SCHEDULE – D: Annex I (Part-IV)

CONSTRUCTION SPECIFICATIONS

DESIGN & CONSTRUCTION SPECIFICATIONS

1.0 Introduction

The purpose of this document is to specify the design basis and criteria & construction
specification for the ATC Tower cum Technical Block, Fire Station & other associated
works such as Substation, as mentioned in the scope.

ATC Tower cum Technical Block Fire Station & other associated works shall be designed
in compliance with this design & construction specification mentioned in this document.
If the specification for a material/ product is not provided in this document, then
contractor will submit the specification for such material/ product and obtain AAI’s prior
approval before use of such material/ product for the works.

The AAI’s Design shall be developed to further and completed by the contractor to
achieve its function, performance and quality in accordance with this specification. The
contractor shall validate the tender drawings against the AAI’s Requirements and then
develop the Designs to completion.

This includes but not limited to:

a. Architectural Planning/ Finishing works
b. Civil & Structural works
c. HVAC Systems
d. Electrical Systems
e. Water Supply, Sewerage and Drainage System
f. Fire Protection System
g. Elevator
h. Fire Alarm System
i. IT System
j. Miscellaneous (Landscape)

All related research, survey and other information gathered, organized and performed
by the Contractor should support to carry out the same design along with the
requirements described herein. The final product of all design including related
structure and services shall be confirmed with best and appropriate quality and
performance in all aspect of function and aesthetics by the Contractor.

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BROAD SPECIFICATION

S. Description/ Item Specification Remarks

No.
A ATC Tower & Fire station

1 Foundation and super structure

i) Pre-construction Anti-termite As per Manufacturer
treatment specs.
ii) Earth works/Cement concrete, As per CPWD specs. - As per Schedule D
Plinth Protection 2019 Annexure I (Part III & Part
iii) Cast - in- situ RCC/RMC As per CPWD specs. - V)
2019

2. Steel Structure
i) Structural Steel sections, As per CPWD specs. -
Tubular-RHS, SHS etc. 2019

3. i) External / Internal wall - Fly As per CPWD specs. – Minimum compressive

Ash Brick/ AAC (Autoclaved 2019 / Manufacturer’s strength of Flyash brick
Aerated Concrete) Block work Specifications/ should be CD-75
Relevant IS Code Minimum compressive
ii) Internal wall - Fly Ash Brick/ strength of AAC Block
AAC (Autoclaved Aerated should be more than 3.0
Concrete) Block work/Dry wall N/sqmm
partitions (Gypsum) as per
design.
4 Doors, Windows, Partitions
i) Wood work in frames/door and As per CPWD specs. –
windows (Second class teak 2019/Manufacturer
wood) specifications
- factory hot pressed laminated
As per Schedule D
Flush Door/cupboard Shutters
Annexure I (Part III & Part
with designer laminates
V)
ii) Fire resistance doors (Two hrs As per CPWD specs. –
Fire Rating) – for Electric panel 2019/ Manufacturer’s
room etc./AHU/Shaft Specification &
Relevant IS/NBC Code

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iii) Main Entry Door - Automatic bi- As per Manufacturer
parting sliding door specs.

iv) Office area/rooms with glass As per Manufacturer

partition – Frameless Glass specs. and CPWD
doors specs. - 2019
Service areas, maintenance,
stores and radar rooms etc. –
flush doors / paneled doors with
glass panel

v) Soft partitions for offices-Glass As per Manufacturer

partition as per drawings specs. and CPWD As per Schedule D
specs. - 2019 Annexure I ( Part III & Part
V)
vi) Doors / Windows – UPVC As per Manufacturer
specs./ CPWD specs. -
2019
vii) Windows / Glazings in offices, As per Manufacturer
conference room etc. – To be specs./ CPWD specs. -
provided with roller blinds. 2019
5 Steel door/rolling shutter As per CPWD specs. –
2019/Manufacturer
specifications
6 False Ceiling As per Manufacturer
specs. & As per CPWD
specs. - 2019
7 Structural Façade / Glazing As per Manufacturer
specs. & As per CPWD
specs. - 2019
8 Compact Laminate Toilets As per Manufacturer
Cubical and modesty panel/ specs.
Urinal Partitions
9 Flooring As per CPWD specs. –
2019
10 Tile /AAC Block - Adhesive/ solid As per Manufacturer
epoxy grout specs.
11 Water Proofing Treatment over As per Manufacturer
RCC roof for Basement, Sub specs.
Station, Pump House, Security
Guard Room, Lift Pit, Sunken

Page -541
 Portion Toilets etc.

12 Sanitary fittings As per CPWD specs. -

2019

13 CP fittings (All exposed fitting in As per Manufacturer

toilets to be chrome plated). - specs.
Angle Valve, Bottle Trap/Flush
Valve/Basin Mixer/Single Lever
Sink Mixer
14 SS Sink As per Manufacturer
specs.

15 Combined unit of tissue paper As per Manufacturer

dispenser, hand dryer and specs.
dustbin As per Schedule D
16 SS (304 grade) satin finished As per Manufacturer Annexure I (Part III & Part
modular (Weld free) railing specs. V)
17 Plastering:- As per Manufacturer
i) Internal wall & ceilings plaster specs.
with light weight Gypsum
plaster.
ii) Exterior wall – Cement plaster As per CPWD specs. -
with grooves 2019
18 Wall Putty As per CPWD specs. -
2019
19 Painting As per CPWD specs. –
2019/ Manufacturer
specs.
20 Demountable partition – Double As per Manufacturer
skinned pre-laminated particle and CPWD specs 2019.
board partition in GI frame work

21 Expansion Joint Cover As per Manufacturer’s

specs.
22 Hardware Like: As per Manufacturer As per Schedule D
Mortice Lock With Pair Of specs. Annexure I (Part III & Part
Handles, Recess Handle Fittings, V)
Floor Spring, Etc.

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23 Door & Window Hardware As per Manufacturer
Fittings, Door closer etc. specs.
24 Plumbing works As per CPWD specs. –
a) External - G.I. Pipe 2019
b) Internal – CPVC pipe As per CPWD specs. -
2019

c) Sewage/Drainage pipe – SW As per CPWD specs. -

pipe/RCC pipe/PVC Structural 2019
Pipe/CI (Hubless)
25 Liquid Recessed Soap As per CPWD specs. -
Dispenser/ Jumbo Roll Tissue 2019
Toilet Dispenser/ SS Grab Bar As per Schedule D
26 Glass Mirror As per Manufacturer Annexure I ( Part III & Part
specs. V)

B Other Requirements
1 Boundary Wall :- 2.4 mtr height As per AAI
RCC Framed Boundary Wall with Specification and
Brick work with 600mm dia CPWD Specs.
concertina coil on top
supported with MS Angles as
per drawing
2 Road, Car park – (Rigid As per AAI
Pavement) Specification and
Moorum filling, GSBC, WMM, CPWD Specs.
DRLC, PQC
3 Sign Boards As per CPWD Specs-
2019
4 Polymer based rain Water As per manufacturer
Harvesting as per NBC/GRIHA specification
guidelines
5 Sewage Treatment Plant with As per manufacturer
solid waste management specification
system as per NBC guidelines
6 Arrangement for façade As per manufacturer
cleaning specification
7 City side security and car As per CPWD Specs-
parking management huts. 2019
8 Canopy – In glass and steel as As per CPWD Specs-
per drawing 2019 / As per
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 manufacturer
specifications.

Note : 1. Exterior wall shall be as per GRIHA Rating – IV using AAC/ Fly Ash AAC Block and
Internal wall with clay brick CD – 75/Fly Ash brick.

2. Wherever for items make/specification is not mentioned, it shall be considered by

the agency to be provided as per relevant code/specification with the approval of
Engineer-in-charge. Nothing Extra shall be paid in this regard.

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2.0 TECHNICAL SPECIFICATIONS (CIVIL)

PREAMBLE

These technical specifications shall be read in conjunction with the various other documents
forming the contract, namely Notice Inviting Tender & Instructions to Tenderers, Conditions of
Contract, Special Conditions of Contract and other related documents, together with any
addendum issued thereto.

Absence of terms such as providing, supplying, laying, installing, fixing etc. in the description does
not even remotely suggest that the contractor is absolved of such providing, supplying etc. unless
an explicit stipulation is made in this contract. The owner shall bear no costs of materials,
equipment’s duties, taxes, royalties etc.

In addition to the general obligation of the Contractor during defect liability period, the Contractor
shall guarantee successful performance of waterproofing treatments for a period of 10 years (05
years Guarantee Bond of value of 5% of total cost of specialized works + 05 years Corporate
Guarantee) from the certified date of completion of the work. The Engineer shall prescribe the
form and the manner of executing such guarantees. The Contractor hereby confirms that there is
nothing in the items/specifications (or a shortcoming therein) as will prevent such successful
performance. The work shall be executed through approved specialists experienced in the
respective trades. Five percent of the cost of the work shall be withheld which shall be released
after Five years. A guarantee bond for 05 (Five) years shall be furnished by the contractor for these
items as per Performa prescribed in the NIT document and Corporate Guarantee for further 05
(Five) Years.

The specifications may have been divided in different sections/sub-head for convenience only.
They do not restrict any cross-reference. The Contractor shall take in to account interrelations
between various parts of works/trades. No claim shall be entertained on basis of compartment
interpretations.

Any builder’s work required as part of electrical and other installation shall be executed by the
Contractor as directed under this contract.

The Contractor shall be required to submit and take approval from the Engineer-in-
Charge/Consultant of shop drawings of the items of work specified in the specifications or as
directed from time to time. No extra payment shall be made for the same. Shop drawings shall be
in metric units and shall be prepared in a format approved by the Engineer-in- Charge.

The Contractor shall prepare and submit as-built drawings by way of making
modifications/changes carried out with respect to the construction drawings issued prior to the
Page -545
construction of respective elements. These will be then incorporated by the respective
Consultant/ agency in to their drawings for maintaining necessary records for the owner.

No walls, terraces shall be cut for making any opening after waterproofing has been done without
approval of the Engineer. Cutting of waterproofing when authorized by the Engineer in writing
shall be done very carefully so that no other portion of the waterproofing is damaged. On
completion of the work at such places, the waterproofing membrane shall be made good and
ensured that the opening/cutting is made fully waterproof as per specifications and details of
waterproofing approved by the Engineer at no extra cost. No structural member shall be cut or
chased without the written permission of the Engineer.

All materials intended to be used at site shall be tested prior to its use in an approved manner. A
list of tests including frequency of tests on construction materials is included in the special
specifications. Cost of all such tests and any other tests felt necessary by the Engineer shall be
deemed to be included in the price of respective materials quoted by the Contractor. Any
defective materials brought to site shall be returned without any extra cost for the same.

Performance tests shall be carried out as the discretion of the Engineer on all/any items, of work
as directed by the Engineer. Should any item shall fail to pass the tests, the Contractor shall be
given opportunity to take corrective measures and have the same re-tested to the satisfaction of
the Engineer, he may at his sole discretion order dismantling of the whole or part of the works
done and order the Contractor to reconstruct the same. The cost of all these operations and
materials shall be borne by the Contractor without any extra claim.

The Contractor may make a special note of the strictness of the concrete mix to be adopted in
items of maximum water-cement ratio, minimum slump, control of total chloride and sulphate
contents, use of admixtures etc.

