage:

 The Contractor shall supply reasonable excess quantities to cover wastage of those

consumable, which will be normally subject to waste during erection, commissioning

and setting to Work.

16.0 Painting – General:

 The Contractor shall be responsible for the cleaning, preparation for painting, and

priming or otherwise protecting, as specified, all parts of the Plant at the place of

manufacture prior to packing.

 Parts may be cleaned but surface defects may not be filled in before testing at the

manufacturer’s works. Parts subject to hydraulic test shall be tested before any

surface treatment. After test, all surfaces shall be thoroughly cleaned and dried out, if

necessary by washing with an approved de-watering fluid prior to surface treatment.

Except where the specification provides to the contrary all painting materials shall be

applied in strict accordance with the paint manufacturer’s instructions.

 All protective coatings shall be suitable for use in warm humid climates. All primers,

under coats and finishes shall be applied by brush or airless spray, except where

otherwise specified. Consecutive coats shall be in distinct but appropriate shades. All

paints shall be supplied from the store to the painters, ready for application, and

addition of thinners or any other material shall be prohibited.

17.0 Painting at Place of Manufacture:

 Steel and cast-iron parts shall be sand blasted to near white cleaning before painting.

Edges, sharp covers etc. shall be ground to a curve before sand blasting. A primer coat

of a zinc rich epoxy resin-based coating with at least 75 microns’ dry film thickness is

to be provided. In addition, the parts are to be provided with adequate number of

coats of coal tar epoxy polyamine coating to a dry film thickness of 175 microns

including primer coating.

18.0 Painting at Site:

 Immediately on arrival at the site, all items of Plant shall be examined for damage to

the paint coat applied at the manufacturer’s works, and any damaged portions shall be

cleaned down to the bare metal, all rust removed, and the paint coat made good with

 After erection, such items, which are not finish painted, shall be done so and, items

that have been finish painted at the manufacturer’s works shall be touched up for any

damaged paintwork. For finish painting, two coats of synthetic enamel conforming to

IS: 2932 shall be applied. Dry film thickness of each coat shall be at least 25 microns.

 The dry paint film thickness shall be measured by Electrometer or other instruments

approved by the Employer. In order to obtain the dry film thickness specified the

Contractor should ensure that the coverage rate given by the paint manufacturer

would enable this thickness to be obtained. Strength of adhesion shall be measured

with an adhesion tester and this value shall not be less than 10 kg/cm2. Painted

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

fabricated steel work which is to be stored prior to erection shall be kept clear of the

ground and shall be laid out or stacked in an orderly manner that will ensure that no

water or dirt can accumulate on the surface. Suitable packing shall be laid between

the stacked materials. Where cover is provided, it shall be ventilated.

19.0 Galvanizing:

 Wherever galvanizing has been specified the hot dip process shall be used. The

galvanized coating shall be of uniform thickness. Weight of zinc coatings for various

applications shall not be less than those indicated below:

a) Fabricated steel :

Thickness less than 2 mm but not less than 1.2 mm - 340 gms/sq.m

Thickness 2 mm and above - 460 gms/sq.m

Up to nominal size M10 - 270 gms/sq.m

Over M10 - 300 gms/sq.m

 Galvanizing shall be carried out after all drilling; punching, cutting, bending and

welding operations have been carried out. Burrs shall be removed before galvanizing.

Any Site modification of galvanized parts should be covered well by zinc rich primer

and aluminum paint.

20.0 Support for Pipe work & Valves:

 All necessary supports, saddles, sling, fixing bolts & foundation bolts shall be supplied

to support the pipe work. Valve and other facilities mounted in the pipe work shall be

supported independent of the pipes to which they connect.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

INSPECTION AND TESTING AT MANUFACTURER’S PREMISES

1.0 Inspection and Tests:

1.1.1 During testing there shall be no visible evidence of structural damage to any of the

valve component.

1.1.2 Motorized valves shall be tested with their actuators, with a differential head

equivalent to their maximum working pressure, to prove that the actuators are

capable of opening and closing the valves under maximum unbalanced head condition

within the specified opening or closing period.

1.1.3 The following test shall be carried out for sluice valves:

a) Seat leakage test at rated pressure

b) Hydrostatic test at 1.5 times the rated pressure

c) Valve operation

1.1.4 The following test shall be carried out for non-return valves:

a) Seat leakage test at rated pressure

b) Body hydrostatic test at 1.5 times rated pressure

1.2.1 Testing of pipes and fitting shall be carried out in accordance with relevant Indian

Standard and internationally approved standard. Pipes, fittings and expansion

bellows shall be hydrostatically tested for 1.5 times the rated pressure.

1.4 Equipment/material for testing:

Equipment required for testing of all construction materials such as sieve analysis,

cone for slump, concrete cubes casting and testing machine shall be available on

site. All construction materials like sand, cement, aggregate etc. have to be tested

on site in representative of engineer in-charge.

Testing of steel bars are to be installed at site or shall be tested in

Government/NABL approved laboratory or as directed by engineer in-charge.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

SECTION:2 SURVEY & GEOTECHNICAL INVESTIGATION FOR

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

Specifications for Minimum Investigations required for Project:

1.0 Survey and Soil Exploration:

 To plan out and obtain pre-approval and subsequently carry out Topographic and level

Survey, preparing cross sections, Longitudinal sections, Soil exploration to obtain

foundation design data at various locations for all the components listed in preamble on

previous page, complete all as per general pre-approved plan and as per detailed

description and specifications and including submitting survey, soil exploration and

analysis reports in six copies along with two soft copies and getting the same approved

by the engineer in charge.

 Work consists of providing all equipment, materials, labour etc. to carry out survey, to

provide permanent markers of various points for later use, to create permanent bench

mark of approved design and approved location on the site, to carry out soil exploration

to obtain information for foundation design as well as collecting data to determine

various design parameters, to collect all data, prepare interim and final reports for

submission and approval of the Engineer in-charge, all as per detailed description,

specifications and as directed by the Engineer in-charge.

 It must be clearly understood that the data furnished with the tender and suggested

procedure for survey and soil exploration are purely for general guidance of the bidders

for selecting the best design criteria. The contractor is expected to carry out additional

work if it becomes necessary in the process of selecting appropriate criteria. In any case

responsibility of assuring the guaranteed water supply will fully rests with him.

2.0 Work Description:

 Work under this item involves survey, soil exploration and investigation as described

below. Survey maps and all interim as well as final reports of soil investigation, other

tests as well as the reporting of final tests shall be submitted in six paper copies as well

as two soft copies and these will form part of a permanent record of the project for use

during construction, operation, and maintenance stages as well as for future use. All

below mentioned work shall be all inclusive and will be carried out as per detailed

specifications and as directed by the Engineer in-charge.

 Survey and soil investigation shall be completed within one & half month. In case after

delay of 15 calendar days the department will get completed the work from

departmental agency at the risk and cost of the contractor which shall be binding to the

3.0 Survey work shall consist of the following:

 To carry out Block level survey based on GTS benchmark, prepare longitudinal section

along alignment of all types of pipeline and prepare contour survey of the allotted plot

of land and the river bed of the width of 100m – 50m on either side - of the suggested

center line of the alignment, and prepare contour maps to a scale of 1:500 or larger.

Survey in the river may be carried out with help of sounding technique or long metallic

rod inserted in water from the boat. All the levels/ distance may be measured with help

of total station or DGPS.

 Selecting most appropriate location (on the basis of survey) to determine various

geotechnical parameters for carrying out design of various components shall be

responsibility of the contractors and it shall be carried out by laboratory approved by

GOG acceptable to GWIL.

 Above survey shall be carried out in stages as and when required, using the latest

equipment like TOTAL STATION or DGPS with high accuracy. In case dumpy level/ auto

level is used, then fly back as well as closing error must be performed without which

survey will be considered as NOT completed. All levels will be based on GTS, and the

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

work shall include transferring level from a reliable established GTS benchmark in the

vicinity of the site of work and establishing a permanent bench mark on site at a

suitable location as per approved design and location. Above survey will be carried out

jointly with the representative of the owner, as per his convenience during day time.

 Detailed Longitudinal Section for each pipe shall be prepared and HGL marked on it for

approval of GWSSB. After marking of such data only, execution of pipeline shall be

 Detailed contour plan of the headwork/ sub headwork etc. prepared with interval of

m so as to determine position of various units.

Soil exploration work for intake, RCC and framed structures, underground sumps, Pump

Houses (positive/ negative suction) shall consist of the following:

 150 mm bores or more diameters (Minimum one no per unit/ structure) will be made to

collect information for the foundation design of the intake well, approach bridge

supports, underground sump, Pump House, other structures. Minimum depth of bores

from the existing level at the location of proposed sump 12 m depth, and pump house

m depth, or more as per requirement of structural design. Disturbed and undisturbed

soil samples will be collected, and grain size analysis by dry sieving/Wet analysis,

determination of liquid/plastic limit and other necessary tests like C value, N value, Ø

value and important parameters to carry out structural design and facilitate execution

of structures shall be carried out. All levels including ground level of the bore point,

levels of various strata and water levels etc. will be noted in reference to GTS.

4.0 Specification for drilling, investigation, furnishing details of bore logs, laboratory testing

 The investigation bores shall be made by percussion method and not by rotary method.

No bentonite slurry or drilling mud shall be used. The bores shall be cased when it is to

be done in sandy and silty strata.

 The quantity of boring mentioned in work description is approximate and likely to vary

materially if investigating alternative location of Infiltration Well becomes necessary.

Any change in the quantity of boring work shall not entitle the contractor for any claim

or compensation. His rates shall be deemed to cover such an eventuality.

 The disturbed samples shall be collected at every 1.5 Mt. Depth or at the points where

the strata changes whichever is less.

 The samples so collected shall be preserved in systematic manner in core boxes, when

the bore is in progress. After the bore is completed, each of the samples shall be

packed in two separate poly thin bags with contents of approx. 0.5 Kg and properly

numbered giving other details so as to identify the position to which the samples

represent. All other details such as the bores Sr. Nos., the depth from which the

samples are taken etc. should be clearly given with the samples.

 Out of the two sets of samples collected for every bore one set of samples with all

requisite details shall be sent to the laboratory for testing and the second set of

samples together with requisite details shall be supplied to the clients in their office for

record. The casing pipes shall be removed after above compliance and with the

approval of the Engineer in-charge. The recovered samples shall be tested in the

laboratory for grain size analysis and Atterberg’s limits to identify the samples in

accordance with the provision in IS.1498, 1971. The testing of samples shall have to be

done at the recognized laboratory approved by the engineer-in charge.

 The drilling shall be terminated at approx. 2.0 Mts. below the impervious (e.g. clay)

strata, when bores are being made primarily to find the level of impervious strata. And

if the samples collected indicate the soil being predominantly clayey further drilling

shall be discontinued. In sandy strata including sand with gravels and small size

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

boulders, Bores shall be extended at least up to 15 Mts. below bed level or low water

level whichever is lower, however if required by Client /Consultants, the bores may

have to be carried further.

 Where bores are required to be done in water channel in river/ nallah bed, necessary

island/islands shall be prepared in sand or sand filled gunny bags. The cost of which

shall be covered within the rates quoted.

 The rates quoted shall be inclusive for drilling in all kinds of strata including boulders,

soft or hard rock.

 For every bore water level encountered shall be recorded together with variation in

water level if during the period of boring.

 All levels shall be with reference to the GTS Bench Hark. For this purpose, a pucca GTS

Bench mark shall be established in the region of proposed survey and investigation area.

 The readings are to be recorded and observations are to be submitted with the reports

in the format as per prosoma 1 and 2 shown below. The Contractor shall prepare bore

charts for each and every bore in the approved manner and Performa as required by

 The disturbed samples are to be analyzed as per relevant clause of I.S. 2720 Part I to IV.

 The water samples of water pumped out during pump test shall be collected and

analyzed covering requirements of I.S. 10500 to establish its portability and the results

of the chemical and other tests submitted in the format shown in Performa

 A Technical report covering the observations and tests is to be submitted to the client

with the contractor’s recommendations for selecting the most suitable site for the

Radial well which could give the desired yield. The site for location of the pumping test

shall be finalized in consultation with the clients before the work of pumping test

including necessary boring work for the same is taken up.

5.0 Specification for preparing and submitting the full technical report:

 The survey work shall be carried out with proper accuracy and permanent Bench Marks

shall be established at points which are approved by the Engineer in-charge. Also,

sufficient number of permanent identification marks shall be established on the bank to

enable establishment of base lines and the survey map to be included in the report shall

contain sufficient details with respect to these permanent marks to enable the

contractor to relocate the soil investigation bores as well as pump well and piezometric

bores positions.

 Based on the soil investigation carried out, a contour map of the area investigated

showing the soil strata shall be prepared and included in the technical report.

 The soil investigation work shall be carried out as per specifications and information

will be recorded in the format given in attached Performa 1 and

 The short chemical analysis of water samples shall be carried out as per I.S. 10500 and

results reported in format given in attached Performa

 The Performa included in the tender are only for guidance and by no means are they to

be considered as the only ones required for reporting the investigation. Additional

information which is considered necessary shall be collected and recorded

systematically in proper format to arrive at the relevant conclusions.

 Using these parameters discharge shall be calculated for different water levels of the

river, and the report shall make definite recommendations as regards to the number of

radials, their levels, and their lengths required to obtain the desired yield.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

Bore hole no. Date of start Date of comp. GTS value Revision no.

Penetration test

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

Bore Date of Date of Termination depth Revision no.

hole no. start comp.

Depth of Grain size analysis

% Gravel % sand Hydrometer LL% PL% PI%

PERFORMA 3: CHEMICAL ANALYSIS OF WATER

Date of arrival Location Village:

Sr. Characteristics Permissible value as per IS

Desirable Relaxation in absence Analytical value

of alternate source

4 Dissolved solids

6 Total hardness as CaCO3

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

SECTION:3 CONCRETE

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

SECTION -3: CONCRETE

1.0 Applicable Codes with latest revisions.

 IS.269 Specification for 33 grade ordinary Portland cement.

 IS.455 Specification for Portland slag cement.

 IS.1489 Specification for Portland- Pozzolana cement (Part 1&2).

 IS:8112 Specification for 43 grade ordinary Portland cement.

 IS:12269 Specification for 53 grade ordinary Portland cement.

 IS:12330 Specification for sulphate resisting Portland cement.

 IS:383 Specification for coarse and fine aggregates from natural sources for

 IS:432 Specification for mild steel and medium (tensile steel bars and hard-drawn

steel) wires for concrete reinforcement. (Part 1 and 2)

 IS:1786 Specification for high strength deformed steel bars and wires for Concrete

 IS:1566 Specification for hard-drawn steel wire fabric for concrete Reinforcement.

 IS:9103 Specification for admixtures for concrete.

 IS:2645 Specification for integral cement water- proofing compounds.

 IS:4990 Specification for plywood for concrete shuttering work.

2.0 Material Testing:

 IS.4031 Methods of physical tests for hydraulic cement (Parts 1 to 15)

 IS:4032 Method chemical analysis of hydraulic cement.

 IS:650 Specification for standard sand for testing of cement.

 IS:2430 Methods for sampling of aggregates for concrete.

 IS: 2386 Methods of test for aggregates for concrete (Parts 1 to 8)

 IS:3025 Methods of sampling and test (physical and chemical) for water used in industry.

 IS:6925 Methods of test for determination of water-soluble chlorides in Concrete

3.0 Material Storage:

 IS:4082 Recommendations on stacking and storing of construction Materials at site.

4.0 Concrete Mix Design:

 IS:10262 Recommended guidelines for concrete mix design.

