Surface Preparation and Construction of RCC Pedestals for Rooftop Solar Power Plant Structures at IGCAR, Kalpakkam

M30 grade with 370 kg. of cement per cu.m. of concrete

Supplying, fabricating, erecting and fixing in position at all levels, centering and shuttering to correct line and levels including strutting, propping, etc., with necessary bracings in all axes to give a stable assembly with provision for making the joints in the shuttering fully leak proof and with provision for fixing coil nuts with tie rods along with suitable channel for lateral supports and for inserts, projecting dowels, anchor bolts or any other fixture, including staging, access and working platforms etc., all complete as specified and directed including dismantling and removing the aforesaid assembly after the concrete attains the sufficient strength to self-support itself without cracking and distortion all as per specification, including all materials and labour complete in all respects at all lifts. The measurement for the formwork will be the actual area of forms in contact with concrete surfaces. Shuttering with plywood panels alone will be permitted. (Refer Section V - Part B, Clause No.B)

Marking and cutting a 700 mm × 600 mm × 100 mm deep section at the specified location for the solar pedestal foundation, including careful dismantling and removal of existing weatherproofing treatment such as brickbat coba, foam, screed concrete, and other associated layers to the required size, without disturbing the surrounding weatherproofing at any level. The scope includes cleaning the exposed surface, carting the dismantled materials manually from the roof, and disposing of debris at the designated dumping yard within a lead of 100 metres, all complete as per specifications and as directed by the Engineer-in-Charge.

Providing, casting, and laying precast concrete elements (dimensions 350 mm x 200 mm x 60 mm) featuring built-in shear keys at specified locations. The item includes: Reinforcement: Furnishing and placing 4 Nos. of 12 mm diameter U-shaped reinforcement rods (total length 400 mm each) and 1 No. of 8 mm diameter stirrup (total length 900 mm). Fabrication: Use of M45 concrete grade, including centering, shuttering, and specialized molds with chicken mesh reinforcement. Execution: Mechanical vibration, thorough curing, and finishing to a smooth surface. Customization: Providing all necessary cutouts and holes of required sizes for service penetrations. Logistics: Yard handling, stacking, loading, unloading, and all leads and lifts to the installation point. All work shall be executed in accordance with the approved drawings and as per the directions of the Engineer-in-Charge.

Providing and applying Adesilex PG2 SP, Sikadur-30 LP, or approved equivalent two-component thixotropic epoxy adhesive for structural bonding between the existing terrace slab and precast concrete slabs/blocks. The adhesive shall be prepared by thoroughly mixing Part A (resin) and Part B (hardener) in the specified ratio as per the manufacturer’s technical data sheet. The work shall include proper surface preparation of both bonding surfaces, each approximately 350 mm × 200 mm, by removing loose particles, dust, laitance, oil, grease, and other contaminants to obtain a clean, dry, and sound substrate. Necessary shading arrangements shall be provided to control the surface temperature and keep it within the manufacturer’s recommended application temperature range during application and initial curing. All applications must be executed in strict accordance with the manufacturer’s specifications and under the direction of the Engineer-in-Charge.

Supply and fixing of GI anchor bolts of 16 mm diameter with nuts and washers, after checking and matching levels with all solar pedestals in the set of structure, including welding, positioning, and setting, complete as per the direction of the Engineer-in-Charge

Providing and laying a cement-based waterproofing treatment (Brickbat Coba type) around solar pedestals, including a coarse layer of broken bricks of various sizes to an average thickness of 100 mm, laid in the gap (approx. 150 mm wide) between the pedestal and the existing waterproofing. The treatment shall be laid over a 20 mm thick base bed of cement mortar 1:5 (1 cement : 5 crushed stone sand) mixed with an approved waterproofing compound. The top surface shall be finished with a 12 mm thick plaster of cement mortar 1:5 (1 cement : 5 crushed stone sand) mixed with a waterproofing compound and finished smooth. The waterproofing compound (South India Waterproofing or equivalent) shall be added as per the manufacturer’s specifications or at a rate of 2% by weight of cement. Rates shall include all preparation of the existing surface, materials, labor, and finishing around pedestals of size 400 mm x 300 mm, as per site requirements and engineer-in-charge instructions.

Fabrication, Supply and Installation of MS plate 16 mm thick, size 200 mm × 350 mm, with 4 Nos. Ø16 mm holes on specified PCD, including marking, cutting, drilling, edge finishing and deburring; complete as per drawing for Solar structure concrete pedestals.

Supply and installation of MS shim plates of required sizes and thicknesses for leveling and alignment of solar structure base plates, including cutting to size, edge finishing, surface cleaning, placement, alignment adjustment, and fixing; complete in all respects as per approved drawings/site requirement and as directed by the Engineer-in-Charge.