Minimum cement contents are given purely from durability point of view. Larger contents shall
have to be provided if demanded by mix design.

Provision of cement slurry to create bond between plain/reinforced concrete surface and
subsequent applied finishes (floor, plaster, dado, skirting etc.) shall not be paid extra.

Mix design using smaller aggregate of 10mm down shall also be done in advance for the use in
junction having congested reinforcement.

All full-fledged laboratories shall be established at site to start of construction and shall also stock
all relevant codes like BIS, EN, ASTM, MORTH, ICAO etc. as per the requirements of the special
specifications/Technical specification.

Procedure of mixing the admixtures shall be strictly as per manufactures recommendations if not
otherwise directed by the Engineer.
Page -546
The batching plant for all concrete shall be used. Alternatively, use of ready mix concrete from an
approved source shall be permitted. Concrete shall be transported using concrete pumps of
adequate capacity including necessary stand by.

All the water tanks and other liquid retaining concrete structures shall undergo hydro-testing as
per special specifications.

Special benches shall be provided at site for stacking reinforcement bars of different sizes as per
the specifications.

Form work for beams of RCC areas shall be designed in such a way that the form work of the
adjacent slabs can be removed without disturbing the props/supports of the beams.

Wherever there are tension/suspended concrete members, which are suspended from upper level
structure members, the shuttering/scaffolding of such members at lower level shall have to be
kept in place till upper level supporting members gain minimum required strength. Cost of such
larger durations of keeping in place the shuttering/scaffolding shall be deemed to be included in
the price quoted for respective structural members.

In the mobilization period, the Contractor shall carry out expeditiously and without delaying the
following works:

a) Material testing and mix design of concrete as contemplated in the specifications.

b) Setting up of full-fledged site laboratory as per the requirement of these specifications.
c) Any other pre-requisite items required for final execution.

The specifications for market rate items to be executed under this contract are enclosed. Items,
which are not covered under the specifications, shall be executed; as per latest CPWD
specifications & relevant IS codes, MORTH specifications, ICAO recommendations & Guidelines
under the directions of Engineer- In-charge.

3.0 SCOPE OF WORK

The work to be carried out under this contract shall consist of various heads as per Scope of Work.

The item unless otherwise specified also include compliance with/supply of the following:

a) General works such as setting out, clearance of site before setting out and clearance of
works after completion.
b) A detailed program for the construction and completion of works (using CPM/PERT
techniques) including updating of all such activities on the basis of decisions taken at the
periodic site review meetings as directed by the Engineer-in-Charges.

Page -547
c) Samples of various materials proposed to be used on the work for conducting tests thereon
is required as per the provisions of the contract.
d) Design of mixes as per relevant clauses of the specifications given proportions of ingredients,
source of aggregates and binder along with accompanying trial mixes to be submitted to the
Engineer-in-Charge for his approval before use on the works.
e) Setting of field-testing laboratory with all required apparatus and staffs for conducting day-
to-day quality control tests.
f) Any other item of work which is not specifically provided in the Bill of Quantities but which is
necessary for complying with the provisions of the contract.

4.0 OBLIGATIONS OF THE CONTRACTOR

In order to ensure that the contract work is executed strictly in accordance with this Agreement
and in time, the Contractor shall have the following obligations at no extra cost to the Engineer-in-
Charge in addition to such other obligations and responsibilities as have been specified elsewhere
in this Contract.

i. Provision of adequate number of constructional Plant and machinery for mechanized system
of construction, handling and transportation.
ii. Provision of special magazine at the site for storage of explosives, if necessary, for which
required license shall be obtained from the concerned authorities. However controlled
blasting/chemical blasting shall be permitted by AAI subjected to other guideline instead of
chiseling where blasting is prohibited, but no extra cost shall be paid on this account.
iii. Fulfill all the Contractor's labour regulations i.e. fair wages, display of notices regarding
wages, payment of wages, labour records, attendance cards-cum-wage slips, labour welfare
etc. as per standard practices and norms applicable at site.

All fossils, gold, silver, oil and other minerals, precious stones, coins, articles of value, of antiquity
and structures and other remains/things of geological or archaeological interest discovered on the
site of the works shall be notified by the Contractor immediately to the Engineer-in-Charge for
onward information to the concerned authorities.

The Contractor shall take all reasonable precaution to prevent his workmen or any other person
from removing or damaging any such article(s) or thing(s) and protect the same till the removal as
per the instructions of the Engineer-in-Charges.

Clearance of the site of all rubbish, debris, vats, tanks, materials, temporary structures, plant and
machinery, scaffoldings and filling of all pits, excavation and hand over the site in a tidy and
cleaned condition.

Opening up of covered work if instructed by the Engineer, if such covering was done before
inspection by the Engineer or without permission/ approval from the Engineer-in-Charge.

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5.0 GENERAL

5.1 The works will be executed as indicated in the nomenclature and technical specifications as
given hereunder as made applicable to this contract.

5.2 In the absence of any definite provision in the technical specifications contained herein,
reference may be made to the latest CPWD, MORTH, IRC, CPCB, GRIHA, NBC, ICAO
Specifications and IS codes, in that order. Wherever these are silent, the construction and
completion of the works shall conform to sound engineering practice and in case of any
dispute arising out of the interpretation of the above, the decision of the Engineer-in-
Charge shall be final and binding on the Contractor.

5.3 In addition, to abbreviations CPWD, IRC, MOST, IS, BS, ICAO, ASTM, AASHTO shall be
considered to have the following meaning: -

CPWD : Central Public Works Department

IRC : Indian Road Congress
MORTH : Ministry of Shipping & Transport (Road Wing) Government of India.
BIS : Bureau of Indian Standards
BS : British Standard of the British Standard
ICAO : International Civil Aviation Organization
ASTM : American Standards of the American Society of Testing Materials.
AASHTO : American Association of State Highway and Transportation Officials.
CPCB : Central Pollution Control Board.
GRIHA : Green Rating for Integrated Habitat Assessment.
NBC : National Building Code

5.4 All the codes of practice, standards and specifications applicable shall be the latest editions
with up to date correction slips etc. or as directed by the Engineer-in-Charges.

6.0 TESTING

It is made clear that cost of testing, cost of material for testing, all field apparatus required for
sampling and testing as per CPWD/IS codes and manpower incident to such testing will be
provided along with necessary transport arrangement to and fro to the approved testing agency
or laboratory by the Contractor during the construction phase of the work and defect liability
period. The expenditure in this regard shall be borne by the Contractor and nothing extra shall be
payable by AAI on this account. Field laboratory with all the required apparatus and staffs shall be
established by the Contractor at site of work at his cost for carrying out field tests at stipulated
frequencies.

Page -549
7.0 SAMPLING, TESTING AND MOCK-UP

7.1 The Contractor or his accredited representative shall be present during sampling/testing
and signify his concurrence for sampling / testing carried out by signing the test records.
The Contractor shall be liable of all actions consequent to the test and their results as if he
himself attended to the tests. The Contractor is duly advised to be present himself for
sampling and testing or in the alternative, have fully qualified duly authorized Engineer for
this purpose.

7.2 The Contractor or his accredited representative shall prepare shop drawings of all
specialized works thereafter prepare mock-up as per approved shop drawings for
specialized works and all finishing items in specified colors and shade (minimum three
options) as specified by Consultant/Engineer –in –Charge and shall execute the same on
based on approved mock-up. The Contractor shall be liable of all actions consequent to the
mock-up and their results as if he himself attended to the mock up. The Contractor is duly
advised to be present himself for mock-up, in the alternative have fully qualified duly
authorized Engineer for this purpose.

8.0 GENERAL LIST OF CODES, STANDARDS AND SPECIFICATIONS ADOPTED IN THE TENDER
DOCUMENTS.

8.1 The following IRC standards and IS, ASTM, British Standards, Codes and CPWD
Specifications have generally been adopted in the tender documents. This list however
does not limit the use of any other relevant code or standards by the Engineer-in-Charge
solely at his discretion either referred to in the tender documents or not, to achieve the
desired quality of work. All the codes practice, standards and specifications applicable shall
be the latest edition with all correction slips, etc. or as directed by the Engineer-in-Charge.

NUMBER/ DESIGNATION TITLE

IRC SPECIFICATION
IRC:10-1961 Recommended Practice for Borrow pits for Road
Embankments Constructed by Manual Operation
IRC:19-1977 Standard Specifications and Code Practice for Water Bound
Macadam (Second Revision)
IRC:SP II-1977 Hand Book of Quality Control for Construction of Roads and
Runways (First Revision).

INDIAN STANDARDS
IRC:383-1970 Coarse and find aggregate from natural sources for
concrete.
IS:456-2000 Code of practice for plain and reinforced concrete
IS:460-1985(Part-I to III) Testing Sieves

Page -550
IS:516-1959 Methods of test for strength of concrete.
IS:1124-1974 Method of test for water absorption, apparent specific
gravity and porosity apparent specific gravity and porosity of
Natural Building Stone.
IS:1199-1959 Methods of sampling and analysis of concrete
IS:2386-1963 Methods of test for aggregate for concrete
(Part-I)-1963 Particle size and shape
Part-II)-1963 Estimation of deleterious materials and organic Impurities.
Part-III)-1963 Specific gravity, density, voids, absorption and bulking.
Part-IV)-1963 Mechanical Properties
Part-V)-1963 Soundness
Part-VI)-1963 Measuring mortar making properties of fine aggregates.
Part-VII)-1963 Alkali Aggregate reactivity
Part-VIII)-1963 Petrographic examination
IS-2720 Methods of test of Soils
Part-II)-1973 Determination of water contents
Part-III)- Section-I 1980 Determination of specific gravity. Section-I Fine grained
soils.
Part-III)- Section-II 1980 Determination of specific gravity fine medium and coarse
grained soils
Part-IV)- 1985 Grain size analysis
Part-V)- 1985 Determination of liquid and plastic limit
Part-VII)- 1980 Determination of water content dry density relation using
light compaction.
Part-VIII)- 1983 Determination of water content dry density relation using
heavy compaction.
Part-XVI)- 1987 Labouratory determination of CBR
Part-XXVII-1977 Determination of total soluble sulphate.
Part-XXVIII-1974 Determination of dry density of soils in place by the sand
replacement methods.
Part-XXIX-1975 Determination of dry density of soils in place by core cutter
method.
IS-5640-1970 Method for determining the aggregate impact value of soft
coarse aggregate.
IS:6241-1971 Method of test for determination of stripping value of road
aggregate.
IS:8112-1989 43 grade ordinary Portland cement
IS 1489 (part 1): 1991 43 grade Portland Pozzolona Cement
IS:12118-1987 (Part I &
II) Two parts polysulphide based sealants.
IS 3812-2003 Fly Ash
ASTM/BS STANDARDS / SPECIFICATIONS
Page -551
 ASTM:D-1559-1976 Test for resistance to plastic flow of bituminous mixtures
using Marshall apparatus.
ASTM:D-2172-1975 Extraction quantitative, of Bitumen from bituminous paving
mixtures
ASTM : E-11-39 Sieves for testing purpose “Wire Cloth sieve round hole and
square” hole plate screen or sieves.
BS:410-1969 Test Sieves.
MOST Specification “Specifications for Road and Bridge works” second revision
reprinted in July 1993. Issued by Ministry of Surface
Transport (Roads Wing) and Published by Indian Roads
Congress.
ASTM- A653 Galvanized Steel
BS – 2989 Galvanized Steel
BS – 476 Fire propagation & surface spread of flames
ICAO Recommendations & Guidelines
Annexure 14 Pavements
Design Manual Part – I, II Pavement Design
& III

9.0 FIELD LABOURATORY AND LIST OF EQUIPMENT:

9.1 The contractor at his own cost shall set up a fully furnished and adequately equipped field
laboratory at site within 15 days from the schedule date of start of work and maintain the
same by providing adequate technical and upkeep staff. The laboratory should have office
space for engineers to do testing and store for storage of samples. The remaining space
shall be provided for the installation of equipment, laboratory tables and cupboards,
working space for carrying out tests, besides a wash basin, toilet facility. The following
minimum equipment shall be provided in the laboratory:

a) Determining Liquid Limit (1 complete set)

i) Liquid limit device (Casagrande type) 1 Set

ii) Grooving tools 1 No.
iii) Evaporating dish 1 No.
iv) Spatula 100mm blade 1 No.
v) Laboratory balance, capacity 500 gm, 1 No.
(sensitivity 0.01 gms.)
vi) Wash bottle, capacity 500 ml. 1 No.
vii) Moisture cans, capacity 50 ml. 24 Nos.