 SP:23 (S&T) Handbook on Concrete Mixes

5.0 Concrete Testing:

 IS.1199 Method of sampling and analysis of concrete.

 IS:516 Method of test for strength of concrete.

 IS:9013 Method of making, curing and determining compressive strength of accelerated

cured concrete test specimens.

 IS:8142 Method of test for determining setting time of concrete by Penetration

 IS:9284 Method of test for abrasion resistance of concrete.

 IS:2770 Methods of testing bond in reinforced concrete.

 IS:1791 Specification for batch type concrete mixers.

 IS:2438 Specification for roller pan mixer.

 IS:4925 Specification for concrete batching and mixing plant.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 IS:5892 Specification for concrete transit mixer and agitator.

 IS:7242 Specification for concrete spreaders.

 IS:2505 General Requirements for concrete vibrators: Immersion type.

 IS:2506 General Requirements for screed board concrete vibrators.

 IS:2514 Specification for concrete vibrating tables.

 IS:3366 Specification for pan vibrators.

 IS:4656 Specification for form vibrators for concrete.

 IS:11993 Code of practice for use of screed board concrete vibrators.

 IS:7251 Specification for concrete finishers.

 IS:2722 Specification for portable swing weigh batchers for concrete (Single and double

 IS:2750 Specification for steel scaffoldings.

7.0 Codes of Practice:

 IS:456 Code of practice for plain and reinforced concrete.

 IS:457 Code of practice for general construction of plain and reinforced Concrete for

dams and other massive structures.

 IS:3370 Code of practice for concrete structure for storage of liquids (Part 1 to 4).

 IS:3935 Code of practice for composite construction.

 IS:2204 Code of practice for construction of reinforced concrete shell roof.

 IS:2210 Criteria for the design of reinforced concrete shell structures and Folded Plates.

 IS:2502 Code of practice for bending and fixing of bars for concrete Reinforcement.

 IS:5525 Recommendation for detailing of reinforcement in reinforced Concrete works.

 IS:2751 Code of practice for welding of mild steel plain and deformed bars used for

reinforced concrete construction.

 IS:9417 Specification for welding cold worked bars for reinforced concrete construction.

 IS:3558 Code of practice for use of immersion vibrators for consolidating concrete.

 IS:3414 Code of practice for design and installation of joints in buildings.

 IS:4326 Code of practice for earthquake resistant design and construction of building.

 IS:4014 Code of practice for steel tubular scaffolding (Parts 1 & 2)

 IS:2571 Code of practice for laying in situ cement concrete flooring.

 IS:7861 Code of practice for extreme weather concreting: Part 1 Recommended practice

for hot weather concreting.

8.0 Construction Safety:

 IS: 3696 Safety code for scaffolds and ladders.

 IS:7969 Safety code for handling and storage of building materials.

 IS:8989 Safety code for erection of concrete framed structures.

 The Engineer in charge shall have the right at all times to inspect all operations

including the sources of materials, procurement, layout and storage of materials, the

concrete batching and mixing equipment and the quality control system. Such an

inspection shall be arranged and the Engineer in charge’s approval obtained, prior to

starting of concrete work. This shall however, not relieve the Contractor from any of his

responsibilities. All materials which do not conform to the Specifications shall be

 Materials should be selected so that they can satisfy the design requirements of

strength, serviceability, safety, durability and finish with due regards to the functional

requirements and the environmental conditions to which the structure will be

subjected. Materials complying with codes/standards shall generally be used. Other

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

materials may be used after approval of the Engineer in charge and after establishing

their performance suitability based on previous data, experience or tests.

10.0 Materials:

 Unless otherwise called for by the Engineer in charge, cement shall be ordinary Portland

cement/Sulphate resistant cement (As per instruction of engineer in-charge) conforming

to IS: 12269. However, in any case, cement grade shall not be lower than 53 grades.

 Fresh quality cement shall be procured only from approved manufacturer /Supplier and

shall be subject to prior approval of the Engineer-in-charge.

 All cement used for the work shall ordinary Portland cement of 53 grade only. Ordinary

Portland Cement shall comply with the requirements of the latest version of IS:

 Only one type of cement shall be used in a particular unit. The source of supply, type or

brand of cement within the same structure or portion thereof shall not be changed

without approval from the Engineer in charge.

 Cement which is not used within 90 days from its date of manufacture shall be tested at

a laboratory approved by the Engineer in charge and until the results of such tests are

found satisfactory, it shall not be used in any work.

 The white cement shall conform to I.S. 8042-1978.

Aggregates (General):

 Aggregates shall consist of naturally occurring stones (crushed or uncrushed), gravel and

sand. They shall be chemically inert, strong, hard, clean, durable against weathering, of

limited porosity, free from dust/silt/ organic impurities/deleterious materials and

conform to IS:383. Aggregates such as slag, crushed over burnt bricks, bloated clay ash,

sintered fly ash and tiles shall not be used.

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

the Engineer in charge.

 Aggregates containing reactive materials shall be used only after tests conclusively

prove that there will be no adverse effect on strength, durability and finish, including

long term effects, on the concrete.

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

 The maximum size of coarse aggregate shall be as stated on the drawings but in no case

greater than 1/4 of the minimum thickness of the member.

 Plums 160 mm and above of a reasonable size may be used in mass concrete where

directed. Plums shall not constitute more than 20% by volume of the concrete.

Grit shall be consist of machined crushed stone and shall be hard, strong, tough, dense,

durable, clean, of proper gradation and free from skin or coating likely to prevent

proper adhesion of mortar. Grit shall generally be cubical in shape and as far as possible

flaky elongated pieces shall be avoided. It shall generally comply with the provisions of

I.S. 383-2016. Grit shall be obtained from the best black trap. The grit shall have no

deleterious reaction with cement.

The grit shall conform to the following gradation as per sieve analysis:

I.S. Sieve % by weight passing I.S. Sieve % by weight passing

Designation sieve Designation sieve

Sand shall consist of natural sand, crushed stone sand or crushed gravel sand or

combination of any of these. The sand shall be clean, well graded, strong, durable and

gritty particles free from injurious amounts of dust, clay, kankar nodules, soft or flaky

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

particles, shale, alkali, salts, organic matter, loam, mica or other deleterious substances

and shall be got approved from the Engineer-in-charge. The sand shall not contain more

than 3% of silt as determined by field tests. If necessary the sand shall be washed to

 FM of sand used for different work:

Sr. No. Type of Work IS Code FM Range

1 For Cement concrete IS 383 zone-I & II 2.11 to

2 For Masonry IS 2116, Table:1 1.15 to

3 For plaster IS 1542 1.20 to

4 For sand bedding below pipe IS 383 zone-I & II 2.11 to

 Water to be used for both mixing and curing shall conform to IS:456. Potable water is

generally satisfactory. Water containing any excess of acid, alkali, sugar or salt shall not

 Water shall not be salty or brackish and shall be clean, reasonably clear and free from

objectionable quantities of silt and traces of oil and injurious alkalis, salts, organic

matter and other deleterious material, which will either weaken the mortar or concrete

or cause efflorescence or attack the steel in R.C.C. Container for transport, storage and

handling of water shall be clean.

 Water for curing mortar, concrete or masonry should not be too acidic or too alkaline. It

shall be free of elements, which significantly affect the hydration reaction or otherwise

interfere with the hardening of mortar or concrete during curing or those which produce

objectionable stains or other unsightly deposits on concrete or mortar surfaces.

 Hard and bitter water shall not be used for curing.

 Potable water shall generally be found suitable for curing mortar or concrete.

 Permissible Limit for Solids

Tested as per Permissible Limit Max.

Organic IS: 456 200 mg/lit

Inorganic IS: 456 3000 mg/lit

Sulphate (as SO3) IS: 456 400 mg/lit

Chlorides (as CI) IS: 456 2000 mg/lit for PCC and

500 mg/lit for RCC

Suspended Matter IS: 456 2000 mg/lit

 All reinforcement steel shall be CRS-FE-500 steel conforming to relevant I.S. for all RCC

structure with conforming to IS-1786.

 All reinforcement shall be clean, free from pitting, oil, grease, paint, loose mill scales,

rust, dirt, dust, or any other substance that will destroy or reduce bond.

 All Grade of reinforcement steel shall be as per Price bid & Data-sheet.

 Accelerating, retarding, water-reducing and air entraining admixtures shall conform to

IS: 9103 and integral water proofing admixtures to IS:

 Admixtures may be used in concrete as per manufacturer's instructions only with the

approval of the Engineer in charge. An admixture's suitability and effectiveness shall be

verified by trial mixes with the other materials used in the works. If two or more

admixtures are to be used simultaneously in the same concrete mix, their interaction

shall be checked and trial mixes done to ensure their compatibility. There should also

be no increase in risk of corrosion of the reinforcement or other embedment.

 Calcium chloride shall not be used for accelerating set of the cement for any concrete

containing reinforcement or embedded steel parts. When calcium chloride is permitted

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

such as in mass concrete works, it shall be dissolved in water and added to the mixing

water by an amount not exceeding 1.5 percent of the weight of the cement in each

batch of concrete. The designed concrete mix shall be corrected accordingly.

 Wastage allowance for cement and steel shall be considered in the item rate and no

extra payment shall be paid to the Contractor on any account.

Samples and Tests:

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

 Manufacturer's test certificate shall be furnished for each batch of cement/steel and

when directed by the Engineer in charge samples shall also be got tested by the

Contractor in a laboratory approved by the Engineer in charge at no extra cost. Engineer

in charge may appoint separate third-party inspection for the material testing to ensure

the quality of the work. The Contractor shall replace the defective material as an

outcome of these tests.

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

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

 The Contractor shall furnish manufacturer's test certificates and technical literature for

the admixture proposed to be used. If directed, the admixture shall be got tested at an

approved laboratory at no extra cost.

Storing of Materials:

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

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

be complied with.

 The Contractor will have to make his own arrangements for the storage of adequate

quantity of cement. If such cement is not stored properly and has deteriorated, the

material shall be rejected. Cement bags shall be stored in dry weatherproof shed with a

raised floor, well away from the outer walls and insulated from the floor to avoid

moisture from ground. Not more than 15 bags shall be stacked in any tier. Storage

arrangement shall be approved by the Engineer in charge. Storage under tarpaulins shall

not be permitted. Each consignment of cement shall be stored separately and consumed

in its order of receipt.

 Each size of coarse and fine aggregates shall be stacked separately and shall be

protected from leaves and contamination with foreign material. The stacks shall be on

hard, clean, free draining bases, draining away from the concrete mixing area.

 The Contractor shall make his own arrangements for storing water at site in tanks to

prevent contamination.

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

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

 Concrete grade shall be as designated on drawings. In concrete grade M15, M20 etc. the

number represents the specified characteristic compressive strength of 150X150X150

mm cube at 28 days, expressed in N/mm2 as per IS:456. Concrete in the works shall be

"DESIGN MIX CONCRETE" or "NOMINAL MIX CONCRETE". All concrete works of grade M5,

M7.5 and M10 shall be NOMINAL MIX CONCRETE whereas all other grades, M15 and

above, shall be DESIGN MIX CONCRETE. Concrete grade shall not be lower than M-25 for

building and M-30 for water retaining structures (all units of STP including distribution

chambers, sludge chambers, inlet/ outlet chambers adjacent to PST/ AT/ SST, sump).

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

12.0 Design Mix Concrete:

Mix Design & Testing

 For Design Mix Concrete, the mix shall be designed according to IS:10262 and SP:23 to

provide the grade of concrete having the required workability and characteristic

strength not less than appropriate values given in IS:456. The design mix shall be

cohesive and does not segregate and should result in a dense and durable concrete and

also capable of giving the finish as specified. For liquid retaining structures, the mix

shall also result in water tight concrete. The Contractor shall exercise great care while

designing the concrete mix and executing the works to achieve the desired result.

 The minimum cement content for Design Mix Concrete shall be as per Appendix-A of

IS:456 or as given below, whichever is higher.

Minimum Cement Content in Kg/m 3 of

Grade of Concrete

 The minimum cement content stipulated above shall be adopted irrespective of whether

the Contractor achieves the desired strength with less quantity of cement. The

CONTRACTOR's quoted rates for concrete shall provide for the above eventuality and

nothing extra shall be paid to the CONTRACTOR on this account. Even in the case where

the quantity of cement required is higher than that specified above to achieve desired

strength based on an approved mix design, nothing extra shall become payable to the

 It shall be the Contractor's sole responsibility to carry out the mix designs at his own

cost. He shall furnish to the EMPLOYER at least 30 days before concreting operations, a

statement of proportions proposed to be used for the various concrete mixes and the

strength results obtained. The strength requirements of the concrete mixes ascertained

on 150 mm cubes as per IS:516 shall comply with the requirements of IS:456.

Grade of Minimum Compressive Specified Characteristic Compressive

Concrete Strength N/sq.mm at 7 days Strength N/sq.mm at 28 days

 A range of slumps which shall generally be used for various types of construction unless

otherwise instructed by the Engineer in charge is given below:

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

Slump in millimeters

Structure/Member

Maximum Minimum

Reinforced foundation walls and 75

Plain footings, caissons and 100

Slabs, Beams and reinforced walls 75

Pump & miscellaneous Equipment

Building columns 50

Heavy mass construction 50

 Characteristic Compressive Strength Compliance Requirement (Table 11: IS 456).

13.0 Batching & Mixing of Concrete:

 Proportions of aggregates and cement, as decided by the concrete mix design, shall be

by weight. These proportions shall be maintained during subsequent concrete batching

by means of weigh batchers capable of controlling the weights within one percent of the

 Amount of water added shall be such as to produce dense concrete of required

consistency, specified strength and satisfactory workability and shall be so adjusted to

account for moisture content in the aggregates. Water- cement ratio specified for use

by the Engineer in charge shall be maintained. Each time when the work stops, the

mixer shall be cleaned out, and while recommencing, the first batch shall have 10%

additional cement to allow for sticking in the drum.

 Arrangement should be made by the Contractor at his own cost to have the cubes tested

in an Government/NABL approved laboratory as per IS 10262-2009 or in field with prior

consent of the Engineer in charge. Prior to start the work as per approved Mix Design,

the cubes shall be casted at site and it shall be sent to “GERI” for testing, confirmation

and to compare the test results for 7 and 28 days with the approved Mix Design.

Concrete work can be started after approval of testing results from GERI for 7 and

days. At least 10% of tests shall be carried out in Government engineering college or in

the GERI. Sampling and testing of strength and workability of concrete shall be as per

IS:1199, IS:516 and IS:456, IS

14.0 Nominal Mix Concrete

Mix Design & Testing

 Mix design and preliminary tests are not necessary for Nominal Mix Concrete.

 However, works tests shall be carried out as per IS:456. Proportions for Nominal Mix

Concrete and Water Cement Ratio may be adopted as per Table 3 of IS:456. However, it

will be the Contractor's sole responsibility to adopt appropriate nominal mix proportions

to yield the specified strength.

15.0 Batching & Mixing of Concrete:

 Based on the adopted nominal mixes, aggregates shall be measured by volume.

However, cement shall be by weight only.

 Formwork shall be all inclusive and shall consist of shoring, bracings, sides of footings,

walls, beams and columns, bottom of slabs etc. including ties, anchors, hangers, inserts,

false work, wedges etc.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 The design and engineering of the formwork as well as its construction shall be the

responsibility of the Contractor. However, if so desired by the Engineer in charge,

 The drawings and calculations for the design of the formwork shall be submitted to the

Engineer in charge for approval.

Formwork shall be designed to fulfill the following requirements:

 Sufficiently rigid and tight to prevent loss of grout/ slurry or mortar from the concrete

at all stages and appropriate to the methods of placing and compacting.

 Formwork shall be made of suitable materials as directed by engineer in-charge.

 Capable of providing concrete of the correct shape and surface finish within the

specified tolerance limits.

 Capable of withstanding without deflection the worst combination of self-weight,

reinforcement and concrete weight, all loads and dynamic effects arising from

construction and compacting activities, earthquake, wind and weather forces.

 Capable of easy striking out without shock, disturbance or damage to the concrete.

 Soffit forms capable of imparting a camber if required.

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

 Capable of being cleaned and/or coated if necessary immediately prior to casting the

concrete; design temporary openings where necessary for these purposes and to

facilitate the preparation of construction joints.

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

type of finish specified. Sliding forms and slip form may be used with the approval of

the Engineer in charge. Timber for formwork shall be well seasoned, free from sap,

shakes, loose knots, worm holes, warps and other surface defects. Joints between

formwork and between formwork and structures shall be sufficiently tight to prevent

loss of slurry from concrete, using seals if necessary.

 The faces of formwork coming in contact with concrete shall be cleaned and two coats

of approved mould oil applied before fixing reinforcement. All rubbish, particularly

chippings, shavings, sawdust, wire pieces dust etc. shall be removed from the interior of

the forms before the concrete is placed. Where directed, cleaning of forms shall be

done by blasting with a jet of compressed air at no extra cost.

 Forms intended for reuse shall be treated with care. Forms that have deteriorated shall

not be used. Before reuse, all forms shall be thoroughly scraped, cleaned, nails

removed, holes suitably plugged, joints repaired and warped lumber replaced to the

satisfaction of the Engineer in charge. The Contractor shall equip himself with enough

shuttering to allow for wastage so as to complete the job in time.

 Permanent formwork shall be checked for its durability and compatibility with adjoining

concrete before it is used in the structure. It shall be properly anchored to the

 Wire ties passing through beams, columns and walls shall not be allowed. In their place

bolts passing through sleeves shall be used. Formwork spacers left in situ shall not

impair the desired appearance or durability of the structure by causing spilling, rust

staining or allowing the passage of moisture.

 For liquid retaining structures, sleeves shall not be provided for through bolts nor shall

through bolts be removed if provided. The bolts, in the latter case, shall be cut at

mm depth from the surface and the hole made good by cement mortar of the same

proportion as the concrete just after striking the formwork.

 Where specified all corners and angles exposed in the finished structure shall have

chamfers or fillets of 20 mm x 20 mm size.

 Forms for substructure may be omitted when, in the opinion of the Engineer in charge,

the open excavation is firm enough (in hard non-porous soils) to act as a form. Such

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

excavations shall be larger, as approved by the Engineer in charge, than that required

as per drawing to compensate for irregularities in excavation.

 The Contractor shall provide adequate props carried down to a firm bearing without

overloading any of the structures.

 The shuttering for beams and slabs shall be so erected that the side shuttering of beams

can be removed without disturbing the bottom shuttering. If the shuttering for a column

is erected for the full height of the column, one side shall be built up in sections as

placing of concrete proceeds or windows left for placing concrete from the side to limit

the drop of concrete to 1.0m or as approved by the Engineer in charge. The Contractor

shall temporarily and securely fix items to be casted (embedment / inserts) in a manner

that will not hinder the striking of forms or permit loss of grout.

 Formwork showing excessive distortion, during any stage of construction, shall be

repositioned and strengthened. Placed concrete affected by faulty formwork, shall be

entirely removed and formwork corrected prior to placement of new concrete at

Contractor's cost.

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

 Development of adequate concrete strength.

 Permissible deflection at time of striking form work.

 Curing procedure employed - its efficiency and effectiveness.

 Subsequent surface treatment to be done;

 Prevention of thermal cracking at re-entrant angles;

 Ambient temperatures; and

 Aggressiveness of the environment (unless immediate adequate steps are taken to

prevent damage to the concrete).

 Under normal circumstances (generally where temperatures are above 20oC) forms may

be struck after expiry of the time period given in IS:456 unless approved otherwise by

the Engineer in charge. For Portland Pozzolana/slag cement the stripping time shall be

suitably modified as approved by the Engineer in charge. It is the Contractor's

responsibility to ensure that forms are not struck until the concrete has developed

sufficient strength to support itself, does not undergo excessive deformation and resist

surface damage and any stresses arising during the construction period.

17.0 Reinforcement Workmanship

 Reinforcing bars supplied bent or in coils shall be straightened cold without damage. No

bending shall be done when ambient temperature is below 5°C. Local warming may be

permitted if steel is kept below 10° C. All bars shall be accurately cut and bent

gradually and according to the sizes and shapes shown on the drawings/ schedules or as

directed by Engineer in charge. Re-bending or straightening incorrectly bent bars shall

not be done without the approval of the Engineer in charge.

 Reinforcement shall be accurately fixed and maintained firmly in the correct position by

the use of blocks, spacers, chairs, binding wire etc. to prevent displacement during

placing and compaction of concrete. The tied in place reinforcement shall be approved

by the Engineer in charge prior to concrete placement. Spacers shall be of such

materials and designs as will be durable, not lead to corrosion of the reinforcement and

not cause spilling of the concrete cover. Binding wire shall be 16-gauge soft annealed

wires. Ends of the binding wire shall be bent away from the concrete surface and in no

case encroach into the concrete cover.

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

Engineer in charge’s approval.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

18.0 Tolerances:

 Tolerance for formwork and concrete dimensions shall be as per IS:456 unless specified

 Tolerances specified for horizontal or vertical building lines or footings shall not be

construed to permit encroachment beyond the legal boundaries.

 The formwork shall be designed and constructed to the shapes, lines and dimensions

shown on the drawings within the tolerances given below:

Deviation from specified dimensions

of cross section of columns and beams

Deviations from dimensions of footings

(Tolerances apply to concrete

dimensions only, not to positioning of

vertical reinforcing steel or dowels

1) Dimension in plan - 12 mm+ 50 mm

0.02 times the width of the

footing in the direction of

2) Eccentricity

deviation but not more than

± 0.05 times the specified

19.0 Preparation Prior to Concrete Placement:

 Before concrete is actually placed in position, the inside of the formwork shall be

cleaned and mould oil applied, inserts and reinforcement shall be correctly positioned

and securely held, necessary openings, pockets, etc. provided.

 All arrangements-formwork, equipment and proposed procedure, shall be approved by

the Engineer in charge. Contractor shall maintain separate Pour Card for each pour as

per the format enclosed.

20.0 Transporting, Placing and Compacting Concrete:

 Concrete shall be transported from the mixing plant to the formwork with minimum

time lapse by methods that shall maintain the required workability and will prevent

segregation, loss of any ingredients or ingress of foreign matter or water.

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

position. To avoid segregation, concrete shall not be re handled or caused to flow. For

locations where, direct placement is not possible and in narrow forms the Contractor

shall provide suitable drops and "Elephant Trunks". Concrete shall not be dropped from a

height of more than 1.0m.

 Concrete shall not be placed in flowing water. Under water, concrete shall be placed in

position by tremie or by pipeline from the mixer and shall never be allowed to fall

freely through the water.

While placing concrete the Contractor shall proceed as specified below and also

ensure the following:

 Continuously between construction joints and pre-determined abutments.

 Without disturbance to forms or reinforcement.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Without disturbance to pipes, ducts, fixings and the like to be cast in; ensure that such

items are securely fixed. Ensure that concrete cannot enter open ends of pipes and

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

 In deep pours only when the concrete and formwork designed for this purpose and by

using suitable chutes or pipes.

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

 Without disturbing the unsupported sides of excavations; prevent contamination of

concrete with earth. Provide sheeting if necessary. In supported excavations, withdraw

the linings progressively as concrete is placed.

 If placed directly onto hardcore or any other porous material, dampen the surface to

reduce loss of water from the concrete.

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

 Record the time and location of placing structural concrete.

 Concrete shall normally be compacted in its final position within thirty minutes of

leaving the mixer. Concrete shall be compacted during placing with approved vibrating

equipment without causing segregation until it forms a solid mass free from voids

thoroughly worked around reinforcement and embedded fixtures and into all corners of

the formwork. Immersion vibrators shall be inserted vertically at points not more than

450 mm apart and withdrawn slowly till air bubbles cease to come to the surface,

leaving no voids. When placing concrete in layers advancing horizontally, care shall be

taken to ensure adequate vibration, blending and melding of the concrete between

successive layers. Vibrators shall not be allowed to come in contact with reinforcement,

formwork and finished surfaces after start of initial set. Over-vibration shall be avoided.

 Concrete may be conveyed and placed by mechanically operated equipment after

getting the complete procedure approved by the Engineer in charge. The slump shall be

held to the minimum necessary for conveying concrete by this method. When concrete

is to be pumped, the concrete mix shall be specially designed to suit pumping. Care

shall be taken to avoid stoppages in work once pumping has started.

 Except when placing with slip forms, each placement of concrete in multiple lift work

shall be allowed to set for at least 24 hours after the final set of concrete before the

start of subsequent placement. Placing shall stop when concrete reaches the top of the

opening in walls or bottom surface of slab, in slab and beam construction, and it shall

be resumed before concrete takes initial set but not until it has had time to settle as

approved by the Engineer in charge. Concrete shall be protected against damage until

final acceptance.

21.0 Mass Concrete Works:

 Sequence of pouring for mass concrete works shall be as approved by the Engineer in

charge. The Contractor shall exercise great care to prevent shrinkage cracks and shall

monitor the temperature of the placed concrete if directed.

 At the time of placing concrete, thickness of layer shall not be more than 450 mm for

vibrated concrete per layer and limiting height of concrete shall be applicable as per IS

457, clause 4.10.7 for particular component.

Curing and protection shall start immediately after the compaction of the concrete

to protect it from:

 Premature drying out, particularly by solar radiation and wind;

 Leaching out by rain and flowing water;

 Rapid cooling during the first few days after placing;

 High internal thermal gradients;

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Low temperature or frost;

 Vibration and impact which may disrupt the concrete and interfere with its bond to the

 All concrete, unless approved otherwise by the Engineer in charge, shall be cured by use

of continuous sprays or ponded water or continuously saturated coverings of sacking,

canvas or other absorbent material for the period of complete hydration with a

minimum of 7 days. The quality of curing water shall be the same as that used for

 Where a curing membrane is approved to be used by the Engineer in charge, the same

shall be of a non-wax base and shall not impair the concrete finish in any manner. The

curing compound to be used shall be approved by the EMPLOYER before use and shall be

applied with spraying equipment capable of a smooth, even textured coat.

 Curing may also be done by covering the surface with an impermeable material such as

polyethylene, which shall be well sealed and fastened.

23.0 Construction Joints and Keys:

 Construction joints will be as shown in the drawing or as approved by the EMPLOYER.

Concrete shall be placed without interruption until completion of work between

construction joints. If stopping of concreting becomes unavoidable anywhere, a properly

formed construction joint shall be made with the approval of the Engineer in charge.

 Dowels for concrete work, not likely to be taken up in the near future, shall be coated

with cement slurry and encased in lean concrete as indicated on the drawings or as

approved by the Engineer in charge.

 Before resuming concreting on a surface which has hardened all laitance and loose stone

shall be thoroughly removed by wire brushing/hacking and surface washed with high

pressure water jet and treated with thin layer of cement slurry for vertical joints and

horizontal layers.

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

laitance shall be removed by wire brushing, the surface wetted, free water removed

and a coat of cement slurry applied. On this, a layer of concrete not exceeding

thickness shall be placed and well rammed against the old work. Thereafter work shall

proceed in the normal way.

24.0 Foundation Bedding:

 All earth surfaces upon which or against which concrete is to be placed, shall be well

compacted and free from standing water, mud or debris. Soft or spongy areas shall be

cleaned out and back filled with either soil-cement mixture, lean concrete or clean

sand compacted as approved by the Engineer in charge. The surfaces of absorptive soils

shall be moistened.

 Concrete shall not be deposited on large sloping rock surfaces. The rock shall be cut to

form rough steps or benches by picking, barring or wedging. The rock surface shall be

kept wet for 2 to 4 hours before concreting.

 The formwork for concrete works shall be such as to give the finish as specified. The

Contractor shall make good any unavoidable defects as approved consistent with the

type of concrete and finish as specified. Defects due to bad workmanship (e.g. damaged

or misaligned forms, defective or poorly compacted concrete) will not be accepted. The

Contractor shall construct the formwork using the correct materials and to meet the

requirements of the design and to produce finished concrete to required dimensions,

plumbs, planes and finishes.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

Surface Finish Type F1:

 The main requirement is that of dense, well-compacted concrete. No treatment is

required except repair of defective areas, filling all form tie holes and cleaning up of

loose or adhering debris. For surfaces below grade, which will receive waterproofing

treatment, the concrete shall be free of surface irregularities, which would interfere

with proper and effective application of waterproofing material specified for use.

Surface Finish Type F2:

 The appearance shall be that of a smooth dense, well-compacted concrete showing the

slight marks of well fitted shuttering joints. The Contractor shall make good any

Surface Finish Type F3:

 This finish shall give an appearance of smooth, dense, well-compacted concrete with no

shutter marks, stain free and with no discoloration, blemishes, arises, air holes etc.

Only lined or coated plywood with very tight joints shall be used to achieve this finish.

The panel size shall be uniform and as large as practicable. Any minor blemishes that

might occur shall be made good by the Contractor.

Integral Cement Finish on Concrete Floor:

 In all cases where integral cement finish on a concrete floor has been specified, the top

layer of concrete shall be screened off to proper level and tamped with tamper having

conical projections so that the aggregate shall be forced below the surface. The surface

shall be finished with a wooden float and a trowel with pressure. The finish shall be

continued till the concrete reaches its initial set. No cement or cement mortar finish

shall be provided on the surface. Where specified, a floor hardener as approved by the

Engineer-In-Charge shall be supplied and used as recommended by the manufacturer.

 The formwork for concrete works shall be such as to give the finish as specified. The

Contractor shall make good any unavoidable defects as approved consistent with the

type of concrete and finish specified; defects due to bad workmanship (e.g. damaged or

misaligned forms, defective or poorly compacted concrete) will not be accepted. The

Contractor shall construct the formwork using the correct materials and to meet the

requirements of the design and to produce finished concrete to required dimensions,

plumbs, planes and finishes.

26.0 Repair and Replacement of Unsatisfactory Concrete:

 Immediately after the shuttering is removed, all the defective areas such as honey-

combed surfaces, rough patches, holes left by form bolts etc. shall be inspected by the

Engineer in charge who may permit patching of the defective areas or reject the

 All through holes for shuttering shall be filled for full depth and neatly plugged flush

 Rejected concrete shall be removed and replaced by the Contractor at no additional

cost to the Employer.

 For patching of defective areas all loose materials shall be removed and the surface

shall be prepared as approved by the Engineer in charge.

 Bonding between hardened and fresh concrete shall be done either by placing cement

mortar or by applying epoxy. The decision of the Engineer in charge as to the method of

repairs to be adopted shall be final and binding on the Contractor. The surface shall be

saturated with water for 24 hours before patching is done with 1:5 cement sand mortar.

The use of epoxy for bonding fresh concrete shall be carried out as approved by the

Engineer in charge.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

27.0 Vacuum Dewatering of Slabs:

 Where specified floor slabs, either grade or suspended, shall be finished by vacuum

dewatering including all operations such as poker vibration, surface vibration, vacuum

processing, floating and toweling as per equipment manufacturers recommendation.