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b) Determining Plastic Limit (1 complete set)

i) Evaporating dish 1 No.

ii) Spatula 100mm blade 1 No.
iii) Glass plate 250mm x 250mm x 12mm 2 No.
iv) Moisture cans, capacity 50 ml. 12 No.
v) Stainless steel rods, 3 mm dia. 2 Nos.

c) Determining Moisture Content (1 complete set)

i) Micro Oven, capacity 35 liters,

control temperature Up to 200 °c 1 No.
ii) Balance, capacity 200 gm., sensitivity 0.01 gm. 1 set
iii) Lab. Tongs 1 No.
iv) Moisture cans 75ml. with lid 36 Nos.

d) Compaction Characteristics (1 complete set)

i) Standard compaction mould 100mm dia. 1 No.

ii) Modified compaction mould 150mm dia. 1 No.
iii) Standard compaction Rammer, 2.5 kg. 1 No.
iv) Modified compaction Rammer, 4.5kg. 1 No.
v) Straight edge 300mm long 1 No.
vi) Sample ejector for 100mm and 150mm mould 1 No.
vii) Sample tray 60 x 60 x 8 cm 3 Nos.
viii) Wash bottle, 500 ml. 2 Nos.
ix) Moisture cans 250 ml. 24 Nos.

e) Density of soil in-place by sand cone method (2 complete set)

i) Sand density cone apparatus, 150mm 2 Nos.

ii) Plate, 300mm x 300mm with centre hold 150mm 2 Nos.
iii) Glass jug for sand cone 2 Nos.
iv) Chisel 25mm x 150mm 2 Nos.
v) Hammer 2 Nos.
vi) One-gallon field cans 24 Nos.
vii) Sampling spoon 2 Nos.
viii) Soft hair brush 2 Nos.
ix) Moisture cans 250 ml. 48 Nos.

f) Sieve Analysis

i) Sieve shaker (portable) 1 unit

ii) Coarse sieves In Sizes from 100mm to 10mm 1 set
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 iii) Fine Sieves #4, #8, #16, #30, #40, #50, #100, #200 each) 1 set
iv) Pans & Covers as required

g) Specific Gravity and Absorption of Coarse Aggregate

i) Wire basket, 200mm dia. 5 No

ii) Heavy duty suspension balance, 20 kg x 1 gm with
accessories for weight in water 1 set
iii) Suitable water container 1 No

h) Unit Weight of Aggregate

i) Balance, 100 kg. Capacity with 10 gm. precision 1 No.

ii) Tamping rod 16mm diameter x 600mm long 1 No.
iii) Measuring containers (3, 10, 15, 30 liters) 1 each

i) Flakiness and Elongation

i) Flakiness gauge, elongation index 1 set

j) Stone Aggregate Impact Value Test Apparatus 1 set

k) Soundness Test
i) Sodium Sulphate 25 kgs
ii) Soaking tank 1 No.
iii) Balance, Capacity 3 kg., Sensitivity 0.1 gm. 1 set
iv) Sieves: Coarse 1 set
v) Sieves: Fine 1 set

l) Concrete

i) Buckets for concrete sampling 6 Nos.

ii) Slump cone 6 Nos.
iii) Tamping rod 6 Nos.
iv) Base plate 6 Nos.
v) Mixing pan for concrete 2 Nos.
vi) Scoop for general purpose 2 Nos.
vii) Concrete thermometer 1 No.
viii) Concrete cylinder mold, 150mm * 300mm; 100mm * 300mm 10 each
ix) Concrete cube mold, 100mm cube & 150mm cube 10 each
x) Adjustable spanners for dismantling cube molds 6 Nos.
xi) Capping set 2 Nos.
xii) Capping compound as required
xiii) Concrete curing tank with capacity for 60 cubes, temperature
Controlled, with circulation system drain and lockable cover 3 Nos.
xiv) Schmidt test hammer 1 No.
xv) Compression Testing machine (Electrical/ simple hand operated) 1 No.
xvi) Mold oil as required
Page -554
 xvii) Temperature chart recorder 1 No.
xviii) Flexural Strength Testing Machine 1 No.

m) Miscellaneous

i) Vernier calipers to measure up to 200mm, with elongated jaws 5 Nos.

ii) Steel rule, 300mm long graduated 2 Nos.
iii) Rubber gloves 10 pr.
iv) Cotton working gloves 20 pr.
v) First aid kit 1 set
vi) Wire brush 6 No.
vii) Steel tape, 3m, 5m, 30m 3 each
viii) Ballpein hammer, 1 kg 2 Nos.
ix) Paint scraper. Approx. 100mm wide 8 Nos.
x) Float, steel Approx. 280mm x 120mm 8 Nos.
xi) Sack barrow 1 No.
xii) Shovel: Square Mouthed 1 No.
xiii) Shovel: Round Mouthed 2 Nos.
xiv) 24-wheel trolley, heavy duty, approx. 0.7m x 1.0m with
Long pneumatic tyre type 2 Nos.
xv) Wheelbarrow, rubber tyre 1 No.
xvi) Comprehensive tool kit. To include screwdrivers, pliers, 1 No.
xvii) Claw hammer, multi-grips, spanners (adjustable) 1 No.
xviii) Type NR Schmidt Hammer and tester with recording device 1 No.
xix) Testing Anvil for Schmidt Hammer test (SHT) 1 No.
xx) Chart recording paper for SHT 10 Pkts
xxi) Cover meter for detecting metal objects to depth of 100mm
below the surface of non-magnetic objects 3 No.
xxii) Noise meter 1 No.
xxiii) Speedy moisture meter complete with chemical 2 sets

n) Serving instrument

i) Auto leveling instrument with staff 2 sets

ii) Total station survey equipment complete 1 set

o) Bituminous work testing apparatus

i) Bitumen extraction apparatus 1 set
ii) Marshall stability testing machine 1 set
iii) Bitumen penetration testing equipment 1 set
iv) Field density testing apparatus 1 set
v) 3 mtr. straight edge 1 set
9.2 In additional to tools, equipment, apparatus and instruments as described above, if any,
additional tool equipment apparatus and instrument is required for laboratory and
Page -555
 execution of work as per technical specification of NIT the same shall be provided by
contractor. Nothing extra shall be payable to contractor on this account.

9.3 The Engineer-in-charge may at his discretion, check the test results obtained at contractor
laboratory by independent test at an approved laboratory. The cost of such material,
transport, cost of testing etc. shall be borne by the contractor.

9.4 In the event of failure to setup laboratory and provide equipment/ apparatus mentioned in
clause no. 8.1 as mentioned above or substitute/ replaced the equipment/ apparatus on
account of maintenance / breakdown Rs. 200.00 per day per equipment / apparatus shall
be debited to the contractors account.

NOTE :–
1. To achieve the scheduled/ Planned progress of work as per completion schedule,
additional plants and machinery if required, to be arranged by the agency and no extra
payment to be made on this account.

2. To Maintain and record of the T&P received & the dates when it has been received at site
also to keep track of the receipt of the material at site, workmen / staff deployed works
diary shall be maintained jointly by the Engineer-in- charge and the agency to maintain a
daily record of these activities to form basis of any analysis of this kind or in case any
dispute occurs at a later date.

Page -556
ANTI-TERMITE TREATMENT WORKS
Providing anti- termite treatment and creating a chemical barrier to the building by injecting
chemical emulsion of required concentrations under grade slab and Grade beam, alround the
footings, column pits, trenches, pits, tunnels, wall trenches, back fill, plinth filling, junction of wall
and floor, Retaining / side walls of basement floor, external perimeter of building, surrounding of
pipes, expansion joints, below UG sump and Retaining / side walls etc.as per instructions of
chemical manufacturer and all as directed. The treatment shall be carried out strictly in
accordance with the CPWD / technical specification and conforming to IS 6313 or equivalent BS
specification. The chemical to be used as insecticides for the treatment shall be in accordance
with the manufacturer's specification, as specified by consultants appointed by the contractor.

Manufacturer should ensure the performance guarantee of the work for a period of 10 years by
submitting a BG for 5(Five)% value of total anti-termite treatment work, for a period of 05 years
and Corporate Guarantee for further 05 (Five) Years.

Page -557
GENERAL SPECIFICATION FOR STRUCTURAL STEEL WORK

1.0 FABRICATION OF STEEL STRUCTURES

1.1 Drawings

1.1.1 The Contractor shall prepare fabrication drawings, erection drawings, bill of
materials, drawing office dispatch lists/shipping documents, schedule of bolts and
nuts and as built drawings. All drawing work shall be in metric system and all
writing work shall be in English.

1.1.2 The fabrication drawings shall show full length with all connecting members and
connections marked thereon. The fabrication drawings shall include all the
necessary blown-up details required for the correct fabrication of the structures to
meet the design requirement. These drawings shall be made in conformity with
the best modern practices and with due regard to speed and economy in
fabrication and erection. Each erection piece shall be clearly identified by an
erection mark in these drawings.

1.1.3 The preparation / detailing of fabrication drawing shall be complete in all respects.
In the case of bolted connections, the bolt dia, the hole dia, the actual location of
holes and the coordinating scheme with connecting / matching elements shall be
clearly indicated. As far as possible, uniformity in the bolt dia shall be maintained
where HSFG bolts are used; method of surface preparation shall be indicated. In
case of welded constructions, the size and length of welds along the relevant weld
lines should be distinctly marked. The length specified shall be the effective length
excluding end crates. For all butt welds, details of appropriate edge preparation
shall be indicated.

1.1.4 Detailing of structural steel members subjected to dynamic loading shall be so as to

keep the stress concentration to a minimum. Cross welding shall be avoided as far
as practicable.

1.1.5 For bolted connections subjected to dynamic loading, lock nuts or spring washers
shall be used in addition to plain washers.

1.1.6 Erection drawings shall consist of line diagrams showing every detailed member in
position with the respective erection mark. Erection marks shall appear on the left
end of the members as detailed. All steel members shall be erected with marks in
the same relative position as shown in plan or elevation. All loose members shall
either be given part marks or wired on to the main erection mark for dispatch.
Page -558
1.1.7 The erection clearances for cleat-connected ends of member’s connection steel to
steel shall preferably not be greater than 10 mm. at each end. The erection
clearance at ends of beams shall not be more than 20mm. at each end but where
for particular reasons greater clearance is necessary, suitably designed seats shall
be provided.

1.1.8 The fabrication drawings shall be prepared in such a manner that structures are
dispatched with maximum transportable lengths and work involved at site is
minimum. Steelwork shall be shop-fitted and ship-assembled as far as practicable.

1.1.9 All edge preparations for welding shall conform to IS: 9595

1.1.10 The Contractor shall ensure correctness & completeness of fabrication drawings.

1.2 Material of Construction

1.2.1 All steel and other materials used for steelwork and in association with steelwork
shall conform to appropriate Indian standards. Only tested materials shall be used
unless written authority is obtained for the use of untested materials for certain
secondary structural members.

Unless otherwise specified in the drawings

a) All rolled sections and plates up to & including 20 mm thickness shall

conform to Grade “A” as per IS: 2062
b) Plates of thickness above 20 mm and Plated structures subjected to dynamic
loading shall conform to Grade “B” as per IS: 2062
c) For High Tensile steel requirements, materials conforming to IS: 8500 or
SAIL-MA (HYA or HYB) shall be used.

1.2.2 Steel sheets shall conform to IS: 1079

1.2.3 Steel tubes for structural purpose shall conform to IS: 1161/4923 (of Grade Yst 310)

1.2.4 Translucent sheets shall be fiberglass reinforced polyester sheets of matching

profile as per IS: 12866.

1.2.5 Colour coated sheets shall be as per appropriate standard.

1.2.6 Gutters shall be of copper bearing steel conforming to Grade “A” as per IS: 2062

Page -559
1.2.7 All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364 (for
precision and semi precision hexagonal bolts) of property class 6.4 unless otherwise
specified. Washers shall conform to IS: 6610

1.2.8 All tapered washer shall be as per IS: 5372 for channels, and IS: 5374 for Joists
Spring washers shall conform to IS: 3063

1.2.9 All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG bolts shall
conform to IS: 4000. Nuts and washers of HSFG bolts shall be as per IS: 6623 & IS:
6649 respectively.

1.2.10 Covered electrodes for arc welding shall conform to IS: 814. Coding of electrodes
shall be as follows:

a) ER421 ‘C’ X for mild steel of Grade ‘A’ and Grade ‘B’ as per IS: 2062

b) EB 542 ‘C’ H3X for Mild steel of Grade ‘B’ as per IS: 2062 for dynamically
loaded structures (arising out of crane, vibratory screen, equipments etc.)
‘C’ is the value of the current as recommended by the electrode
manufacturer.

1.2.11 Certified mill test reports of materials used in the work shall be made available for
inspection by the Engineer-In-charge upon request.

1.2.12 All materials shall be straight and if necessary before being worked shall be
straightened and /or flattened by pressure including de-coiling of plates unless
required to be of curvilinear form and shall be free from twists.

1.2.13 The MS / GI gratings shall be electro-forged and shall be of approved brand and
manufacturer unless otherwise agreed to by the Engineer-In-charge. The type of
grating selected shall be based on the loading in the area in which the grating is
provided and shall be subject to approval of Engineer-In-charge.

1.3 Material Preparation

1.3.1 Cut edges shall be finished smooth by grinding or machining wherever necessary.
Sufficient allowance (3 mm to 5 mm) should be kept in the items in case machining
is necessary.
1.3.2 Cutting may be effected by gas cutting, shearing, cropping or sawing. In gas cutting
of high tensile steel, special care is to be taken to leave sufficient metal to be
removed by machining so that all metal that has been hardened by flame is
removed.
Page -560
1.3.3 Sufficient shrinkage allowance (@1mm/M) shall be kept wherever heavy welding is
involved.
1.3.4 Straightening and bending shall be done in cold condition as far as practicable.

1.3.5 If required, straightening and bending may be done by application of heat between
900ºC and 1100ºC. Cooling down of the heated item shall be done slowly.

1.4 Drilling and Punching of Holes

1.4.1 Drilling and punching of holes for bolts shall be done as per clause no. 11.4.4 of IS:
800:1984, unless otherwise specified by the Owner.

1.4.2 Drifting of holes for bolts during assembly shall not cause enlargement of holes
beyond permissible limit or damage the metal.

1.4.3 Holes of bolted connection should match well to permit easy entry of bolts. Gross
mismatch of holes shall be avoided.

1.4.4 Permissible deviation in holes for mild steel bolts of normal accuracy and high
strength bolts are given in the ANNEXURE-A.

1.5 Assembly for Fabrication

1.5.1 Fabrication of all structural steel work shall be in accordance with IS: 800-1984 and
in conformity with various clauses of this specification, unless otherwise specified in
the drawings.
1.5.2 Fabrication of structures shall preferably be taken up as per the sequence of
erection.

1.5.3 All erection units shall bear erection mark no. and reference drg. no. at a prominent
location on the structures for easy identification at site.

1.5.4 Fabricated structures shall conform to tolerance as specified in this standard and in
IS: 7215-1974. In case of contradiction, tolerances specified in this standard shall
prevail.

1.5.5 All the components of structures shall be free from twist, bend, damage etc.

1.5.6 Assembly of structures shall be carried out by using suitable jigs and fixtures in
order to obviate distortion during welding.

1.5.7 Cutting of items specially for truss, bracing, bunker, hopper, galleries surge girder,
portal etc, shall be done only after checking of sizes as per layout.
Page -561
1.5.8 Surface, wherever machining is specified, shall be either planed or milled or ground
to ensure maximum contact.

1.5.9 If end-milling or machining is planned after the assembly is over, sufficient

allowance(5 mm to 15 mm) shall be kept in the items where milling/machining is to
be done.

1.5.10 If pre-bending of the plate is required to avoid welding distortion; it shall be done in
cold condition.

1.5.11 Sufficient trail assembly of fabricated components (dispatch elements) shall be

carried out in the fabrication works to control the accuracy of workmanship.

1.5.12 Where necessary, washers shall be tapered or otherwise suitably shaped to give the
heads of nuts and bolts satisfactory bearing.

1.5.13 The threaded portion of each bolt shall project through the nut at least by one
thread.

1.5.14 Tolerance of assembled components of structures are given in IS: 7215: 1924

1.5.15 Permissible deviations from designed (true) geometrical form of the dispatch
elements shall be in accordance with IS: 7215-1974.

1.6 Method of Construction

1.6.1 The method of construction shall be either by welding or by bolting limiting the site
work to the minimum possible.

1.6.2 Bolt diameter shall not be less than 16mm. except for bolts securing roof and wall
sheeting, windows, doors and stitching of thin coverings. For bolted joints, min two
bolts shall be used.

1.6.3 The size of fillet welds shall not be less than 5mm for load-bearing joints.

1.6.4 Main structural elements shall be welded continuously. Intermittent welds shall be
used only on secondary members, which are not exposed to weather or other
corrosive influence.

1.6.5 Connections and splices shall be made by welding, or by bolting with high tensile
turned and fitted bolts. Black bolts shall be used in connections and attachments of

Page -562
 secondary members such as purlins, wall girts, etc. Bolts shall be prevented from
loosening by means of lock nuts, single coil spring washers or similar devices.

1.6.6 Method of splicing shall be similar to the method of construction adopted for
structures. All splices shall be full-strength splice unless exception is specified.

1.6.7 Roof and wall sheets shall be fixed to purlins and wall girts by stainless steel top
speed screws/galvanized J-hook bolts, each complete with neoprene and stainless
steel /galvanized washers. The connections shall ensure water tightness into the
buildings. The spacing of these screws/bolts shall be sufficient to prevent uplift of
sheets by suction. The roof and wall sheets shall be stitched together at their edges
by using studs, rivets or screws. The end and side overlaps of sheeting shall be
sufficient to prevent ingress of rainwater. End lap shall not be less than 75mm and
side lap shall not be less than one a half corrugation for GCS sheets. For troughed
aluminum sheets manufacturer’s recommendations shall be followed.

1.7 Structural Steel connection

1.7.1 The Contractor shall be responsible for the design and the detailing of all
connections. The design of connections shall provide for adequate strength for the
transfer of force in the structural elements indicated on the design drawings. For
purposes of detailing of connections, the allowable stresses in material, bolts and
welds shall be as per IS: 800 and IS: 816 or as specified in the design drawings.

1.7.2 For all full strength butt welding of plates and sections thicker than or equal to
10mm, edge preparation shall be done and got approved by the Engineer-In-
charge.

1.7.3 Two numbers of washers shall be used for all bolted connections, one washer
bearing against the head and other bearing against the nut.
1.7.4 The magnitude of forces shown on design drawings shall be used at face values
with no reductions for connections.

1.7.5 If extra joints are to be provided in column, crane girder etc, prior approval on the
same shall be obtained from the Engineer-In-charge. However, as general guidance,
the following is suggested:

a) Splice joint on column and crane girder shall be of full strength but weld,
and, wherever possible, shall be located at the section of minimum or
substantially lesser stress.

Page -563
 b) Splice joints of web and flange should be sufficiently staggered in position.

1.7.6 All penetration for piping, conduit, cable trays, etc., through grating or plate
flooring shall be cut and suitably banded in the field, except when such
penetrations are dimensioned in the drawings in which case they shall be shop cut
and banded.

1.8 Fabrication

1.8.1 Fabrication of all structural steelwork shall be in accordance with IS: 800 or their
equivalent foreign national standard of the country of origin of supply unless
otherwise specified, and in conformity with various clauses of the Technical
Specification.

1.8.2 Wherever practicable and wherever perfect matching of parts is required at site,
members shall be shop assembled before dispatch to minimize site work. Parts not
completely assembled in the shop shall be secured, to the extent possible, to
prevent damage during dispatch.
1.8.3 All pieces shall be properly identified and bundled for transportation to work site.
Care shall be exercised in the delivery, handling and storage of material to ensure
that material is not damaged in any manner. Materials shall be kept free of dirt,
grease and foreign matter and shall be protected from corrosion. All materials shall
be stored properly on skids above the ground which shall be kept clean and
properly drained. Girders and beams shall be placed upright and stored. Long
members such as columns and chord members shall be supported on skids spaced
near enough to prevent damage due to deflection.

1.8.4 Bolts shall be furnished according to bolt lists showing the location of their use and
additional bolts shall be supplied to cover wastage.

1.8.5 All fabricated pieces shall bear erection mark numbers painted/punched according
to appropriate erection and shop drawings at a prominent location on the structure
for easy identification.

1.8.6 All workmanship shall be in accordance with the best practice in modern structural
shops. Greatest accuracy shall be achieved in the manufacture of every part of the
work and all identical parts shall be strictly interchangeable.

Page -564
1.8.7 Shearing or flame cutting may be used at the Contractor’s option provided that a
mechanically controlled cutting torch is used for flame cutting and that the
resulting edges are clean and straight.

1.8.8 Unless clean square and true to shape all flame cut edges shall be planed/cleaned
by chipping or grinding. Where machine flame cutting is permitted of high tensile
steel, special care shall be taken to leave sufficient margin and all flame hardened
material shall be removed by machining/edge grinding.