The equipment to be used shall be subject to the Engineer in charge's approval.

28.0 Hot Weather Requirements:

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

 Adequate provisions shall be made to lower concrete temperatures which shall not

exceed 40º C at the time of placement of fresh concrete.

 Where directed by the Engineer in charge, the Contractor shall spray non-wax based

curing compound on unformed concrete surfaces at no extra costs.

29.0 Cold Weather Requirements.

 Concreting during cold weather shall be carried out as per IS: 7861 (Part II).

 The ambient temperature during placement and up to final set shall not fall below 5º C.

Approved antifreeze/accelerating additives shall be used where directed.

 For major and large-scale concreting works the temperature of concrete at times of

mixing and placing, the thermal conductivity of the formwork and its insulation and

stripping period shall be closely monitored.

30.0 Liquid Retaining Structures:

 The Contractor shall take special care for concrete for liquid retaining structures,

underground structures and those others specifically called for to guarantee the finish

and water tightness.

 The minimum level of surface finish for liquid retaining structures shall be as defined

elsewhere. All such structures shall be hydro-tested.

 The Contractor shall make all arrangements for hydro-testing of structure, all

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

 The Contractor shall also make all temporary arrangements that may have to be made

to ensure stability of the structures during construction.

 Any leakage that may occur during the hydro-test or subsequently during the defects

liability period or the period for which the structure is guaranteed shall be effectively

stopped either by cement/epoxy pressure grouting, guiniting or such other methods as

may be approved by the Engineer in charge. All such rectification shall be done by the

Contractor to the entire satisfaction of the Engineer in charge at no extra cost.

Placing Concrete Underwater:

 Under all ordinary conditions all foundations shall be completely dewatered and

concrete placed in the dry. However, when concrete placement under water is

necessary, all work shall conform to IS:456 and the procedure shall be as described in

the following paragraphs:

 Concrete shall be deposited underwater by means of tremies, or drop bottom buckets of

 All work requiring placement of concrete underwater shall be designed, directed and

inspected with due regard to local circumstances and purposes. All underwater concrete

shall be placed according to the plans or Specifications and as directed and approved by

Engineer In-charge.

31.0 Testing Concrete Structures for Leakage:

Hydro-static test for water tightness shall be done at full storage level or soffit of

cover slab, as may be directed by the Engineer in charge, as described below:

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 In case of structures whose external faces are exposed, such as elevated tanks, the

requirements of the test shall be deemed to be satisfied if the external faces show no

sign of leakage or sweating and remain completely dry during the period of observation

of seven days after allowing a seven-day period for absorption after filling with water.

 In the case of structures whose external faces are buried and are not accessible for

inspection, such as underground tanks, the structures shall be filled with water and

after the expiry of seven days after the filling; the level of the surface of the water

shall be recorded. The level of water shall be recorded again at subsequent intervals of

24 hrs. Over a period of seven days. Backfilling shall be withheld till the tanks are

tested. The total drop in surface level over a period for seven days shall be taken as an

indication of the water tightness of the structure. The Engineer in charge shall decide

on the actual permissible nature of this drop in the surface level, considering whether

the structures are open or closed and the corresponding effect it has on evaporation

 Unless specified otherwise, a structure whose top is covered shall be deemed to be

water tight if the total drop in the surface level over a period of seven days does not

 Each compartment/segment of the structure shall be tested individually and then all

 For structures such as pipes, tunnels etc. the hydrostatic test shall be carried out by

filling with water, after curing as specified, and subjecting to the specified test

pressure for specified period. If during this period the loss of water does not exceed the

equivalent of the specified rate, the structure shall be considered to have successfully

passed the test.

Optional Tests:

 If the Employer feels that the materials i.e. cement, sand, coarse aggregates,

reinforcement and water are not in accordance with the Specifications or if specified

concrete strengths are not obtained, he may order tests to be carried out on these

materials in laboratory, to be approved by the Engineer in charge, as per relevant IS

Codes. Contractor shall have to pay for these tests.

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

removal or if the works cubes do not give the stipulated strengths, the Engineer in

charge reserves the right to order the Contractor to take out cores and conduct tests on

them or do ultrasonic testing or load testing of structure, etc. The Engineer in charge

also reserves the right to ask the Contractor to dismantle and re-do such unacceptable

work, at no cost to the Engineer in charge. Alternately Engineer in charge also reserves

the right to ask the CONTRACTOR to dismantle and re-do such unacceptable work at the

cost of CONTRACTOR.

Standard Grout:

 Grout shall be provided as specified on the drawings.

 The proportion of Standard Grout shall be such as to produce a flow able mixture

consistent with minimum water content and shrinkage. Surfaces to be grouted shall be

thoroughly roughened and cleaned. All structural steel elements to be grouted shall be

cleaned of oil, grease, dirt etc. The use of hot, strong caustic solution for this purpose

will be permitted. Prior to grouting, the hardened concrete shall be saturated with

water and just before grouting, water in all pockets shall be removed. Grouting once

started shall be done quickly and continuously. Variation in grout mixes and procedures

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

shall be permitted if approved by the Engineer in charge. The grout proportions shall be

limited as follows:

Use Grout Thickness Mix Proportions

Cement Ratio (max)

One-part Portland Cement

1. Fluid mix Under 25mm

to one-part sand

25mm and over but One-part Portland Cement

less than 50mm to 2 parts of sand

One-part Portland Cement

c) Stiff mix 50mm and over

to 3 parts of sand

Non-Shrink Grout:

 Non-shrink grout where required shall be provided in strict accordance with the

manufacturer's instructions / specifications on the drawing.

 All materials, workmanship and finished construction shall be subject to continuous

inspection and approval of Engineer in charge. Materials rejected by Engineer in charge

shall be expressly removed from site and shall be replaced by Contractor immediately.

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

protective coverings and any debris, scraps of wood, etc. resulting from the work shall

be removed and the premises left clean.

Acceptance Criteria:

 Any concrete work shall satisfy the requirements given below individually and

collectively for it to be acceptable.

 Properties of constituent materials;

 Characteristic compressive strength;

 Specified mix proportions;

 Minimum cement content;

 Maximum free-water/cement ratio;

 Temperature of fresh concrete;

 Density of fully compacted concrete;

 Cover to embedded steel;

 Tolerances in dimensions;

 Tolerances in levels;

 Surface finishes;

 Special requirements such as;

 Water tightness

 Resistance to aggressive chemicals

 Resistance to freezing and thawing

 Very high strength

 Improved fire resistance

 Wear resistance

 Resistance to early thermal cracking

 The Engineer in charge's decision as to the acceptability or otherwise of any concrete

work shall be final and binding on the Contractor. For work not accepted, the Engineer

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

in charge may review and decide whether remedial measures are feasible so as to

render the work acceptable. The Engineer in charge shall in that case direct the

Contractor to undertake and execute the remedial measures. These shall be

expeditiously and effectively implemented by the Contractor. Nothing extra shall

become payable to the Contractor by the Employer for executing the remedial

33.0 Water stops:

 The material for the PVC water stops shall be a plastic compound with the basic resin of

polyvinyl chloride and additional resins, plasticizers, inhibitors, which satisfies the

performance characteristics specified below as per IS:12200. Testing shall be in

accordance with IS:8543.

a) Tensile strength : 3.6 N/mm2 minimum

c) Ultimate elongation : 300 % minimum

d) Tear resistance : 4.9 N/mm2 minimum

e) Stiffness in flexure : 2.46 N/mm2 minimum

f) Accelerated extraction

g) Tensile strength : 10.50 N/mm2 minimum

h) Ultimate elongation : 250% minimum

i) Effect of Alkali : 7 days

j) Weight increase : 0.10% maximum

k) Weight decrease : 0.10% maximum

l) Hardness change : ± 5 points

m) Effect of Alkali : 28 days

n) Weight increase : 0.40% maximum

o) Weight decrease : 0.30% maximum

p) Dimension change : ±1%

 PVC water stops shall be either of the bar type, serrated with center bulb and end grips

for use within the concrete elements or of the surface (kicker) type for external use.

 PVC water stops shall be of approved manufacture. Samples and the test certificate

shall be got approved by the Engineer in charge before procurement for incorporation in

the works. Alternatively, G.I. sheet of 18 gage (1.3mm) thick and 200mm wide can be

used by the contractor as construction joints.

 Alternatively, contractors can use G.I sheet 200mm wide and 18 gauge thick as

constructions joints.

34.0 Workmanship:

 Water stops shall be cleaned before placing them in position. Oil or grease shall be

removed thoroughly using water and suitable detergents.

 Water stops shall be procured in long lengths as manufactured to avoid joints as far as

possible. Standard L or T type of intersection pieces shall be procured for use depending

on their requirement. Any non-standard junctions shall be made by cutting the pieces

to profile for jointing. Lapping of water stops shall not be permitted. All jointing shall

be of fusion welded type as per manufacturer’s instructions.

 Water stops shall be placed at the correct location/level and suitably supported at

intervals with the reinforcement to ensure that it does not deviate from its intended

position during concreting and vibrating. Care shall also be taken to ensure that no

honey-combing occurs because of the serrations/end grips, by placing concrete with

smaller size aggregates in this region. Projecting portions of the water stops embedded

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

in concrete shall be thoroughly cleaned of all mortar/ concrete coating before resuming

further concreting operations. The projecting water stop shall also be suitably

supported at intervals with the reinforcement to maintain its intended position during

concreting so as to ensure that it does not bend leading to formation of pockets. In

addition, smaller size aggregates shall be used for concreting in this region also.

35.0 Preformed Fillers and Joint Sealing Compound:

 Preformed filler for expansion/isolation joints shall be non-extruding and resilient type

of bitumen impregnated fibers conforming to IS:1838 (Part I).

 Bitumen coat to concrete/masonry surfaces for fixing the preformed bitumen filler strip

shall conform to IS:702. Bitumen primer shall conform to IS:3384.

 Sealing compound for filling the joints above the preformed bitumen filler shall conform

to Grade 'A' as per IS:1834.

 The thickness of the preformed bitumen filler shall be 25mm for expansion joints and

50mm for isolation joints around foundation supporting rotatory equipment's. Contractor

shall procure the strips of the desired thickness and width in lengths as manufactured.

Assembly of small pieces/thicknesses of strips to make up the specified size shall not be

 The concrete/masonry surface shall be cleaned free from dust and any loose particles.

When the surface is dry, one coat of industrial blown type bitumen of grade 85/25

conforming to IS:702 shall be applied hot by brushing at the rate of 1.20 kg/m2. When

the bitumen is still hot the preformed bitumen filler shall be pressed and held in

position till it completely adheres. The surface of the filler against which further

concreting/masonry work is to be done shall similarly be applied with one coat of hot

bitumen at the rate of 1.20 kg/m2.

 Sealing compound shall be heated to a pouring consistency for enabling it to run molten

in a uniform manner into the joint. Before pouring the sealing compound, the vertical

faces of the concrete joint shall be applied hot with a coat of bitumen primer

conforming to IS: 3384 in order to improve the adhesive quality of the sealing

 Expansion joints between beams/slabs shall be provided with 100mm wide x 4mm thick

mild steel plate at the soffit of RCC beams/slabs to support and prevent the preformed

joint filler from dislodging. This plate shall be welded to an edge angle of ISA 50 x 50 x

6mm provided at the bottom corner, adjacent to the expansion joint of one of the

beams/slabs, by intermittent fillet welding. Steel surfaces shall be provided with

coats of red oxide zinc chrome primer and 3 coats of synthetic enamel paint finish.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

CONCRETE POUR CARD

POUR NO.: DATE:

DRG. NO.: STRUCTURE:

CONCRETE GRADE/QUANTITY/: MAX. AGGREGATE SIZE /

SLUMP: START / COMPLETION TIME:

BEFORE CENTRELINES

CONCRETING CHECKED

STAGING CHECKED

STRENGTH & FINISH

4 REINFORCEMENT YES/NO

5 CERTIFICATE FOR YES/NO

6 MATERIALS / YES/NO

EQUIPMENT FOR POUR

EMBEDDED CIVIL YES/NO

PARTS MECH. YES/NO

PLUMB) ELEC. YES/NO

SOFFIT(S) & POUR TOP(T) LEVELS T(B)

8 CHECKED BEFORE (B) & AFTER (A)

CONSTRUCTION JOINTS LOCATION &

EXPANSION JOINTS – LOCATION AND

10 CEMENT CONSUMPTION IN KGS.

REINFORCEMENT CONSUMPTION

NUMBER OF CUBES AND

IDENTIFICATION MARKS

TEST CUBE RESULTS (7 DAYS /

CONCRETE CONDITION ON FORM V.GOOD/GOOD/FAIR/

Contractor's Representative Engineer- in-charge's Representative

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 EACH POUR TO HAVE SEPARATE CARDS, IN TRIPLICATE ONE EACH FOR CLIENT,

CONTRACTOR & SITE OFFICE.

 UNDER REMARKS, INDICATE DEVIATIONS FROM DWGS. & SPECIFICATIONS, CONGESTION IN

REINFORCEMENT IF ANY, UNUSUAL OCCURRENCES SUCH AS FAILURE OF EQUIPMENTS,

SINKING OF SUPPORTS / PROPS. HEAVY RAINS AFFECTING CONCRETING, POOR

COMPACTION, IMPROPER CURING, OTHER DEFICIENCIES, OBSERVATIONS ETC.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

SECTION -4 BUILDING ITEMS

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

BUILDING ITEMS.

Applicable Codes and Specifications

 The following codes and standards are included in this section, as part of these

specifications. However, respective IS codes for the works not mentioned here shall also be

applicable for those particular items of work.

IS:110 - Ready mixed paint, brushing, gray filler, for Enamels for use over primers

IS:269 - Specification for 33 grade ordinary Portland cement

IS:280 - Specification for mild steel wire for general Engineering purposes

IS:287 - Recommendations for maximum permissible Moisture content of timber used for

different purposes

IS:383 - Specif. for coarse &fine aggregates from natural sources for concrete

IS:412 - Expanded metal steel sheets for general purposes

IS:419 - Specification for putty for use on window frames

IS:428 - Distemper, oil emulsion, color as required

IS:459 - Specification for unreinforced corrugated and semi-corrugated asbestos cement

IS:702 - Specification for industrial bitumen

IS:710 - Specification for marine plywood

IS:712 - Specification for building limes

IS:730 - Specification for hook bolts for corrugated sheet Roofing

IS:733 - Wrought aluminum and aluminum alloys, bars, Rods and sections for general

engineering purposes

IS:777 - Specification for glazed earthenware tiles

IS:1003 - Specification for timber paneled and glazed shutters (Parts 1 & 2)

IS:1038 - Specification for steel doors, windows and ventilators

IS:1077 - Specification for common burnt clay building bricks

IS:1081 - Code of practice for fixing and glazing of metal (steel &aluminum) doors,

windows and ventilators.

IS:1124 - Method of test for determination of water absorption, apparent specific

gravity and porosity of natural building stones

IS:1237 - Specification for cement concrete flooring tiles

IS:1322 - Bitumen felts for water proofing and damp proofing

IS:1346 - Code of practice for water proofing of roofs with bitumen felts

IS:1361 - Specification for steel windows for industrial buildings

IS:1443 - Code of practice for laying and finishing of cement concrete flooring tiles

IS:1477 - Code of practice for painting of ferrous metals in buildings (Parts 1 & 2)

IS:1542 - Specification for sand for plaster

IS:1580- Specification for bituminous compounds for water-proofing and caulking purposes.