1.8.9 Wherever shearing is used for cutting to size, sheared members shall be free from
distortions at sheared edge.

1.8.10 The ends of all girder stiffeners shall be in contact with the compression flange and
shall be planed or ground to fit tightly against flange plates unless otherwise stated
on the drawings. Care shall be taken to ensure full bearing of the stiffeners at the
supports by machining the contact surfaces of both bearing stiffeners and bearing
plates. The ends shall not be drawn or caulked.

1.8.11 Column splices and butt joints of struts and compression members depending on
contact for stress transmission shall be accurately machined and close butted over
the whole section with a clearance not exceeding 0.1mm locally at any place.

1.8.12 In column cap and bases, the ends of shafts, should be accurately machined so that
the parts connected butt over the entire surface of contact. Care should be taken
so that these connecting members are fixed with such accuracy that they are not
reduced in thickness by machining by more than 1.0mm. On secondary members,
where sufficient gussets and welds are provided to transmit the entire loading. The
column ends may not be machined subject to the approval of the Engineer-In-
charge.

1.8.13 Holes for permanent black bolts shall not be more than 1.5mm larger than the
nominal diameter of the back bolts unless specified otherwise. All holes for turned
and fitted bolts shall be sub punched or drilled and reamed at site under assembly
of connected parts to a tolerance of +.3mm unless specified otherwise.

Holes in purlins, side-sheeting runners, packing plates and lacing bars may be
punched full size. Holes in light framing with the exception of joint holes may be
punched full size. All punching and sub-punching shall be clean and accurate and all
drilling free from burrs. In block/batch drilling, parts shall be separated after drilling
and burrs removed. No hole shall be made by gas cutting process.
Page -565
1.8.14 The component parts shall be so assembled that they are neither twisted not
otherwise damaged and specified cambers, if any, shall be provided. No drifting of
hole shall be permitted except to draw the parts together. Drifts used shall not be
larger than the nominal diameter of the bolt.

Drifting done during assembling shall not distort the metal or enlarge the holes.
Sufficient trial assembly shall be carried out in the fabrication works to prove the
accuracy of workmanship of the and the number of such trials required shall be at
inspector’s discretion.

1.8.15 Where necessary, washers shall be tapered or otherwise suitably shaped to give the
heads and nuts of bolts a satisfactory bearing. The threaded portion of each bolt
shall project through the nut by at least one thread.

1.8.16 In all cases where the full bearing area of the bolt is to be developed, the bolt shall
be provided with a washer of sufficient thickness, under the nut so as to avoid any
threaded portion of the bolt being within the thickness of the parts bolted
together. Column bases and caps, shall be in one solid piece, and except when cut
from plates with true surfaces, shall be accurately machined over the bearing
surfaces, and shall be in effective contact over the whole area of the machine end
of the stanchion.

1.8.17 Each piece shall be distinctly marked before delivery in accordance with an
approved marking diagram and shall bear such other marks as well to facilitate
erection. For easy identification at site a small distinguishing mark for each building
shall be painted at each end of every member before dispatch from fabrication
shop. The fabricated steel work shall be dispatched in sequence as per agreed
programme and for such portion as may be found convenient for erection or as
ordered by the Engineer-In-charge.

1.8.18 The Contractor shall provide suitable packing wherever necessary to guard against
damage during handling and transportation to site. All fabricated parts shall be
adequately braced to prevent damage during transit.

1.8.19 The tolerance for fabrication of steel structures shall generally conform to IS: 7215
and to suit the technological requirements as specified by the equipment supplier.

1.8.20 Any fabrication work which is considered not to be in keeping with the Technical
Specification forming the Contract, or in absence of Technical Specification with
recognized good practice, shall be rectified/replaced/corrected at the Contractor’s
Page -566
 expense as directed by the Engineer-In-charge. Site fabrication work shall also
conform to all specifications, stipulations, terms and conditions applicable for shop-
welded structures as mentioned above.

1.9 Dispatch Instructions

1.9.1 Each dispatchable structure shall bear mark no. along with reference drawing
number at two prominent locations (e.g. on flange and bottom of base plate of a
column).
1.9.2 “As built” drawing shall be prepared after fabrication is completed to indicate
additions/alterations made during the process of fabrication.

1.9.3 Control assembly of important structures shall be done in the shop floor before
dispatch to avoid mismatching. For all such important structures, match marking
shall be given at the control assembly stage in the shop floor as such match
markings shall be made clearly visible while assembling the structures at site.

1.9.4 Centre lines of column flanges and both sides of web shall be punched preferably at
top and bottom to facilitate alignment after erection.

2. ERECTION OF STEEL STRUCTURE

2.1 Scope

The scope of work under erection includes in addition to provision of erection and
transport equipment, tools and tackles, consumables, materials labour and
supervision the following.

a) Storing and stacking at site of erection of all fabricated structural

components/ units/ assemblers at the time of erection.
b) Transportation at the site of structures.
c) Receiving at site of structures including site handling /movement, unloading,
storing at site of erection of technological structures such as bunkers and
the related structure.
d) All minor rectification/ modification such as :
i) Removal of bends, kinks, twists etc. for parts damaged during transportation
and handling.
ii) Cutting, chipping, filling, grinding etc. if required for preparation and
finishing of site connections.
iii) Reaming for use of next higher size bolt for holes which do not register or
which are damaged.

Page -567
 iv) Welding of connections in place of bolting for which holes are either not
drilled at all or wrongly drilled during fabrication.
e) Other rectification work such as :
i) Re-fabrication of parts damaged during fabrication beyond repair during
transportation and handling or incorrectly fabricated.
ii) Fabrication of parts omitted during fabrication by oversight or subsequently
found necessary.
iii) Plug welding and re-drilling of holes which do not register and which cannot
be reamed for use of next higher size bolt.
iv) Drilling of holes which are either not drilled at all or are drilled at incorrect
position during fabrication.
f) Fabrication of minor items/ missing items or such important items as
directed by the Engineer-In-charge.
g) Assembly at site of steel structural components wherever required including
temporary supports and staging.
h) Making arrangements for and providing all facilities for conducting
ultrasonic X-rays or gamma ray tests on welds, getting the tests conducted,
reports and interpretation.
i) Rectifying at site damaged portions of shop primer by cleaning and touch-up
paint.
j) Erection of structures including making connections by bolts/high strength
friction grip bolts/welding.
k) Alignment of all structures true to line level plumb and dimensions within
specified limits of tolerances as per IS : 12843 “Tolerance for Erection of
Steel Structures”
l) Application of second coat of primer paint and two coats of finishing paint at
site after erection.
m) Grouting of all columns bases after proper alignment of columns and only
after obtaining clearance from Engineer-In-charge.
n) Supply of labour in sufficient numbers where necessary, as directed by the
Engineer-In-charge.
o) Conducting preliminary acceptance and final acceptance tests.
p) Preparation of as built drawings, preparing of sketches/drawings to suit field
engineering decisions, availability of material, convenience of fabrication,
transportation and erection and changes during fabrication and erection.
All such works are subject to approval by the Engineer-In-charge.
2.2 Erection Drawings
2.2.1 The erection drawings prepared by the Contractor and any approved arrangement
drawings specifications or instructions accompanying them shall be followed in
erection of structures and miscellaneous connected items throughout the project.

Page -568
2.3 Storing and handling
2.3.1 The fabricated materials on receipt at site shall be carefully unloaded, examined for
defects, checked, stored out for each building and stacked securely on skids above
level ground which shall be kept and properly drained. Girders and beams shall be
placed upright and stored. Long members, such as columns and chord members
shall be supported on skids spaced near enough to prevent damage from defection.
2.3.2 The fabricated materials shall be verified with respect to markings on the marking
plan or shipping list which shall be supplied by the Contractor.
2.3.3 Any material found damaged or defective shall be stacked separately and the
damaged or defective portions shall be painted in distinct colour for identification.
Such materials shall be dealt with as ordered by the Engineer-In-charge.
2.3.4 The handling and storing of the component parts of a structure shall involve the use
of materials and applications not likely to produce injury by twisting, bending or
otherwise deforming the structures. No member slightly bent or twisted shall be
put in place until the defects are corrected. Members seriously damaged in
handling shall be rejected.

2.4 Defects in material fabrication

2.4.1 All materials shall be straight unless required to be of curvilinear from and shall be
free from twists. All cold straightening shall be done by pressure only.

2.4.2 During assembly and during erection of the units to position, the Contractor shall
compare the structure with drawings to ensure that there are no fabrication
omissions or errors. Should any omission or defect be found the same shall be
brought to the notice of the Engineer-In-charge who will issue necessary
instructions for the rectification.
2.5 Setting out
2.5.1 The Contractor shall prepare geodetic survey of all embedded parts and holding
down bolts and submit the same to Engineer-In-charge. The Contractor shall inform
the Engineer-In-charge about any discrepancy with approved design drawings well
in advance of erection and if necessary shall make necessary adjustments at site
during fabrication of structures.
2.5.2 The Contractor shall assume, full responsibility for the free and correct setting out
of all steel work and erection correctly in accordance with position, alignment,
dimensions and levels shown on the approved drawings and plumbing vertical
members. Particular care shall be taken to ensure free expansion and contraction
wherever provided. Notwithstanding any assistance rendered to the Contractor by
the Engineer-In-charge if at any time during the progress of the work, any error
should appear or arise therein, on being required to do so, the Contractor at his
own cost shall remove and amend the work to the satisfaction of the Engineer-In-
charge.

Page -569
2.6 Assembly and Erection
2.6.1 Before starting erection, the Contractor shall submit to the Engineer-In-charge for
his approval the method he propose to follow and the number of types of
equipment and temporary works he propose to use for the erection.
2.6.2 The approval of drawings by the Engineer-In-charge will not relieve the Contractor
from the basic approach to design as regards the loads which the erection
equipment and temporary work shall be called upon to carry and support.
Adequate allowance and provisions shall be made for lateral forces and wind loads.
2.6.3 If in the opinion of the Engineer-In-charge, the tools, tackles, plant and equipment,
instruments, apparatus etc. arranged by the Contractor are not sufficient or are
inadequate for the fulfillment of the contractual obligations of the Contractor
within the stipulated period, the Engineer-In-charge will have the right to order the
Contractor and the Contractor shall comply with the order to bring /arrange such
additional tools, tackles, plant and equipment instruments, apparatus etc. to the
site and employ the same to complete the work in time. All charges in connection
thereof shall be borne by the Contractor.
2.6.4 Proper consideration shall be given to the following items during erection.
i) Frame of building to be true and plumb.
ii) Temporary guying and bracing shall be used to align the framing during
erection if required.
iii) Temporary bracing may be required to sustain forces due to erection loads
and equipment. Erected parts of the structures shall be made stable during
all stages of erection. The stability of structure subjected to the action of
wind, dead weight and erection forces shall be attained by observing
specified sequence of erection of vertical and horizontal structural members
and by installing permanent and temporary bracings.
iv) Erection members shall be held securely in place by bolts to take care of
dead load, wind load and erection load.
v) Free expansion and contraction wherever provided.
vi) No final bolting or welding of joints shall be done until the structure has
been properly aligned and consent obtained from Engineer-In-charge.
vii) Erection tools and machinery shall be suitable capacity for handling the
materials furnished and must be in safe operating conditions at all times to
avoid danger to materials and personnel.
viii) In positioning beams, columns or other steel members the use of steel
sledges shall not be permitted.
ix) The Contractor shall report all failures of the fabricated steel to fit together
properly to the Engineer-In-charge and shall obtain approval prior to taking
corrective measures.
x) Steel members shall not be allowed to fall or be subject to shock or impact
due to other members being swung into position or for any other cause.
xi) All exposed bolts holes not required shall be plugged.

Page -570
2.6.5 Erection shall be carried out according to the best modern practices and as laid
down in the IS : 800-1984 and other relevant standards referred to therein and
according to this erection specification together with approved erection drawings
and technical specifications.
2.6.6 The Contractor shall design, manufacture, erect and provide false work, staging,
temporary supports etc. required for safe and accurate erection of structural steel
work and shall be fully responsible for the adequacy of the same.
2.6.7 The Contractor shall, if so required by the Engineer-In-charge, get his drawings,
erection schemes and designs for such false work, staging etc. approved by the
Engineer-In-charge, but such approval by the Engineer-In-charge shall not relive the
Contractor of any of his responsibilities for the safety of such works. As far as
possible, assemblies of structures shall be made on the ground itself.
2.6.8 The Contractor shall provide adequate supervision at all stages of the work and
examine each portion of the work for accuracy before commencing the erection of
the next structural member. The Contractor shall also provide facilities such as
adequate temporary access ladders, tools and tackles, instruments etc. satisfactory
to Engineer-In-charge / Consultant for his inspection at any stage during erection.
2.6.9 Instrumental checking for correctness of initial setting out of structures and
adjustment shall be carried out in sequence at different stages as determined by
design as against checking and adjustment of alignment in one stage after
completion of entire erection. The final leveling and alignment shall be carried out
immediately after completion of each section of a building or when called for by the
Engineer-In-charge.
2.6.10 All structural members shall be erected with erection marks in the same relative
position as shown in the appropriate erection and shop drawings.

2.7 Field connections

2.7.1. The holes of erection joints required to be machine bolted shall be filled with
temporary bolts and plugs after mounting the structures. The number of bolts and
plugs shall be determined by design but shall not be less than 50% of the total
number of holes. In joints where the number of holes is equal to 5 or less, not less
than 3 holes shall be filled. The number of plug shall be about 20% of the holes
filled.
2.7.2 The number of washers on permanent bolts shall not be more than two (and not
less than one) for nut and one for the bolt head. Wooden rams or mallet shall be
used for forcing members into position in order to protect the metal from injury
and chipped edges shall be finished with a file and all short corner and hammered
rough faces shall be rounded off. Chipping with the use of sledge hammer shall only
be permitted in exceptional cases and shall be done without resulting in fractured
edges.
2.7.3 Where bolting is specified on the drawings, the bolts shall be tightened to the
maximum limit. The threaded portion of each bolt shall project through the nut by
at least one thread. Tapered washers shall be provided for all heads and nuts having
Page -571
 bearing on beveled surfaces. Use of special bolts, such as high strength friction grip
bolts, shall be according to the relevant Indian or other recognized standards and
shall be subject to the prior approval of the Engineer-In-charge before use.
2.7.4 Spring washers or lock nuts shall be provided as specified in the design/ shop
drawings. All machine fitted bolts shall be perfectly tight and the ends shall be
checked to prevent nuts from becoming loose. No unfitted holes shall be left in any
part of the structures. All field assembly and welding shall be executed in
accordance with the requirements for shop fabrication. Where the steel has been
delivered painted, the paint shall be removed before field welding for a distance of
at least 50 mm on either side of the joints.
2.7.5 Erection bolts shall be retained in position permanently even after site welding.

2.8 Assembly by high strength friction grip bolts

2.8.1 The mating surface shall be absolutely free from grease, lubricant, dust, rust etc.
and shall be thoroughly cleaned before assembly. The preparation of mating
surface shall be done as specified in the design drawings.
2.8.2 Nuts shall be tightened up to the specified torque with the help of torque wrench or
by half turn method with the help of pneumatic wrench lever. Torque value has to
be specified in design/ fabrication drawings itself. The direction of tightening of the
nuts shall be from the middle towards the periphery of the joint. The bolt head,
nuts and edges of the mating surface shall be sealed with a coat of paint to obviate
entry of moisture. As far as possible, the diameter of bolts and nature of mating
surface preparation shall be kept uniform to have specified unique torque.

2.9 Bedding and grouting

2.9.1 Base plate shall be set to elevations shown in the drawings supported and aligned
using steel wedges and shims or any other approved method. The supply of
wedges, shims and any other materials for alignment shall be the responsibility of
the Contractor as part of his work. Plates shall be leveled properly positioned and
the anchor bolts properly tightened. The bedding/grouting shall not be carried out
until a sufficient number of columns have been properly aligned, plumbed and
sufficient girders, beams, trusses and bracing to the satisfaction of the Engineer-In-
charge.
2.9.2 Grouting shall be done before casting of elevated RCC floor, if equipments
contributing to the loading on columns are placed moving equipment shall be
tested and no trial run of any equipment before grouting has been done and cured
to the satisfaction of the Engineer-In-charge.
2.9.3 Grouting shall be minimum M-25 grade or one grade higher that the concrete with
10 mm and below graded coarse aggregate. Ready mixed free-flow grout from
recognized manufacturer as approved by the Engineer-In-charge shall be used with
pressure grouting as technique to ensure up of all void spaces underneath the base

Page -572
 plate. Manufacturer’s recommendation/instruction shall be followed for proper
application of grout materials.
2.9.4 The Contractor shall inform the Engineer-In-charge when the work is ready for
grouting for their verification. The Contractor shall be responsible for the final
vertical and horizontal alignment of all the base plates.

2.10 Painting after erection.

The painting shall be as per painting specifications and instructions and in GS for
painting works.

2.11 Acceptance of work

2.11.1 Acceptance of erected steel structures shall be either after erection of the whole
building or in blocks.
Intermediate acceptance certificate will be given in the following
i) Any steel work or part thereof embedded in concrete.
ii) Steel structures which are to be covered in the process of further work.
2.11.2 The following documents shall be prepared and produced at the time of acceptance
of erected steel structures:
i) Documents showing approved deviations made during erection of work.
ii) Documents showing acceptance of embedded structures
iii) Certificate/documents on control checking and tests of nuts and welds.
iv) Data and results of geodetic measurement while checking of structures.
v) Copies of ‘As built Drawings’ showing thereon all alterations.

3.0 Welding specifications

3.1 General
The welding and welded work shall conform to IS: 816 and other relevant codes
unless otherwise specified. Electrodes shall conform to IS: 814 and shall be
approved by the Engineer-In-charge.
3.1.1 Welding shall be done by Electrical Arc Process, Automatic welding shall be
employed for important structures as specified in the drawings. Generally
submersed arc. Automatic & Semi-automatic welding shall be employed. Only
where it is not practicable. Manual Arc. Welding may be restored to. In case of
Manual Arc. Welding, recommendation of electrode manufacturer are to be strictly
followed.
3.1.2 Welding shall not be done under weather conditions which might adversely affect
the efficiency of the welding and where necessary, effective protection and other
safeguard shall be provided.
3.1.3 Only qualified welders suitable for the job shall be employed. The Engineer-In-
charge at his discretion can order periodic tests in accordance with IS: 817 of the

Page -573
 welders and/ or of the welds produced by them at no extra cost. Welding shall be
done using requisite jigs and fixtures to avoid distortions or damage to members
during /after welding. Welds on exposed work shall be finished uniformly smooth to
present a neat appearance.
3.1.4 The layouts and sequence of operations shall be arranged so as to eliminate
distortion and shrinking stress to the satisfaction of the inspector. Welding work
shall be under constant supervision of competent welding supervisor and shall be
done in a properly organized manner with the approved quality welding sets and
with automatic welding machines. Detailed welding procedure shall be submitted
to the Engineer-In-charge and approval of the same shall be obtained before
fabrication is commended.

3.2 Welding procedure

3.2.1 Welding procedure to be prepared by the Contractor shall include the following.
i) Type and size of electrodes.
ii) Current and voltage (for automatic welding)
iii) Length of run per electrode or (for automatic welding) speed of travel.
iv) Number and arrangement of rungs in multi-run welds.
v) Position of welding
vi) Preparation of set up parts
vii) Welding sequence
viii) Pre or post heating
ix) Specifications and thickness of steel
x) Welding process (manual arc. /submerged arc. Welding)
xi) Pre and post heating requirement
xii) Weather condition – restriction thereof
xiii) Use of jigs and fixtures
xiv) Type of non-destructive testing to be carried out
xv) Inspection procedure to be followed
xvi) Sequence and process to be followed in different multiple pass butt
welding for different plate thickness.
The welding procedure shall be subject to Engineer-In-charge approval.
3.2.2 The welding procedure shall be arranged to suit the details of the joints as indicated
in the drawings and the position in which the welding is to be carried out. The welds
shall meet the requirement of quality specified.
3.2.3 All electrodes for use in the work to which the specification relates shall be kept
under dry conditions. Electrodes which are damaged by moisture shall not be used
unless it is certified by the manufacturer that when it is properly dried there shall
be no determinable effect. Any electrode which has part of its flux coating broken
away or is otherwise damaged shall be discarded.
Page -574
3.2.4 Low hydrogen electrode and flux for submerged arc. Welding shall be dried at 250-
300 deg. C for one hour in drying oven before use.
3.2.5 At site the electrode shall be kept in proper coves while using them for welding.
3.2.6 All metal arc. Welding shall be as per IS : 9595
3.2.7 For multi-run weld deposit the succeeding run shall be done only after the
preceding run is cleaned of all slag and flux deposit.
3.2.8 The Contractor shall prepare the edge with an automatically controlled flame
cutting torch followed by grinding correctly to the shape, size and dimensions of the
groove, prescribed in the design and shop drawings. In case of U-groove joint, the
edges shall be prepared with an automatic flame cutting torch in two passes
following a bevel cut with a gouging pass or by machining.
3.2.9 The welding surface shall be smooth, uniform and free from fins, tears, notches or
any other defect which may adversely affect welding. Welding surface or the
surrounding surface within 50 mm of weld shall be free from loose scale, slag, rust,
grease, paint, moisture or any other foreign materials. Pre-bending of plates for
three plate welded sections shall be done where found necessary.
3.2.10 Manipulators may be used where necessary and shall be designed to facilitate
welding and to ensure that all welds are easily accessible to the operators. Where
full strength built welds are specified run-on pieces shall be used. The welding shall
be such that the face of weld deposit at all places be proud of the surface of the
parent metal by 1 to 1.5 mm. Where a flush surface is required the surplus weld
metal shall be ground and dressed off.
3.2.11 After completing each run of weld all slag shall be thoroughly removed and the
surface cleaned before starting the next run of weld. The weld metal as deposited
(including lack welds if to be incorporated) shall be free from cracks, slag,
inclusions, gross porosity, cavities and other deposition faults. The weld metal shall
be properly fused with the parent metal without serious undercutting or
overlapping at the toes of the weld. The surface of the weld shall have a uniform
and consistent contour and uniform appearance.
3.2.12 All weld runs found defective shall be cut by using either chipping hammer gouging
torch or suitable grinding wheel in such a manner that adjacent materials is not
injured in any way. Peeling of the welds involving deformation of the weld surface
either during de-slagging or thereafter shall not be allowed.
3.2.13 Arc.-strikes on parent surface of structures shall be strictly avoided.