IS:1597- Code of practice for construction of stone masonry: Part 1 Rubble stone masonry

IS:1661 - Code of practice for application of cement and cement-lime plaster finishes

IS:1834 - Specification for hot applied sealing compound for joint in concrete

IS:1838- Specification for preformed fillers for expansion joint in concrete Pavements and

structures (none extruding and resilient type): Part 1 Bitumen impregnated fiber.

IS:1948 - Specification for aluminum doors, windows and ventilators

IS:1949 - Specification for aluminum windows for industrial buildings

IS:2074 - Ready mixed paint, air drying, red oxide- zinc chrome, priming

IS:2114 - Code of practice for laying in-situ terrazzo floor finish

IS:2116 - Specification for sand for masonry mortars

IS:2185 - Specification for concrete masonry units (Parts 1,2& 3)

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

IS:2202 - Specification for wooden flush door shutters (Solid core type): Parts 1&2

IS:2212 - Code of practice for brickwork

IS:2250 - Code of practice for preparation and use of masonry mortars

IS:2338 - Code of practice for finishing of wood and wood-based materials (Parts 1 & 2)

IS: 2395- Code of practice for painting concrete, masonry and plaster surfaces (Parts 1 & 2)

IS:2402 - Code of practice for external rendered finishes

IS:2571 - Code of practice for laying in-situ cement concrete flooring

IS:2572 - Code of practice for construction of hollow concrete block masonry

IS:2645 - Specification of integral cement waterproofing compounds

IS:2690 - Specification for burnt clay flat terracing tiles: Part 1 Machine made

IS:2691 - Specification for burnt clay facing bricks

IS:2750 - Specification for steel scaffoldings

IS:2835 - Flat transparent sheet glass

IS:2932 - Specification for enamel, synthetic, exterior type (a) undercoating,(b) finishing

IS:3007- Code of practice for laying of asbestos cement sheets - corrugated and

(Part 1 & 2) semi-corrugated sheets

IS:3067 - Code of practice of general design details and preparatory work for

Damp-proofing and water- proofing of buildings

IS:3068- Specification for broken brick (burnt clay) coarse aggregates for use in Lime

IS:3384 - Specification for bitumen primer for use in water-proofing and damp-proofing

IS:3462 - Specification for unbaked flexible PVC flooring

IS:3495 - Method of test for burnt clay building bricks: Part 1 to

IS:3536 - Specification for ready mixed paint, brushing, and wood primer, pink

IS:3696 - Safety code of scaffolds and ladders (Parts 1 & 2)

IS:4020 - Methods of test for wooden flush door: Type test

IS:4021 - Specification for timber door, window and ventilator frames

IS:4351 - Specification for steel door frames

IS:4443 - Code of practice for use of resin type chemical resistant mortars

IS:4457 - Specification for ceramic unglazed vitreous acid resisting tile

IS:4631 - Code of practice for laying epoxy resin floor toppings

IS:4832 - Specification for chemical resistant mortars (Part II)

IS:4860 - Specification for acid resistant bricks

IS:4948 - Specification for welded steel wire fabric for general use

IS:5318 - Code of practice for laying of flexible PVC sheet and tile flooring

IS:5410 - Cement paint, color as required

IS:5411 - Specification for plastic emulsion paint (Parts 1 & 2)

IS:5437 - Wired and figured glass

IS:5491 - Code of practice for laying of in-situ granolithic concrete floor topping

IS:6042 - Code of practice for construction of light weight concrete block masonry

IS:6248 - Specification for metal rolling shutters and rolling grilles

IS:7193 - Specification for glass fiber base coal tar pitch and bitumen felts

IS:7452 - Specification for hot rolled steel sections for doors, windows and Ventilators

IS:8042 - Specification for white Portland cement

IS:9197- Specification for epoxy resin, hardeners and epoxy resin composites for floor

IS:9862 Specification for ready mixed paint, brushing, bituminous, black, lead-free, acid,

alkali, water and chlorine resisting

IS:12200- Code of practice for provision of water stops at transverse contraction

joints in masonry and concrete dams

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Bricks used in the works shall conform to the requirements laid down in IS: 1077. The class

of the bricks shall be as specifically indicated in the respective items of work.

 The nominal size of the modular brick shall be 200 mm x 100 mm x 100 mm with the

permissible tolerances over the actual size of 190mm x90 mm x 90 mm as per IS: 1077. The

nominal thickness of one brick and half brick walls using modular bricks shall be considered

as 200 mm and 100 mm respectively. In the event of use of traditional bricks of nominal size

230 mmx115mmx75mm with tolerance up to ±3 mm in each dimension, one brick and half

brick walls shall be considered as 230 mm and 115 mm respectively.

 Bricks shall be sound, hard, and homogenous in texture, well burnt in kiln without being

vitrified, hand/machine mounded, deep red, cherry or copper colored, of regular shape and

size & shall have sharp and square edges with smooth rectangular faces. The bricks shall be

tested from approved laboratory and free from pores, cracks, flaws and nodules of free

lime. Hand moulded bricks shall be moulded with a frog and those made by extrusion

process may not be provided with a frog. Bricks shall give a clear ringing sound when struck

and shall have a minimum crushing strength of 3N/sq.mm unless otherwise specified in the

Items of work prepared by the Contractor.

 The average water absorption shall not be more than 20 percent by weight up to class

and 15 percent by weight for higher classes. Bricks which do not conform to this

requirement shall be rejected. Over or under burnt bricks are not acceptable for use in the

works. Sample bricks shall be submitted to the GWIL for approval and bricks supplied shall

conform to approved samples. If demanded by GWIL, brick samples shall be got tested as

per IS: 3495 by Contractor. Bricks rejected by GWIL shall be removed from the site of works

within 24 hours.

 Mortar for brick masonry shall consist of cement and sand and shall be prepared as per IS:

2250. Mix shall be in the proportion of 1:5 for brickwork of thickness one brick or above and

1:4 for brickwork of thickness half brick or below, unless otherwise specified in the

respective items of work prepared by the Contractor. Sand for masonry mortar shall conform

to IS:218. The sand shall be free from clay, shale, loam, alkali and organic matter and shall

be of sound, hard, clean and durable particles. Sand shall be approved by GWIL. If so

directed by the GWIL, sand shall be screened and washed till it satisfies the limits of

deleterious materials.

 For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry

condition. Water shall then be added and mixing continued to give a uniform mix of required

consistency. Mixing shall be done thoroughly in a mechanical mixer, unless hand mixing is

specifically permitted by the GWIL. The mortar thus mixed shall be used as soon as possible,

preferably within 30 minutes from the time water is added to cement. In case, the mortar

has stiffened due to evaporation of water, this may be re-tempered by adding water as

required to restore consistency, but this will be permitted only up to 30 minutes from the

time of initial mixing of water to cement. Any mortar which is partially set shall be rejected

and shall be removed from the site. Droppings of mortar shall not be re-used under any

circumstances. The Contractor shall arrange for test on mortar samples if so directed by the

 Workmanship of brick work shall conform to IS: 2212. All bricks shall be thoroughly soaked in

clean water for at least one hour immediately before being laid. The cement mortar for

brick masonry work shall be as specified in the respective item of work prepared by the

Contractor. Brick work 200mm/230mm thick and over shall be laid in English Bond unless

otherwise specified. 100mm/115mm thick brickwork shall be laid with stretchers. For laying

bricks, a layer of mortar shall be spread over the full width of suitable length of the lower

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

course. Each brick shall be slightly pressed into the mortar and shoved into final position so

as to embed the brick fully in mortar. Only full-size bricks shall be used for the works and

cut bricks utilized only as closers to make up required wall length or for bonding. Bricks

shall be laid with frogs on top.

 All brickwork shall be plumb, square and true to dimensions shown. Vertical joints in

alternate courses shall come directly one over the other and be in line. Horizontal courses

shall be leveled. The thickness of brick courses shall be kept uniform. In case of one brick

thick or half brick thick wall, at least one face should be kept smooth and plane, even if the

other is slightly rough due to variation in size of bricks. For walls of thickness greater than

one brick both faces shall be kept smooth and plane. All interconnected brickwork shall be

carried out at nearly one level so that there is uniform distribution of pressure on the

supporting structure and no portion of the work shall be left more than one course lower

than the adjacent work. Where this is not possible, the work shall be raked back according

to bond (and not saw toothed) at an angle not exceeding 45 deg. But in no case the level

difference between adjoining walls shall exceed one meter. Brickwork shall not be raised

more than one meter per day.

 Bricks shall be so laid that all joints are well filled with mortar. The thickness of joints shall

not be less than 6 mm and not more than 10 mm. The face joints shall be raked to a

minimum depth of 10mm/15mm by raking tools during the progress of work when the mortar

is still green, so as to provide a proper key for the plastering/ pointing respectively to be

done later. When plastering or pointing is not required to be done, the joints shall be

uniform in thickness and be struck flush and finished at the time of laying. The face of

brickwork shall be cleaned daily and all mortar droppings removed. The surface of each

course shall be thoroughly cleaned of all dirt before another course is laid on top. During

inclement weather conditions, newly built brick masonry works shall be protected by

tarpaulin or other suitable covering to prevent mortar being washed away by rain.

 Brickwork shall be kept constantly moist on all the faces for at least seven days after 24 hrs

of laying. The arrangement for curing shall be got approved from the E.I.C.

 Double scaffolding having two sets of vertical supports shall be provided to facilitate

execution of the masonry works. The scaffolding shall be designed adequately considering

all the dead, live and possible impact loads to ensure safety of the workmen, in accordance

with the requirements stipulated in IS:2750 and IS:3696(Part I).

 Scaffolding shall be properly maintained during the entire period of construction. Single

scaffolding shall not be used on important works and will be permitted only in certain cases

as decided by the GWIL. Where single scaffolding is adopted, only minimum number of

holes, by omitting a header shall be left in the masonry for supporting horizontal scaffolding

poles. All holes in the masonry shall be carefully made good before plastering/pointing.

 In the event of usage of traditional bricks of size 230 mm x115mm x75mm, the courses at

the top of the plinth and sills as well as at the top of the wall just below the roof/floor slabs

and at the top of the parapet shall be laid with bricks on edge. All brickwork shall be built

tightly against columns, floor slabs or other structural members.

 To overcome the possibility of development of cracks in the brick masonry following

measures shall be adopted. For resting RCC slabs, the bearing surface of masonry wall shall

be finished on top with 12 mm thick cement mortar 1:3 and provided with 2 layers of Kraft

paper Grade 1 as per IS:1397 or 2 layers of 50-micron thick polyethylene sheets.

 RCC/ steel beams resting on masonry wall shall be provided with reinforced concrete bed

blocks of 50 mm thickness, projecting 50mm on either side of the beam, duly finished on top

with 2 layers of Kraft paper Grade 1 as per IS:1397 or 2 layers of 50-micron thick

polyethylene sheets.

 Steel wire fabric shall be provided at the junction of brick masonry and concrete before

taking up plastering work. Bricks for partition walls shall be stacked adjacent to the

structural member to pre-deflect the structural member before the wall is taken up for

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

execution. Further, the top most course of half or full brick walls abutting against either a

de-shuttered slab or beam shall be built only after any proposed masonry wall above the

structural member is executed to cater for the deflection of the structural element.

 Reinforced cement concrete transoms and mullions of dimensions as indicated in the

construction Drawings to be prepared by the Contractor are generally required to be

provided in the half brick partition walls.

 Where the drawings prepared by the Contractor indicate that structural steel sections are to

be encased in brickwork, the brickwork masonry shall be built closely against the steel

section, ensuring a minimum of 20mm thick cement-sand mortar 1:4 over all the steel

surfaces. Steel sections partly embedded in brickwork shall be provided with bituminous

protective coating to the surfaces at the point of entry into the brick masonry.

 Facing bricks of the type specified conforming to IS: 2691 shall be laid in the positions

indicated on the Drawings prepared by the Contractor and all facing brickwork shall be well

bonded to the backing bricks/RCC surfaces. The level of execution of the facing brickwork

shall at any time be lower by at least 600 mm below the level of the backing brickwork.

Facing bricks shall be laid over 10 mm thick backing of cement mortar. The mortar mix,

thickness of joint and the type of pointing to be carried out shall be as specified in the item

of works prepared by the Contractor. The pattern of laying the bricks shall be as specifically

indicated in the Drawings prepared by the Contractor. For facing brickwork, double

scaffolding shall be used. Faced works shall be kept clean and free from damage,

discoloration etc., at all times.

Uncoursed Random Rubble Masonry, in Foundation, Plinth and Superstructure.

 Stones for the works shall be of the specified variety, which are hard, durable, fine grained

and uniform in color (for superstructure work) free from veins, flaws and other defects.

Quality and work shall conform to the requirements specified in IS: 1597 (Part-I). The

percentage of water absorption shall not exceed 5 percent as per test conducted in

accordance with IS: 1124. The Contractor shall supply sample stones to the GWIL for

approval. Stones shall be laid with its grains horizontal so that the load transmitted is always

perpendicular to the natural bed.

 Cement-sand mortar for stone masonry works shall be in the proportion of 1:6.

 Materials and preparation of mortar shall be as specified above.

 For All Works below ground level the masonry shall be random rubble uncoursed with

ordinary quarry dressed stones for the hearting and selected quarry dressed stones for the

 For all works above ground level and in superstructure the masonry shall be random rubble

uncoursed, well bonded, faced with hammer dressed stones with squared quoins at corners.

The bushings on the face shall not be more than 40 mm on an exposed face and on the face

to be plastered it shall not project by more than 12 mm nor shall it have depressions more

than 10 mm from the average wall surface.

 Face stones shall extend back sufficiently and bond well with the masonry. The depth of

stone from the face of the wall inwards shall not be less than the height or breadth at the

face. The length of the stone shall not exceed three times the height and the breadth on

base shall not be greater than three-fourths the thickness of wall nor less than 150 mm.

The height of stone may be up to a maximum of 300 mm. Face stones or hearting stones

shall not be less than 150 mm in any direction. Chips and spalls shall be used wherever

necessary to avoid thick mortar joints and to ensure that no hollow spaces are left in the

masonry. The use of chips and spalls in the hearting shall not exceed 20 percent of the

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

quantity of stone masonry. Spalls and chips shall not be used on the face of the wall and

below hearting stones to bring them to the level of face stones.

 The maximum thickness of joints shall not exceed 20 mm. All joints shall be completely

filled with mortar. When plastering or pointing is not required to be done, the joints shall

be struck flush and finished as the work proceeds. Otherwise, the joints shall be raked to a

minimum depth of 20 mm by a raking tool during the progress of the work while the mortar

is still green.

 Through or bond stones shall be provided in walls up to 600 mm thick and in case of walls

above 600 mm thickness, a set of two or more bond stones overlapping each other by at

least 150 mm shall be provided in a line from face to back. In case of highly absorbent

types of stones (porous lime stone and sand stone, etc.) the bond stone shall extend about

two-thirds into the wall and a set of two or more bond stones overlapping each other by at

least 150 mm shall be provided. Each bond stone or a set of bond stones shall be provided

for every 0.5 sq.m of wall surface.

 All stones shall be sufficiently wetted before laying to prevent absorption of water from

the mortar. All connected walls in a structure shall be normally raised uniformly and

regularly. However, if any part of the masonry is required to be left behind, the wall shall

be raked back (and not saw toothed) at an angle not exceeding 45deg. Masonry work shall

not be raised by more than one meter per day. Green work shall be protected from rain by

suitable covering. Masonry work shall be kept constantly moist on all the faces for a

minimum period of seven days for proper curing of the joints.