3.3 Control in welding

The extent of quality control in respect of welds for structural elements for both
statically and dynamically loaded structure shall be as follows and shall be
conducted by the Contractor at his own cost.
a) Visual Examination - All welds shall be 100% visually inspected to check the
following.
i) Presence of under cuts
Page -575
 ii) Visually identifiable surface crack in both welds and base metal
iii) Unfilled craters
iv) Improper weld profile and size
v) Excessive reinforcement in weld
vi) Surface porosity
Before inspection, the surface of weld metal shall be cleaned of all slag,
spatter, beads, scales etc. by using wire brush or chisel.
b) Dye Penetration Test (DPT) – This shall be carried out for all important fillet
welds and groove welds for both statically and dynamically loaded
structures to check the following
i) Surface cracks
ii) Surface porosities
Dye Penetration Test shall be carried out in accordance with American
National Standard ASTME-166
c) Ultrasonic Testing – Ultrasonic test shall be conducted for all groove welds
and heat affected zone in dynamically loaded structures and for other
important load bearing butt welds in statically loaded structures as desired
by the Engineer-In-charge to detect the following.
i) Cracks
ii) Lack of fusion
iii) Slag inclusions
iv) Gas porosity
Ultrasonic testing shall be carried out in accordance with American National
Standard ANSI/AWS DI.1-96. Before ultrasonic test is carried out, any
surface irregularity like undercuts, sharp ridges etc. shall be rectified.
Material surface to be used for scanning by probes must allow free
movement of probes. For this purpose, surface shall be prepared to make it
suitable for carrying out ultrasonic examination.
d) Radiographic Testing (X-ray and & Gamma-Ray Examination)
This test shall be limited to 2% of length of welds for welds made by manual
or semi automatic welding and 1% of length of weld if made by automatic
welding machines. The location and extent of weld to be tested by this
method will be decided by the Owner to detect the following defects.
i) Gas porosity
ii) Slag inclusion
iii) Lack of penetration
iv) Lack of fusion
v) Cracks

Page -576
 Radiographic testing shall be conducted in accordance with American National
Standard ANSI/AWSDI 1-96. Any surface irregularity like undercuts, craters pits
etc. shall be removed before conducting radiographic test. The length of weld to
be tested shall not be more than 0.75xfocal distance. The width of the
radiographic film shall width of the weld joint plus 20mm on either side of the
weld.
3.3.1 The Contractor shall provide testing equipment for conducting non-destructive
tests for confirming the integrity of welding wherever necessary as directed by the
Engineer-In-charge.
Acceptable Limits of Defects of Weld
Limits of acceptability of welding defects shall be as follows:
a) Visual inspection and Dye Penetration Test
The limit of acceptability of defects detected during visual inspection and
Dye Penetration Test shall be in accordance with American National
Standard ANSI/AWS D1-96.
b) Ultrasonic Testing – The limits of acceptability of defect detected during
ultrasonic testing shall be in accordance with American National Standard
ANSI/AWS D1-96.
c) Radiographic Testing – The limit of acceptability of defects during
Radiographic testing shall be in accordance with American National
Standard ANSI/AWS D1-96.
General guidelines for permissible deviations in welding have been given in section
5.0 of this document.
3.4 Rectification Defects in Welds
In case of detection of defects in welds, the rectification on the same shall be done
as follows .
i) All craters in the weld and breaks in the weld run shall be thoroughly
filled with weld.
ii) Undercuts, beyond acceptable limits shall be repaired with dressing so
as to provide smooth transition of weld to parent metal.
iii) Welds with cracks and also welds with incomplete penetration,
porosity, slag inclusion etc. exceeding permissible limits shall be rectified by
removing the length of weld at the location of such defects plus 10mm from
both ends of defective weld and shall be re welded. Defective weld shall be
removed by chipping hammer gouging torch or grinding wheel. Care shall be
taken not to damage the adjacent material.

Page -577
4.0 PAINTING OF BUILDING STEEL STRUCTURES
All steel structure work shall be painted as follows unless otherwise stated in the
drawing/technical specifications. Relevant sections of the GS shall be referred for
further guidelines on painting.
4.1 Surface preparation for encased columns
The steel surface which is to be painted will be cleaned of dirt and grease
and the heavier layer of rust shall be removed by chipping prior to actual
surface preparation to a specified grade.
Prior to paint application all surfaces should be assessed and treated in
accordance with ISO 8504:1992. Oil or grease should be removed in
accordance with SSPC-SP1 solvent cleaning.
Abrasive blast cleans to Sa 2-1/2 (ISO 8501-1:1988) or SSPC-SP6. If oxidation
has occurred between blasting and application, the surface should be re-
blasted to the specified visual standard. Surface defects revealed by the
blast cleaning process, should be ground, filled, or treated in the
appropriate manner.
4.2 Paints and Painting
Guidelines stipulated here shall be considered along with those specified in
GS separately for painting.
4.2.1 Manufacturer of paints, mixing of paints etc. shall be generally according to
the relevant IS codes of practice and as per guidelines in the General
Specification in the relevant chapter.

4.2.2 In the event of conflict between this General Specification for painting and
the paint manufacturer’s specifications, this conflict shall be immediately
brought to the notice of the Engineer-In-charge. Generally in case of such
conflict, manufacturer’s specification /recommendations shall prevail.

4.2.3 Generally compatibility between primer intermediate and finishing paint

shall be certified by the paint manufacturer supplying the paints. Before the
Contractor buys the paint in bulk, it is recommended to obtain sample of
paint Control Areas of Painting on Control Area, surface preparation and
painting shall be carried out in the presence of the manufacturer of paint.

5.0 Inspection and Testing of Welds

The extent of quality control in respect of welds for structural elements shall
be as follows.

Page -578
5.1 Visual Examination

5.1.1 All welds shall be 100% visually inspected to cheek the following:
i) Presence of undercuts
ii) Surface cracks in both welds and base metals.
iii) Unfilled craters
iv) Improper weld profile and size
v) Excessive reinforcement in weld
vi) Surface porosity

5.1.2 Before inspection, the surface of weld metal shall be cleaned of all slag,
spatter matter, scales etc. by using wire brush or chisel.

5.2 Dye Penetration Test ( DPT)

5.2.1 This shall be carried out for all important fillet welds and groove welds to
check the Surface cracks and Surface porosities

5.2.2 Dye Penetration Test shall be carried out in accordance with American
National Standard ASTME 165.

5.3 Ultrasonic testing:

5.3.1 Ultrasonic test shall be conducted for all groove welds and heat affected zone
in dynamically loaded structures and for other important load bearing butt
welds in statically loaded structures as desired by OWNER to detect the
following:
i) Cracks
ii) Lack of fusion
iii) Slag inclusions
iv) Gas porosity

5.3.2 Ultrasonic Testing Shall Be Carried Out In Accordance With American National
Standard ANSI / AWS Dl -92 Chapter 6 : Part C.

5.3.3 Before Ultrasonic test is carried out, any surface irregularity like undercuts,
sharp ridges etc. shall be rectified. Material surface to be used for scanning by

Page -579
 probes must allow free movement of probes. For this purpose, surface shall
be prepared to make it suitable for carrying out ultrasonic examination.

5.4 Radiographic Testing (X — ray and Gamma — ray Examination)

5.4.1 This test shall be limited to 2% of length of welds for welds made by manual
or semi-automatic welding and 1% of length of weld if made by automatic
welding machines. The location and extent of weld to be tested by this
method shall be decided by OWNER to detect the following defects:
i) gas porosity
ii) slag inclusions
iii) lack of penetration
iv) lack of fusion
v) cracks

5.4.2 Radiographic testing shall be conducted in accordance with American National

Standard ANSI / AWSD1.1-92.

5.4.3 Any surface irregularity like undercuts, craters, pits etc shall be removed
before conducting radiographic test. The length of weld to be tested shall not
be more than 0.75 x focal distance. The width of the radiographic film shall be
width of the welded joint plus 20 mm on either side of the weld.

5.5 CONTRACTOR shall provide testing equipment for conducting non destructive
tests for confirming the integrity of welding wherever necessary as directed
by the purchaser / consultant.

5.6 Acceptable Limits of defects of weld

i) Visual inspection & Dye Penetration Test
The limits of acceptability of defects detected during visual inspection
and Dye Penetration Test shall be in accordance with clauses 8.15.1 &
clauses 9.25.3 of American National Standard ANSI / AWS Dl.1-92
respectively, for statically and dynamically loaded structures.
ii) Ultrasonic Testing
The limits of acceptability of defects detected during ultrasonic testing
shall be in accordance with clause 8.15.4 & clause9.25.3 of American
National Standard ANSI / AWS Dl. 1-92 respectively, for statically and
dynamically loaded structures.

Page -580
 iii) Radiographic Testing
The limits of acceptability of defects detected during Radiographic
testing shall be in accordance with clause 8.15.3 & 9.25.2 of American
National Standard
ANSI / AWS Dl .1-92 respectively for statically and dynamically loaded
structures.
5.7 Rectification of Defects in Welds

5.7.1 The rectification of defects in welds shall be done as follows:

i) All craters in the weld and breaks in the weld run shall be thoroughly
filled with weld
ii) Undercuts, beyond acceptable limits, shall be repaired with dressing so
as to provide smooth transition of weld to parent metal.
iii) Welds with cracks and also welds with incomplete penetration, porosity, slag
inclusion etc. exceeding permissible limits shall be rectified by removing the
length of weld at the location of such defects plus 10 mm from both ends of
defective weld and shall be re-welded. Defective weld shall be removed by
chipping hammer gouging torch or grinding wheel. Care shall be taken not to
damage the adjacent material.

GUIDELINE FOR INSPECTION OF WELDING

Sr. Inspection or Coverage Procedure Evaluation findings &

Test remedy of defects.
No.
1. Inspection of All welds Naked eye or lens. All faulty welds shall be
weld seams rectified.
appearances
2. Checking of At least one Ordinary measuring Should faulty weld be
sizes for each instruments (rule, found all welds shall be
weld seam templates) checked and all defects
shall be rectified.

Page -581
 3. Mechanical As per IS 9595. As per IS 9595.
tests for
welding
procedure
performance
& electrodes

6.0 SHOP INSPECTION AND APPROVAL

6.1 General

The Engineer-in-charge or his representatives shall have free access at all

reasonable times to the fabrication shop and shall be afforded all reasonable
facilities for satisfying himself that the fabrication is being undertaken in
accordance with drawings and specifications.

Technical approval of the steel structures in the shop by the Engineer-in-chage is

mandatory.

The Contractor shall not limit the number and kinds of test, final as well as
intermediate tests or extra tests requested by the Engineer-in-charge. All necessary
tools, gauges, instruments etc. and technical and non-technical personnel shall be
furnished for shop tests to the Engineer at contractor's cost as and when required
by the Engineer-in-charge.