Coursed Rubble Masonry (First Sort) for Superstructure:

The Material specification for the work shall be as specified above.

 All Courses shall be laid truly horizontal and shall be of the same height in any course. The

height of course shall not be less than 150 mm and not more than 300 mm. The width of

stone shall not be less than its height.

 Face stones shall tail into the work for not less than their height and at least 1/3rd the

number of stones shall tail into the work for a length not less than twice their height but

not more than three-fourths the thickness of the wall whichever is smaller. These should

be laid as headers and stretchers alternately to break joints by at least 75 mm.

 The face stones shall be squared on all joints and beds; the bed joints being hammer or

chisel dressed true and square for at least 80 mm back from the face and the side joints

for at least 40 mm. The face of the stone shall be hammer dressed so that the bushing

shall not be more than 40 mm on an exposed face and 10 mm on a face to be plastered. No

portion of the dressed surface shall show a depth of gap more than 6 mm from a straight

edge placed on it. The remaining unexposed portion of the stone shall not project beyond

the surface of bed and side joints. No spalls or pinning shall be allowed on the face.

 All bed joints shall be horizontal and side joints shall be vertical and no joints shall be

more than 10 mm in thickness. When plastering or pointing is not required to be done, the

joints shall be struck flush and finished as the work proceeds. Otherwise, the joints shall

be raked to a minimum depth of 20 mm by a raking tool, during the progress of the work

while the mortar is still green.

 Hearting shall consist of flat bedded stones carefully laid on their proper beds and solidly

bedded in mortar. The use of chips shall be restricted to the filling of interstices between

the adjacent stones in hearting and these shall not exceed 10 percent of the quantity of

the stone masonry. Care shall be taken so that no hollow spaces are left anywhere in the

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 The requirement regarding through or bond stones shall be as specified in clause 7.3.2 with

the further stipulation that these shall be provided at 1.5 m to 1.8m apart clear in every

course but staggered at alternate courses.

 The quoins which shall be of the same height as the course, in which they occur, shall not

be less than 450 mm in any direction. Quoin stones shall be laid as stretchers and headers

alternately. They shall be laid square on their beds, which shall be rough chisel dressed to

a depth of at least 100 mm from the face. These stones shall have a minimum uniform

chisel draft of 25mm width at four edges, all the edges being in the same plane.

Concrete Block Masonry:

 Masonry units of hollow and solid concrete blocks shall conform to the requirements of IS:

2185 (Part I). Masonry units of hollow and solid light-weight concrete blocks shall conform

to the requirements of IS: 2185 (Part 3). Masonry units of autoclaved cellular concrete

blocks shall conform to the requirements of IS:2185 (Part 3). The height of the concrete

masonry units shall not exceed either its length or six times its width.

 The nominal dimensions of concrete block shall be as under.

Length 400, 500 or 600 mm

Height 100 or 200 mm

Width 100 to 300 mm in 50 mm increments

 Half blocks shall be in lengths of 200, 250 or 300mm to correspond to the full-length

 blocks. Actual dimensions shall be 10mm short of the nominal dimensions.

 The maximum variation in the length of the units shall not be more than ±5 mm and

maximum variation in height or width of the units shall not be more than ± 3mm.

 Concrete blocks shall be either hollow blocks with open or closed cavities or solid blocks.

Concrete blocks shall be sound, free of cracks, chipping or other defects which impair the

strength or performance of the construction. Surface texture shall as specify. The faces of

the units shall be flat and rectangular, opposite faces shall be parallel and all arises shall

 The bedding surfaces shall be at right angles to the faces of the block.

 The concrete mix for the hollow and solid concrete blocks/light weight concrete blocks

shall not be richer than one part of cement to six parts of combined aggregates by volume.

Concrete blocks shall be of approved manufacture, which satisfy the limitations in the

values of water absorption, drying shrinkage and moisture movement, as specified for the

type of block as per relevant IS code. Contractor shall furnish the test certificates and also

supply the samples for the approval of GWIL.

 The type of the concrete block, thickness and grade based on the compressive strength for

use in load bearing and/or non-load bearing walls shall be as specified. The minimum

nominal thickness of non-load bearing internal walls shall be 100mm. The minimum

nominal thickness of external panel walls in framed construction shall be 200 mm.

 The workmanship shall generally conform to the requirements of IS:2572 for concrete block

masonry, IS:6042 for light weight concrete block masonry and IS:6041 for autoclaved

cellular concrete block masonry works.

 From considerations of durability, generally concrete block masonry shall be used in

superstructure works above the damp-proof course level.

 Concrete blocks shall be embedded with a mortar which is relatively weaker than the mix

of the blocks in order to avoid the formation of cracks. Cement mortar of proportion 1:6

shall be used for the works. Preparation of mortar shall be as specified above.

 Thickness of both horizontal and vertical joints shall be 10mm. The first course shall be

laid with greater care, ensuring that it is properly aligned, leveled and plumb since this

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

will facilitate in laying succeeding courses to obtain a straight and truly vertical wall. For

the horizontal (bedding) joint, mortar shall be spread over the entire top surface of the

block including front and rear shells as well as the webs to a uniform layer of 10mm. For

vertical joints, the mortar shall be applied on the vertical edges of the front and rear

shells of the blocks. The mortar may be applied either to the unit already placed on the

wall or on the edges of the succeeding unit when it is standing vertically and then placing

it horizontally, well pressed against the previously laid unit to produce a compacted

vertical joint. In case of two cell blocks with slight depression on the vertical sides these

shall also be filled up with mortar to secure greater lateral rigidity. To assure satisfactory

bond, mortar shall not be spread too far ahead of actual laying of the block as the mortar

will stiffen and lose its plasticity Mortar while hardening shrinks slightly and thus pulls

away from the edges of the block. The mortar shall be pressed against the units with a

jointing tool after it has stiffened to effect intimate contact between the mortar and the

unit to obtain a weather tight joint. The mortar shall be raked to a depth of 10mm as each

course is laid to ensure good bond for the plaster.

 Dimensional stability of hollow concrete blocks is greatly affected by variations of moisture

content in the units. Only well dried blocks should be used for the construction. Blocks

with moisture content more than 25% of maximum water absorption permissible shall not

be used. The blocks should not be wetted before or during laying in the walls. Blocks

should be laid dry except slightly moistening their surfaces on which mortar is to be

applied to obviate absorption of water from the mortar.

 As per the design requirements and to effectively control cracks in the masonry, RCC

bound beams/studs, joint reinforcement shall be provided at suitable locations. Joint

reinforcement shall be fabricated either from mild steel wires conforming to IS:280 or

welded wire fabric/high strength deformed basis.

 For jambs of doors, windows and openings, should concrete blocks shall be provided. If

hollow units are used, the hollows shall be filled with concrete of mix 1:3:6. Hold fasts of

doors/windows should be arranged so that they occur at block course level.

 At intersection of walls, the courses shall be laid up at the same time with a true masonry

bond between at least 50% of the concrete blocks. The sequence for construction of

partition walls and treatment at the top of load bearing walls for the RCC slab shall be as

for the brick work. Curing of the mortar joints shall be carried out for at least 7 days. The

walls should only be lightly moistened and shall not be allowed to become excessively wet.

Double scaffolding as per clause shall be adopted for execution of block masonry work.

Cutting of the units shall be restricted to a minimum. All horizontal and vertical

dimensions shall be in respectively, adopting modular co-ordination for walls, opening

locations for doors, windows etc.

 Concrete blocks shall be stored at site suitably to avoid any contact with moisture from the

ground and covered to protect against wetting.

Damp - Proof Course:

Materials and Workmanship:

 Where Specified, all the walls in a building shall be provided with damp-proof course cover

at plinth to prevent water from rising up the wall. The damp-proof course shall run without

a break throughout the length of the wall, even under the door or other openings. Damp-

proof course shall consist of 50 mm thick cement concrete of 1:2:4 nominal mix with

approved water-proofing compound admixture conforming to IS: 2645 in proportion as

directed by the manufacturer. Concrete shall be with 10 mm downgraded coarse

 The surface of brick work/stone masonry work shall be leveled and prepared before laying

the cement concrete. Side shuttering shall be properly fixed to ensure that slurry does not

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

leak through and is also not disturbed during compaction. The upper and side surface shall

be made rough to afford key to the masonry above and to the plaster.

 Damp-proof course shall be cured properly for at least seven days after which it shall be

allowed to dry for taking up further work.

Miscellaneous Inserts, Bolts etc.

 All the miscellaneous inserts such as bolts, pipes, plate embedment etc., shall be

accurately installed in the building works at the correct location and levels, all as detailed

in the construction Drawings to be prepared by the Contractor. Contractor shall prepare

and use templates for this purpose, if so directed by the GWSSB. In the event, of any of

the inserts are improperly installed, Contractor shall make necessary arrangements to

remove and reinstall at the correct locations/levels, all as directed by the GWSSB.

Wood Work for Doors, Windows, Ventilators & Partitions

 Timber to be used shall be first class Teak wood as per IS:4021. Timber shall be of the best

quality and well seasoned by a suitable process before being planed to the required sizes.

The maximum permissible moisture content shall be from 10 to 16 percent for timber

50mm and above in thickness and 8 to 14 percent of timber less than 50mm in thickness for

different regions of the country as stipulated in IS:287. Timber shall be close grained, of

uniform color and free from decay, fungal growth, boxed heart, pitch pockets or streaks on

the exposed edges, borer holes, splits and cracks.

 Flush door shutters of the solid core type with plywood face panels shall conform to

IS:2202 (Part 1) and with particle board/hard board face panels shall conform to IS:2202

 Transparent sheet glass shall conform to the requirements of IS:2835. Wired and figured

glass shall be as per IS:5437.

 Builder’s hardware for fittings and fixtures shall be of the best quality from approved

 The workmanship and finish of wood work in doors, windows, ventilators and partitions

shall be of a very high order. Contractor shall ensure that work is executed in a

professional manner by skilled carpenters for good appearance, efficient and smooth

operation of the shutters.

 All works shall be executed as per the detailed Drawings prepared by the Contractor

and/or as directed by the GWIL.

 All members of the door, window, and ventilator shall be straight without any warp or bow

and shall have smooth well-planned faces. The right angle shall be checked from the inside

surfaces of the respective members of the frame. Frames shall have mortise and tenon

joints which shall be treated with an approved adhesive and provided with metal or wood

pins. The vertical members of the door frame shall project 50 mm below the finished floor

level. The finished dimension of frames shall be rebated on the solid for keying with the

plaster and for receiving the shutters. The depth of rebate for housing the shutter shall be

15 mm. The size of the frames shall be as specified in the respective items of work

prepared by the Contractor. The workmanship shall generally conform to the requirements

specified in IS:4021.

 The face of the frames abutting the masonry or concrete shall be provided with a coat of

 Three hold fasts using 25 mm x 6 mm mild steel flats 225 mm long with split ends shall be

fixed on each side of door and window frames, one at the center and the other two at

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

mm from the top and bottom of the frame. For window and ventilator frames less than 1 m

in height, two hold fasts on each side shall be fixed at quarter points.

 Timber paneled shutters for doors, windows and ventilators shall be constructed in the

form of framework of stiles and rails with panel insertion. The panels shall be fixed by

either providing grooves in the stiles and rails or by beading. Glazing bars shall be as

detailed in the Drawings prepared by the Contractor. The stiles and rails shall be joined by

mortise and tenon joints at right angles. All members of the shutter shall be straight

without any warp or bow and shall have smooth, well planed faces at right angles to each

other. The right angle for the shutter shall be checked by measuring the diagonals and the

difference shall not be more than ±3 mm. Timber panels made from more than one piece

shall be jointed with a continuous tongued and grooved joint, glued together and

reinforced with metal dowels.

 The workmanship shall generally conform to the requirements specified in IS: 1003 (Parts

& 2). The thickness of the shutter, width/thickness of the stiles/rails/panel type shall be

as specified. Marine plywood panels conforming to IS:710 shall be used for doors where

 Details of the wooden flush door shutters, solid core type with specific requirement of the

thickness, core, face panels, viewing glazed panel, Venetian louver opening, teak wood

lapping etc. shall be as specified. Panels of shutter shall be of marine plywood conforming

to IS:710. Flush door shutters shall be from reputed manufacturers and Contractor shall

submit test results as per IS:4020, if so desired by the GWIL.

 Glazing of door, window, ventilator and partitions shall be with either flat transparent

sheet glass, wired or figured glass. Transparent sheet glass shall be of 'B' quality as per IS:

2835.The thickness and type of glazing to be provided shall be as specified.

 The material of the fittings and fixtures either of chromium plated steel, cast brass,

copper oxidized or anodized aluminum shall be as specified. The number, size and type of

the fittings and fixtures shall be as specified.

 Woodwork shall not be provided with the finishes of painting/varnishing etc. unless it has

been approved by the GWIL. The type of finish and the number of coats shall be as

stipulated in the respective items of work prepared by the Contractor. Preparation of the

wood surfaces and application of the finishes shall be in accordance with clause 7.32.

 Wooden hand railing and architraves shall be of the size and shape with the fixing

arrangement as indicated in the Drawings prepared by the Contractor.

 The framework of the partitions with mullions and transoms shall be with the sections of

dimensions as specified. Panels of double/single glazing/plywood shall be fixed as per

details specified. Partitions shall be fixed rigidly between the floor and structural

columns/beams including provision of necessary shims for wedging etc. Finished work shall

be of rigid construction, erected truly plumb to the lines and levels, at locations as per the

construction Drawings prepared by the Contractor.

 Any carpentry work which shows defects due to inadequate seasoning of the timber or bad

workmanship shall be removed and replaced by Contractor with work as per Specifications.

Steel Doors, Windows and Ventilators:

 Hot rolled steel sections for the fabrication of steel doors, windows and ventilators shall

conform to IS: 7452, which are suitable for, single glazing.

 Pressed steel door frames for steel flush doors shall be out of 1.25mm thick mild steel

sheets of profiles as per IS:

 Transparent sheet glass shall conform to the requirements of IS:

 Wired and figured glass shall be as per IS:

 Builder’s hardware of fittings and fixtures shall be of the best quality from the approved

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 All steel doors, windows and ventilators shall be of the type as specified in the respective

items of work prepared by the Contractor and of sizes as indicated in the Drawings

prepared by the Contractor prepared by the Contractor. Steel doors, windows and

ventilators shall conform to the requirements as stipulated in IS: 1038. Steel windows shall

conform to IS: 1361, if so specified.

 Doors, windows and ventilators shall be of an approved manufacture. Fabrication of the

unit shall be with rolled section, cut to correct lengths and metered. Corners shall be

welded to form a solid fused welded joint conforming to the requirements of IS:

Tolerance in overall dimensions shall be within ±1.5mm. The frames and shutters shall be

free from wrap or buckle and shall be square and truly plain. All welds shall be dressed

flush on exposed and contact surfaces. Punching of holes, slots and other provisions to

install fittings and fixtures later shall be made at the correct locations as per the

requirements. Samples of the units shall be got approved by the GWIL before further

manufacture/purchase by the Contractor.

 Type and details of shutters, hinges, glazing bar requirement, couplings, locking

arrangement, fittings and fixtures shall be as described in the respective items of work and

/ or as shown in the Drawings prepared by the Contractor for single or composite units.

 For windows with fly proof mesh as per the item of work prepared by the Contractor, rotor

operator arrangement, for the operation of the glazed shutters from the inside shall be

 Pressed steel door frames shall be provided with fixing lugs at each jamb, hinges, lock-

strike plate, mortar guards, angle threshold, shock-absorbers of rubber or similar material

as per the requirements of IS: 4351. Pressed steel doorframes shall be fixed as `built-in’ as

the masonry work proceeds. After placing it plumb at the specified location, masonry walls

shall be built up solid on either side or each course grouted with mortar to ensure solid

contact with the doorframe, without leaving any voids. Temporary struts across the width

shall be fixed, during erection to prevent bow/sag of the frame. Door shutters of flush

welded construction shall be 45 mm thick, fabricated with two outer skills of 1.25mm thick

steel sheets, 1mm thick steel sheet stiffeners and steel channels on all four edges. Double

shutters shall have meeting stile edge beveled or rebated. Provision of glazed viewing

panel, louvers shall be made as per the items of works and/or Drawings prepared by the

Contractor. Shutters shall be suitably reinforced for lock and other surface hardware and

to prevent sagging/twisting. Single sheet steel door shutters shall be fabricated out of

1.25mm thick steel sheets, mild steel angles and stiffeners as per the Drawings prepared

by the Contractor.

 Doors, windows and ventilators shall be fixed into the prepared openings. They shall not be

‘built-in’ as the masonry work proceeds, to avoid distortion and damage of the units. The

dimensions of the masonry opening shall have 10mm clearance around the overall

dimensions of the frame for this purpose. Any support of scaffolding members on the

frames/glazing bars is prohibited.

 Glazing of the units shall be either with flat transparent glass or wired / figured glass of

the thickness as specified in the items of works prepared by the Contractor. All glass

panels shall have properly squared corner and straight edges. Glazing shall be provided on

the outside of the frames.

 Fixing of the glazing shall be either with spring glazing clips and putty conforming to IS:419

or with metal beads. Pre-formed PVC or rubber gaskets shall be provided for fixing the

beads with the concealed screws. The type of fixing the glazing shall be as indicated in the

items of work and/or in Drawings prepared by the Contractor.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Steel doors, windows and ventilators shall be provided with finish of either painting as

specified or shall be hot dip galvanized with thickness of the zinc coating as stipulated all

as described in the respective items of works prepared by the Contractor.

 The material of the Builders hardware of fittings and fixtures of chromium plated steel,

cast brass, brass copper oxidized or anodized aluminum shall be as specified in the items

of works prepared by the Contractor. The number, size and type of fittings and fixtures

shall be as in the Drawings /items of works prepared by the Contractor.

 Installation of the units with fixing lugs, screws, mastic caulking compound at the specified

locations shall generally conform to the requirements of IS:1081. Necessary holes etc

required for fixing shall be made by the Contractor and made good after installation.

Workmanship expected is of a high order for efficient and smooth operation of the units.

Aluminum Doors, Windows, Ventilators & Partitions:

 Aluminum alloy used in the manufacture of extruded sections for the fabrication of doors,

windows, ventilators shall conform to designation HE9-WP of IS:733.

 Transparent sheet glass shall conform to the requirements of IS:2835. Wired and figured

glass shall be as per IS:5437.

 Builder's hardware of fittings & fixtures shall be of the best quality from approved

 All aluminum doors, windows, ventilators and partitions shall be of the type and size as

specified. The doors, windows, ventilators shall conform to the requirements of IS:1948.

Aluminum windows shall conform to IS:1949, if so specified.

 All aluminum units shall be supplied with anodized finish. The minimum anodic film

thickness shall be 0.015 mm. Doors, windows and ventilators shall be of an approved

manufacture. Fabrication of the units shall be with the extruded sections, cut to correct

lengths, mitered and welded at the corners to a true right angle conforming to the

requirements of IS:1948. Tolerance in overall dimensions shall be within ± 1.5mm. The

frames and shutters shall be free from warp or buckle and shall be square and truly plane.

Punching of holes, slots and other provisions to install fittings or fixtures later shall be

made at the correct locations, as per the requirements. Aluminum swing type doors,

aluminum sliding windows, partitions shall be as specified.

 IS:1948 and IS:1949 referred to incorporates the sizes, shapes, thicknesses and weight per

running meter of extruded sections for the various components of the units. However, new

sizes, shapes, thicknesses with modifications to suit snap-fit glazing clips etc. are being

continuously being added by various leading manufacturers of extruded sections, which are

available in the market. As such, the sections of the various components of the unit

proposed by the Contractor will be reviewed by the GWIL and will be accepted only if they

are equal to or marginally more than that given in the codes/as specified.

 The framework of the partitions with mullions and transom shall be with anodized

aluminum box sections. Anodized aluminum box sections shall be in-filled with timber of

class 3 (silver oak or any other equivalent) as per IS:4021. Panels of double/single

glazing/plywood shall be fixed as per details indicated in the Drawings to be prepared by

the Contractor. Partitions shall be fixed rigidly between the floor and the structural

columns/beams including provision of necessary shims for wedging etc. Finished work shall

be of rigid construction, erected truly plumb to the lines and levels, at locations as per the

construction Drawings to be prepared by the Contractor.

 Specific provisions as stipulated for steel doors, windows, ventilators under clause 7.9.2

shall also be applicable for this item work. Glazing beads shall be of the snap-fit type

suitable for the thickness of glazing proposed as indicated in the items of works prepared

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

by the Contractor. A layer of clear transparent lacquer shall be applied on aluminum

sections to protect them from damage during installation. This lacquer coating shall be

removed after the installation is completed.

Steel Rolling Shutters:

Materials and Workmanship:

 Rolling shutters shall be of an approved manufacture, conforming to the requirements

specified in IS:6248.

 The type of rolling shutter shall be self-coiling type (manual) for clear areas up to 12 m2,

gear operated type (mechanical) for clear areas up to 35 m2 and electrically operated type

for areas up to 50 sq.m. Mechanical type of rolling shutters shall be suitable for operation

from both inside and outside with the crank handle or chain gear operating mechanism

duly considering the size of wall/column. Electrical type of rolling shutter shall also be

provided with a facility for emergency mechanical operation.

 Rolling shutters shall be supplied duly considering the type, specified clear width/height of

the opening and the location of fixing as indicated in the Drawings prepared by the

Contractor. Shutters shall be built up of interlocking laths 75 mm width between rolling

centers formed from cold rolled steel strips. The thickness of the steel strip shall not be

less than 0.90 mm for shutters up to 3.50m width and not less than 1.20 mm for shutters

above 3.50 m width. Each lath section shall be continuous single piece without any welded

joint. The guide channels out of mild steel sheets of thickness not less than 3.15 mm shall

be of either rolled, pressed or built up construction. The channel shall be of size as

stipulated in IS:6248 for various clear widths of the shutters.

 Hood covers shall be of mild steel sheets not less than 0.90 mm thick and of approved

shape. Rolling shutters shall be provided with a central hasp and staple safety device in

addition to one pair of lever locks and sliding locks at the ends.

 All component parts of the steel rolling shutter (excepting springs and insides of guide

channels) shall be provided with one coat of zinc chrome primer conformity to IS:2074 at

the shop before supply. These surfaces shall be given an additional coat of primer after

erection at the site along with the number of coats and type of finish paint as specified in

the respective items of works prepared by the Contractor. Painting shall be carried out as

specified in specifications or as per engineer in charge direction.

 In case of galvanized rolling shutter, the lath sections, guides, lock plate, bracket plates,

suspension shaft and the hood cover shall be hot dip galvanized with a zinc coating

containing not less than 97.5 percent pure zinc. The weight of the zinc coating shall be at

least 610gms/m2.

 Guide channels shall be installed truly plumb at the specified location. Bracket plate shall

be rigidly fixed with necessary bolts and holdfasts. Workmanship of erection shall ensure

strength and rigidity of rolling shutter for trouble free and smooth operation.

Rubble Sub-Base:

 Stones used for rubble packing under floors on grade, foundations etc., shall be clean,

hard, durable rock free from veins, flaws, laminations, weathering and other defects.

Stones shall generally conform to the requirements stipulated in IS: 1597 (Part I).

 Stones shall be as regular as can be obtained from quarries. Stones shall be of height equal

to the thickness of the packing proposed with a tolerance of 10 mm. Stones shall not

have a base area less than 250 sq cm nor more than 500 sq.cm, and the smallest dimension

of any stone shall not be less than half the largest dimension. The quality and size of

stones shall be subject to the approval of the GWSSB.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Stones shall be hand packed carefully and laid with their largest base downwards resting

flat on the prepared sub-grade and with their height equal to the thickness of the packing.

Stones shall be laid breaking joints and in close contact with each other. All interstices

between the stones shall be wedged-in by small stones of suitable size, well driven in by

crow bars and hammers to ensure tight packing and complete filling-in of the interstices.

The wedging shall be carried out simultaneously with the placing in position of rubble

packing and shall not lag behind. After this, any interstices between the smaller wedged

stones shall be unfilled with clean hard sand by brooming so as to fill the joints

 The laid rubble packing shall be sprinkled with water and compacted by using suitable

 The thickness and grade of concrete and reinforcement shall be as specified in items of

works prepared by the contractor.

 Before placing the blinding concrete, the sub-base of rubble packing shall be properly

wetted and rammed. Concrete for the base shall then be deposited between the forms,

thoroughly tamped and the surface finished level with the top edges of the forms. Two or

three hours after the concrete has been laid in position, the surface shall be roughened

using steel wire brush to remove any scum or laitance and swept clean so that the coarse

aggregates are exposed. The surface of the base concrete shall be left rough to provide

adequate bond for the floor finish to be provided later.

Terrazzo and Plain Cement Tiling Work:

 Terrazzo tiles and cement tiles shall generally conform in all respects to standards

stipulated in IS:1237. Tiles shall be of the best quality manufactured adopting hydraulic

pressure of not less than 14N/mm2.

 The type, quality, size, thickness color etc, of the tiles for flooring/dado/skirting shall be

 The aggregates for terrazzo topping shall consist of marble chips which are hard, sound

and dense. Cement to be used shall be either ordinary Portland cement or white cement

with or without coloring pigment. The binder mix shall be with 3 parts of cement to 1 part

of marble powder by weight. The proportion of cement shall be inclusive of any pigments.

For every one part of cement-marble powder binder mix, the proportion of aggregates

shall be 1.75 parts by volume, if the chips are between 1mm to 6mm and 1.50 parts by

volume if the chips are between 6mm to 25mm.

 The minimum thickness of wearing layer of terrazzo tiles shall be 5mm for tiles with chips

of size varying from 1mm up to 6mm or from 1mm up to 12mm. This shall be 6mm for tiles

with chips varying from 1mm up to 25mm. The minimum thickness of wearing layer of

cement/colored cement tiles shall be 5mm. This shall be 6mm for heavy duty tiles.

Pigment used in the wearing layer shall not exceed 10 percent of the weight of cement

used in the mix.

 Laying and finishing of tiles shall conform to the requirements of workmanship stipulated

 Tiling work shall be commenced only after the door and window frames are fixed and

plastering of the walls/ ceiling is completed. Wall plastering shall not be carried out up to

about 50 mm above the level of proposed skirting/dado.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 The base concrete shall be finished to a reasonably plane surface about 40 to 45mm below

the level of finished floor. Before the tiling work is taken up, the base concrete or

structural slab shall be cleaned of all loose materials, mortar droppings, dirt, laitance etc.

using steel wire brush and well wetted without allowing any water pools on the surface. A

layer of 25mm average thickness of cement mortar consisting of one part of cement to

parts of sand shall be provided as bedding for the tiles over the base concrete.

 The thickness of bedding mortar shall not be less than 10mm at any place. The quantity of

water to be added for the mortar shall be just adequate to obtain the workability for

laying. Sand for the mortar shall conform to IS:2116 and shall have minimum fineness

modulus of 1.5. The surface shall be left rough to provide a good bond for the tiles.

 The bedding shall be allowed to harden for a day before laying of the tiles. Neat cement

slurry using 4.4 kg of cement per m2of floor area shall be spread over the hardened mortar

bedding over such an area at a time as would accommodate about 20 tiles.

 Tiles shall be fixed in this slurry one after the other, each tile being gently tapped with a

wooden mallet till it is properly bedded and in level with the adjoining tiles. The joints

shall be in straight lines and shall normally be 1.5mm wide.

 On completion of laying of the tiles in a room, all the joints shall be cleaned and washed

fairly deep with a stiff broom/wire brush to a minimum depth of 5mm. The day after the

tiles have been laid, the joints shall be filled with cement grout of the same shade as the

color of the matrix of the tile. For this purpose, white cement or grey cement with or

without pigments shall be used.

 The flooring should be kept moist and left undisturbed for 7 days for the bedding/joints to

set properly. Heavy traffic shall not be allowed on the floor for at least 14 days after fixing

 About a week after laying the tiles, each and every tile shall be lightly tapped with a small

wooden mallet to find out if it gives a hollow sound; if it does, such tiles along with any

other cracked or broken tiles shall be removed and replaced with new tiles to proper line

 The same procedure shall be followed again after grinding the tiles and all damaged tiles

replaced, properly jointed and finished to match. For the purpose of ensuring that such

replaced tiles match with those laid earlier, it is necessary that the Contractor shall

procure sufficient quantity of extra tiles to meet this contingency.

 Wherever a full tile cannot be provided, tiles shall be cut to size and fixed. Floor tiles

adjoining the wall shall go about 10mm under the plaster, skirting or dado.

 Tile skirting and dado work shall be executed only after laying tiles on the floor. For dado

and skirting work, the vertical wall surface shall be thoroughly cleaned and wetted.

Thereafter it shall be evenly and uniformly covered with 10mm thick backing of 1:4

cement sand mortar.

 For this work the tiles as obtained from the factory shall be of the size required and

practically full polished. The back of each tile to be fixed shall be covered with a thin

layer of neat cement paste and the tile shall then be gently tapped against the wall with a

wooden mallet. Fixing shall be done from the bottom of the wall upwards. The joints shall

be in straight lines and shall normally be 1.5mm wide. Any difference in the thickness of

the tiles shall be evened out in the backing mortar or cement paste so that the tile faces

are in conformity & truly plumb. Tiles for use at the corners shall be suitably cut with

beveled edges to obtain a neat and true joint. After the work has set, hand polishing with

carbonado stones shall be done so that the surface matches with the floor finish.

 Wall plastering of the strip left out above the level of skirting/dado shall be taken up after

the tiles are fixed.

 Chequered terrazzo tiles for flooring and for stair treads shall be delivered to site after the

first machine grinding.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Machine grinding and polishing shall be commenced only after a lapse of 14 days of laying.

The sequence and three numbers of machine grinding operations, usage of the type of

carborundum stones, filling up of pin holes, watering etc. shall be carried out all as

specified in IS:1443.

 Tiles shall be laid to the levels specified. Where large areas are to be tiled the level of the

central portion shall be kept 10mm higher than that at the walls to overcome optical

illusion of a depression in the central portion. Localized deviation of ±3mm in any 3m

length is acceptable in a nominally flat floor.

In-Situ Terrazzo Work:

 The requirements of marble aggregates for terrazzo topping shall be as mentioned above.

 Cement shall first be mixed with the marble powder in dry state. The mix thus obtained

shall be mixed with the aggregates in the specified proportions. Care shall be taken not to

get the materials into a heap which results in the coarsest chips falling to the edges and

cement working to the center at the bottom.

 Materials shall be kept, as far as possible, in an even layer during mixing. After the

materials have been thoroughly mixed in the dry state, water shall be added, just

adequate to obtain plastic consistency for the desired workability for laying. The mix shall

be used in the works within 30 minutes of the addition of water to the cement.

 The thickness, type, quality, size and color of chips etc. for the in-situ terrazzo finish for

flooring/dado/ skirting shall be as specified in the respective items of works prepared by

the Contractor. Laying and finishing of in-situ work shall conform to the requirements of

workmanship stipulated in IS:

 In-situ terrazzo finish shall be laid over hardened concrete base. The finish layer consists

of an under layer and terrazzo topping. The under layer shall be of cement concrete of mix

1:2:4 using 10mm downgraded coarse aggregates. The combined thickness of under layer

and topping shall not be less than 30 mm for flooring and 20mm for dado/skirting work.

 The minimum thickness of topping shall be 6mm if chips used are between 1mm to 4mm,

9mm if chips are between 4mm to 7mm and 12mm if chips are between 7mm to 10mm. If

chips larger than 10mm size are used, the minimum thickness shall be one and one third

the maximum size of chips.

 Both the under layer and later the topping shall be divided into panels not exceeding

m2for laying so as to reduce the possibility of development of cracks. The longer dimension

of any panel shall not exceed 2m. Dividing strips shall be used to separate the panels.

When the dividing strips are not provided, the bays shall be laid alternately, allowing an

interval of at least 24 hours between laying adjacent bays.

 Dividing strips shall be either of aluminum, brass or other material as indicated in the

items of works prepared by the Contractor. Aluminum strips should have a protective

coating of bitumen. The thickness of the strips shall not be less than 1.5mm and width not

less than 25mm for flooring work.

 Concrete base shall be finished to a reasonably plane surface to a level below the finished

floor elevation equal to the specified thickness of terrazzo finish. Before spreading the

under layer, the base concrete surface shall be cleaned of all loose materials, mortar

droppings, dirt, laitance etc. and well wetted without allowing any water pools on the

surface. Dividing strips or screed strips, if dividing strips are not provided shall be fixed on

the base and leveled to the correct height to suit the thickness of the finish.

 Just before spreading the under layer the surface shall be smeared with cement slurry at

2.75 Kg/m2. Over this slurry, the under layer shall be spread and leveled with a screening

board. The top surface shall be left rough to provide a good bond for the terrazzo topping.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Terrazzo topping shall be laid while the under layer is still plastic and normally between

to 24 hours after the under layer is laid. Cement slurry of the same color as the topping

shall be brushed on the surface immediately before laying is commenced.

 The terrazzo mix shall be laid to a uniform thickness and compacted thoroughly by tamping

and with a minimum of toweling. Straight edge and steel floats shall be used to bring the

surface true to the required level in such a manner that the maximum amount of marble

chips come up and spread uniformly all over the surface.

 The surface shall be left dry for air-curing for a period of 12 to 18 hours. Thereafter it shall

be cured by allowing water to stand in pools for a period of not less than 4 days.

 Machine grinding and polishing shall be commenced only after a lapse of 7 days from the

time of completion of laying. The sequence and four numbers of machine grinding

operations, usage of the type of carborundum stones, filling up of pinholes, wet curing,

watering etc. shall be carried out all as specified in IS:

Shahabad / Tandur/ Kota Stone Slab work:

 The slabs shall be of approved selected quality, hard, sound, dense and homogenous in

texture, free from cracks, decay, weathering and flaws. The percentage of water

absorption shall not exceed 5 percent as per test conducted in accordance with IS:

 The slabs shall be hand or machine cut to the required thickness. Tolerance in thickness

for dimensions of tile more than 100mm shall be ±5mm. This shall be ±2mm on dimensions

less than 100mm. Slabs shall be supplied to the specified size with machine cut edges or

fine chisel dressed to the full depth. All angles and edges of the slabs shall be true and

square, free from any chipping giving a plane surface. Slabs shall have the top surface

machine polished (first grinding) before being brought to site. The slabs shall be washed

clean before laying.

 The type, size, thickness and color/shade etc. of the slabs for flooring/dado/skirting shall

be as specified in the respective items of works prepared by the Contractor.

 Preparation of the concrete base, laying and curing shall be as mentioned above.

 Dado / skirting work shall be as per mentioned above. The thickness of the slabs for

dado/skirting work shall not be more than 25mm. Slabs shall be so placed that the back

surface is at a distance of 12mm. If necessary, slabs shall be held in position temporarily

by suitable method. After checking for verticality, the gap shall be filled and packed with

cement sand mortar of proportion 1:3. After the mortar has acquired sufficient strength,

the temporary arrangement holding the slab shall be removed.

 Grinding and polishing shall be as per mentioned above, except that first grinding with

coarse grade carborundum shall not be done and cement slurry with or without pigment

shall not applied before polishing.

Carborundum Tile Finish:

 Carborundum tiles shall generally conform in all respects to the standards stipulated in

IS:1237 for heavy duty tiles. Tiles shall be of the best quality manufactured adopting

hydraulic pressure of not less than 14 N/mm2.

 The topping shall be uniform and of thickness not less than 6mm. The quantity of

Carborundum grit shall be not less than 1.35 kg/sq.m used with cement with or without

pigment. The Carborundum grit shall pass through 1.18mm mesh and shall be retained on

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 Requirements as detailed for terrazzo/cement tile finish as mentioned above shall be

applicable for Carborundum tile flooring.

Glazed Tile Finish:

 Glazed earthenware tiles shall conform to the requirements of IS: 777. Tiles shall be of the

best quality from an approved manufacturer. The tiles shall be flat, true to shape and free

from flaws such as crazing, blisters, pinholes, specks or welts. Edges and underside of the

tiles shall be free from glaze and shall have ribs or indentations for a better anchorage

with the bedding mortar. Dimensional tolerances shall be as specified in IS:

 The total thickness of glazed tile finish including the bedding mortar shall be 20 mm in

flooring/dado/skirting. The minimum thickness of bedding mortar shall be 12mm for

flooring and 10mm for dado/skirting work.

 The bedding mortar shall consist of 1 part of cement to 3 parts of sand mixed with just

sufficient water to obtain proper consistency for laying. Sand for the mortar shall conform

to IS: 2116 and shall have minimum fineness modulus of 1.5.

 Tiles shall be soaked in water for about 10 minutes just before laying. Where full size tiles

cannot be fixed, tiles shall be cut to the required size using special cutting device and the

edges rubbed smooth to ensure straight and true joints.

 Colored tiles with or without designs shall be uniform and shall be preferably procured

from the same batch of manufacture to avoid any differences in the shade.

 Tiles for the flooring shall be laid over hardened concrete base. The surface of the

concrete base shall be cleaned of all loose materials, mortar droppings etc well wetted

without allowing any water pools on the surface. The bedding mortar shall then be laid

evenly over the surface, tamped to the desired level and allowed to harden for a day. The

top surface shall be left rough to provide a good bond for the tiles. For skirting and dado

work, the backing mortar shall be roughened using a wire brush.

 Neat cement slurry using 3.3 kg cement per m2of floor area shall be spread over the

hardened mortar bed over such an area as would accommodate about 20 tiles. Tiles shall

be fixed in this slurry one after the other, each tile being gently tapped with a wooden

mallet till it is properly bedded and in level with the adjoining tiles. For skirting and dado

work, the back of the tiles shall be smeared with cement slurry for setting on the backing

mortar. Fixing of tiles shall be done from the bottom of the wall upwards.

 The joints shall be in perfect straight lines and as thin as possible but shall not be more

than 1mm wide. The surface shall be checked frequently to ensure correct level/required

slope. Floor tiles near the walls shall enter skirting/dado to a minimum depth of 10mm.

Tiles shall not sound hollow when tapped. All the joints shall be cleaned of grey cement

with wire brush to a depth of at least 3mm and all dust, loose mortar etc. shall be

 White cement with or without pigment shall then be used for flush pointing the joints.

Curing shall then be carried out for a minimum period of 7 days for the bedding and joints

to set properly. The surface shall then be cleaned using a suitable detergent, fully washed

 Specials consisting of coves, internal and external angles, cornices, beads and their corner

pieces shall be of thickness not less than the tiles with which they are used.

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

In-Situ Cement Concrete Floor Topping:

 The mix proportion for the in-situ concrete floor topping shall be 1:2.5:3.5 (one-part

cement: two and half parts sand: three and half parts coarse aggregates) by volume unless

otherwise specified.

 The aggregates shall conform for the requirements of IS:383.

 Coarse aggregates shall have high hardness surface texture and shall consist of crushed

rock of granite, basalt, trap or quartzite. The aggregate crushing valve shall not exceed

percent. The grading of the aggregates of size 12.5mm and below shall be as per IS:2571.

 Grading of the sand shall be within the limits indicated in IS:2571.

 The thickness of the floor topping shall be as specified in the items of work prepared by

the Contractor. The minimum thickness of the floor topping shall be 25mm.

 Preparation of base concrete/structural slab before laying the topping shall be as

mentioned above. The surface shall be rough to provide adequate bond for the topping.

 Mixing of concrete shall be done thoroughly in a mechanical mixer unless hand mixing is

specifically permitted by the GWIL. The concrete shall be as stiff as possible and the

amount of water added shall be the minimum necessary to give just sufficient plasticity for

laying and compacting. The mix shall be used in the work within 30 minutes of the addition

of water for its preparation.

 Floor finish shall be laid in suitable panels to reduce the risk of cracking. No dimension of a

panel shall exceed 2 meters and the length of a panel shall not exceed one and a half

times its breadth. Topping shall be laid in alternate panels, the intermediate panels being

cast after a gap of at least one day. Construction joints shall be plain vertical butt joints.

 Screed strips shall be fixed dividing the area into suitable panels. Immediately before

depositing the concrete topping, neat cement slurry at 2.75 kg/m2of area shall be

thoroughly brushed into the prepared surface. Topping shall then be laid, very thoroughly

tamped, struck off level and floated with wooden float. The surface shall then be tested

with a straight edge and mason's spirit level to detect any inequalities and these shall be

made good immediately.

 Finishing of the surface by Trowelling shall be spread over a period of one to six hours

depending upon the temperature and atmospheric conditions. The surface shall be

trowelled 3 times at intervals so as to produce a smooth uniform and hard surface.

Immediately after laying, the first Trowelling just sufficient to give a level surface shall be

carried out avoiding excessive Troweling at this stage.

 The surface shall be re- trowelled after sometime to close any pores and to scrap off

excess water or laitance, which shall not be trowelled back into the topping. Final

Trowelling shall be done well before the concrete has become too hard but at a time when

considerable pressure is required to make any impression on the surface. Sprinkling of dry

cement or cement-sand mixture for absorbing moisture shall not be permitted.

 Immediately after the surface is finished, it shall be protected suitably from rapid drying

due to wind/ sunlight. After the surface has hardened sufficiently to prevent any damage

to it, the topping shall be kept continuously moist for a minimum period of 10 days.

 It is preferable to lay the topping on hardened base concrete, as against being laid

monolithically with a lesser thickness, since proper levels and slopes with close surface

tolerances is achievable in practice, owing to its greater thickness. Further, as this would

be laid after all other building operations are over, there will be no risk of any damages or

discolorations to the floor finish which are difficult to repair satisfactorily.

In-Situ Granolithic Concrete Floor Topping:

Materials and Workmanship:

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

 The Requirements of materials and workmanship shall be all as mentioned above for in-situ

cement concrete floor topping except that the mix proportion of the concrete shall be

1:1:2 (cement: sand: coarse aggregates) by volume.

 The minimum thickness of granolithic floor topping on hardened concrete base shall be

Floor Hardener Topping:

Materials & Workmanship:

 Floor Hardener topping shall be provided either as integrally finished over the structural

slab/grade slab or lay monolithically with the concrete/granolithic floor finish on top of

hardened concrete base.

 Floor hardener of the metallic or non-metallic type suitable for the performance of normal

/ medium/ heavy duty function of the floor, the quantum of ingredients and the thickness

of topping shall be as specified in the respective items of work prepared by the Contractor.

For monolithic application with the floor finish/slab the thickness of the layer shall be

15mm. The topping shall be laid within 2 to 3 hours after concrete is laid when it is still

plastic but stiffened enough for the workmen to tread over it by placing planks.

 The surface of the concrete layer shall be kept rough for providing adequate bond for the

topping. Laitance shall be removed before placing the topping. The topping shall be

screened and thoroughly compacted to the finished level. Trowelling to a smooth finish

shall be carried out. After the surface has hardened sufficiently, it shall be kept

continuously moist for at least 10 days. The procedure for mixing the floor hardener

topping shall be as per manufacturer's instructions.

 Surface shall be prevented from any damages due to subsequent building operations by

covering with 75 mm thick layer of sand.

PVC Sheet/Tile Flooring:

 PVC floor covering shall be of either unbaked homogeneous flexible type in the form of

sheets/tiles conforming to IS:3462 or homogeneous PVC asbestos tiles conforming to

IS:3461. Surface of the sheets/tiles shall be free from any physical defects such as pores,

blisters, cracks etc. which affects the appearance and serviceability. Tiles/ sheets shall

meet with the tolerance limits in dimensions specified in the IS. Contractor shall submit

the test certificates, if so desired by the GWIL.

 Each tile/sheet shall be legibly and indelibly marked with the name of the manufacturer or

his trade mark, IS certificate mark, and batch number.

 The adhesive to be used for laying the PVC flooring shall be rubber based and of the make

as recommended and approved by the manufacturer of PVC sheets/tiles.

 The type, size, colour, plain or mottled and the pattern shall be as specified in the

respective items of work prepared by the Contractor.

 PVC Floor covering shall be provided over an under bed of cement concrete floor finish

over the base concrete or structural slab. It is essential that the sub-floor and the under

bed are perfectly dry before laying the PVC flooring. This shall be ensured by methods of

testing as stipulated in Appendix-A of IS:5318.

 The surface of the underbed shall have trowelled finish without any irregularities, which

creates poor adhesion. Surface shall be free of oil or grease and thoroughly cleaned of all

dust, dirt and wiped with a dry cloth.

 PVC sheets/tiles shall be brought to the temperature of the area in which they are to be

laid by stacking in a suitable manner within or near the laying area for a period of about

hours. Where air-conditioning is installed, the flooring shall not be laid on the underbed

VOLUME IIB Technical Specifications Civil NC-09 (Maliya to Bhachau)

until the A/C units have been in operation for at least 7 days. During this period, the

temperature range shall be between 20deg.C and 30deg.C and this shall be maintained

during the laying operations and also for 48 hours thereafter.

 Layout of the PVC flooring shall be marked with guidelines on the underbed and PVC

tiles/sheets shall be first laid for trial, without using the adhesive, according to the layout.

 The adhesive shall be applied by using a notched trowel to the surface of the underbed and

to the backside of PVC sheets/tiles. When the adhesive has set sufficiently for laying, it

will be tacky to the touch, which generally takes about 30 minutes. The time period need

be carefully monitored since a longer interval will affect the adhesive properties. Adhesive

shall be uniformly spread over only as much surface area at one time which can be covered

with PVC flooring within the stipulated time.

 PVC sheet shall be carefully taken and placed in position from one end onwards slowly so

that the air will be completely squeezed out between the sheet and the background

surface and no air pockets are formed. It shall then be pressed with a suitable roller to

develop proper contact. The next sheet shall be laid edge to edge with the sheet already

laid, so that there is minimum gap between joints. The alignment shall be checked after

each row of sheet is completed and trimmed if considered necessary.

 Tiles shall be laid in the same manner as sheets and preferably, commencing from the

center of the area. Tiles should be lowered in position and pressed firmly on to the

adhesive with minimum gap between the joints. Tiles shall not be slide on the surface.

Tiles shall be rolled with a light wooden roller of about 5kg to ensure full contact with the

underlay. Work should be constantly checked to ensure that all four edges of adjacent tiles