6.2 Shop Acceptance

The Engineer-in-charge shall inspect and approve at the following stages -

a. - Intermediate approval of work that can not be inspected later.

b. - Partial approvals.

c. - Final approval.

a. Intermediate approval of work shall be given when a part of the work

performed can not be inspected later or when inspection would be difficult
to perform and results would not be satisfactory.

b. Partial approval in the shop is given on members and assemblies of steel

structures before the primer coat is applied and include:

Approval of field joints.

Approval of parts with planned surfaces.

Page -582
 Test erection

Approval of members

Approval of markings.

Inspection and approvals of special features like rollers, loading platform

mechanism etc.

During the partial approval, intermediate approvals as well as all former

approvals, shall be taken into considerations.

c. Final Approval in the shop.

The final approval refers to all elements and assemblies of the steel
structures, with shop primer coat, ready for delivery from shop, to be
loaded for transportation or stored.

The final approval comprises of -

Partial approvals.

Approval of shop primer coat

Approval of mode of loading and transport, approval of storage (for

materials stored)

7.0 INSPECTION ON SITE

7.1 General

Contractor shall give due notice to Engineer-in-charge in advance of structural

members or workmanship getting ready for inspection. All rejected material shall
be promptly removed from the shop and replaced with new material for Engineer-
in-charge’s approval.

The fact that certain material has been accepted shall not invalidate final rejection
at site by Engineer-in-charge if it fails to be in proper assembly. No material shall be
painted or despatched to site without inspection and approval by Engineer-in-
charge.

Shop inspection by Engineer-in-charge or submission of test certificate and

acceptance thereof by Engineer-in-charge shall not relieve Contractor from the
responsibility of furnishing fabricated material conforming to requirements of these
specification nor shall it invalidate any claims which Engineer may make because of
defective, unsatisfactory workmanship.

Page -583
 For fabrication work carried out on the field, the same standard of supervision of
quality control shall be maintained as in shop fabricated work. Inspection and
testing shall be conducted in a manner satisfactory to Engineer-in-charge.

Members shall be inspected at all stages of fabrication and assembly or verify that
dimensions, tolerances, alignment, surface finish etc. ate in accordance with the
requirements shown on drawings and as per IS codes.

In the event of any failure of members to meet an inspection or test requirement

contractor shall notify Engineer-in-charge. The quality control procedure to be
followed to ensure satisfactory repair shall be subject to approval by Engineer-in-
charge. In such cases, Engineer has right to specify additional inspection or testing
as deems necessary and the additional cost of such testing will be borne by
Contractor.

Holes in members required for installing equipment or steel furnished by other

manufacturers or other contractors shall be drilled in Contractor's shop as part of
this contract the information for which will be supplied before fabrication of steel.

7.2 Packing, Transportation, Delivery

After final shop acceptance and marking, the item shall be packed and loaded for
transportation.

Packing must be adequate to protect items against warping during loading and
unloading. Proper lifting devices shall be used for loading, in order to protect items
against warping.

Slender projecting parts shall be braced with additional steel bars, before loading,
for protection against warping during transportation rules. If certain parts can not
be transported in the lengths stipulated in the design, the position and type of
additional splice joints shall be approved by Engineer-in-charge. Damaged parts and
members due to transportation may be rejected by Engineer-in-charge and re
fabricated at site or at shop and redelivered at Contractor's cost.

Items must be carefully loaded on platforms of transportation means to prevent

warping, bending or falling, during transportation. The small parts such as
fishplates, plates, gussets etc. shall be securely tied with wire to their respective
parts.

Bolts, nuts and washers shall be packed and transported in crates. The parts shall
be delivered in the order stipulated by the Engineer-in-charge and shall be
accompanied by document showing:

Quality and quantity of structure or members

Page -584
 Position of member in the structure

Particulars of structure

Identification number / job symbol

7.3 Storage and Preparation of Parts prior to erection

The storage plane for steel parts shall be prepared and got approved by the
Engineer-in-charge before the steel structures start arriving from the shop.

A platform shall be provided by the Bidder near the erection site for preliminary
erection work.

The Contractor shall make the following verifications upon receipt of material at
site:

For quality certificate regarding material and workmanship according to the general
specifications and drawings.

Whether parts received are complete without defects due to transportation,

loading and unloading and defects, whether the defects if any are well within the
admissible limit.

For the above work sufficient space must be allotted in the storage area. The
storage area should be clean and free of water and moisture and should be
approved by Engineer-in-charge.

Precautions shall be taken to prevent warping of items during unloading. The parts
shall be unloaded, sorted and stored so as to be easily identified.

The parts shall be stored according to construction symbol and markings so that
these may be taken out in order of erection / sequence. The parts shall be set at
least 150 mm clear from ground on wooden or steel blocks for protection against
direct contact with ground moisture. If minor rectification of members like
straightening etc. are required, these shall be done in a special place allotted which
shall be adequately equipped.

The parts shall be clean when delivered for erection.

8.0 TOLERANCES

The dimensional and weight tolerances for rolled shapes shall be in accordance
with IS 1852. The acceptable limits for straightens (sweep and camber) for rolled or
fabricated member are:

Struts and columns = L / 1000 or 10 mm whichever is smaller.

Page -585
all other members - L / 500 or 15 mm

where L : Length of finished member tolerances in specified camber of structural

members shall be = 3 mm

Tolerance in specified length shall be:

for column finished for contractor bearing - 1 mm

other members upto 10 mm - 3 mm.

Page -586
METAL FALSE CEILING

Designing, Providing and Fixing of Perforated Torsion Spring Tile Ceiling System of approved
manufacturer comprising of Tile of 600mm wide and 600mm long manufactured out of 0.7mm thick
Aluminium Alloy 3105. The panel shall be perforated with 1.5mm dia. to give an 22% open area. The
metal ceiling panels shall be downward accessible with a minimum of four (4) torsion springs per
panel. The Tile will be manufactured on advanced CAD/CAM equipment that includes several leveling
stages in the manufacturing process. Torsion Spring panel with two side legs die formed and two end
legs die formed and punched to receive torsion springs (min two springs each end or side) for secure
engagement into Tee Grid main runners which are factory punched to receive torsion springs. Tiles
will be square edged. The Tile shall be Polyester powder coated (50-60 micron) in approved color.

Acoustical Felt: Non-Woven felt made of Glass Reinforced Fiber (GRC) glued over the perforation for
better sound absorption to offer an NRC of 0.45 – 0.7

Main Runners: 24mm deep, inverted “T” sections, 3.6m long, with factory punched flanges to receive
torsion spring assembly. Main Tee on center spacing to match panel length.

Cross Runners: 24 mm deep, inverted “Tee” sections designed to interlock in to web of main tee
section on designated spacing. Cross tee length to match panel length. Cross tees are spaced spacing
1200mm on center maximum.

Suspension System: As per manufacturer standard considering type of plenum and its height.

Paint finish: The panels will be pre-treated in latest nano technology process and electro statically
powder coated with automatic Carona system and cured with gas catalytic technology.

1.1 GENERAL

This section covers the requirements for all materials, labour, tools, scaffolding and equipment
complete with all respect for suspended false ceiling at all heights.

1.2. MATERIAL

1. M6 Anchor Fasteners with Vertical M6 Threaded Rods

The suspension system to be suspended from the ceiling /soffit with the help of Anchor
fasteners of M6 gauge including matching nut and washer to be used for reinforced
concrete sockets along with vertical hanger made of galvanized steel of size25mm x
25mm and thickness 1.2 mm with galvanization thickness of minimum 50 g /Sq.m for
suspending the threaded rod / angle.

Page -587
 2. Threaded Rod / Angle:

Threaded rod of dia 6mm/Angle with a galvanization thickness of minimum 50g/sq.m

and tensile strength upto 344-413 MPa. The Threaded rod / Angle in desired length
upto 3 mtrs should be used in conjunction with the adjustable Suspension clip.

3. Torsion Spring Hanging System:

Panels shall be connected using 24mm deep Main T, inverted “Tee” sections, 3.6m
long, with factory punched flanges to receive torsion spring assembly. Main Tee on
center spacing to match panel length. 4 springs are required to install 1 no. of 600 x
600mm tile to the Main T.

4. Frame work:

24mm deep Main T, inverted “Tee” sections, 3.6m long, with factory punched flanges
are hanged to the RCC/Soffit by means of the 6mm threaded rod. Main T is provided
with the punched holes to receive the springs. Main T are placed 600mm apart from
each other for 600 X 600mm tiles. 24mm deep Cross T’s of 600mm are provided
between the Main T’s at a maximum spacing of 1200mm to create a grid of 600 X
1200mm. Length of Cross T should match the panels length. 4 springs are required to
install 1 no. of 600 x 600mm tile to the Main T.

The last hanger at the end of each Main Tee/ Cross tee should not be greater than
500mm from the adjacent wall. The system shall be perfectly levelled, aligned at
desired height in plain, curved and vertical face in accordance with the false ceiling
pattern as per drawing and the system shall be installed in accordance with the
Manufacturer's specifications and directions of the Engineer in Charge. The suspension
system should be fixed to rigid threaded rod of 6mm with ceiling brackets and
necessary fasteners. Perimeter wall angle of pre-painted galvanized steel to be of white
colour secured to walls by means of screws at 450mm c/c.

1.3. FIXING THE G.I. SUSPENSION SYSTEM TO THE CEILING:

To comprise of Torsion Spring/ secure & rigid system securely fixed to the structural soffit by
support clamp & approved hangers. The last hanger at the end of each Carrier should not be
greater than 500mm from the adjacent wall. The system shall be perfectly levelled, aligned at
desired height in plain, curved and vertical face in accordance with the false ceiling pattern as
per drawing and the system shall be installed in accordance with the Manufacturer's
specifications and directions of the Engineer in Charge. The suspension system should be fixed
to rigid threaded rod of 6mm with brackets and necessary fasteners.

Page -588
 a) Storage and Handling precautions:

1. Ceiling Tile Panels shall be supplied in neatly packed cartons.

2. Not to store the cartons in flat and wet locations.
3. Handle cartons and individual Panels with care.
4. Do not drop or stand cartons of Panels on edges or corners.
5. Open cartons completely and using both hands with protective gloves, remove
Tiles in pairs with fair faces together.

b) Installation Precautions:

1. The following to be ensured before installation of the ceiling system

i) The area is dry prior to ceiling installation work.

ii) Air conditioning duct work is completed.
iii) Electrical chasing or drawing lines etc are in place.
iv) No unauthorized weight is put on ceiling. Lighting fixtures to be
suspended independently.
v) Panels should be installed by experienced Interior Contractors in
compliance with manufacturers specifications and conditions.
vi) Installations shall be done in areas free from chemical fumes / freezing
temperatures and vibrations.
vii) Panels shall not be used to support any unauthorized loads.
viii) Panels shall be mechanically suspended properly and shall not be
cemented nor glued to the surface of any other material.

c) Cut outs for light and A/C fixtures:

Work shall include the making of cut outs required for fixing light fixtures, air-
conditioning diffusers, and fire detectors, trap doors etc. as per design requirement
and drawings.

1.4 TESTING:

One test from each 2000 Sq.m shall be carried from the approved lab by AAI. Testing charges
shall be deemed to be included in quoted rates.

Guarantee:-
Manufacturer should ensure the performance guarantee of the system for a period of 10 years by
submitting a Guarantee Bond for 5(Five)% value of total False Ceiling work, for a period of 05
years and Corporate Guarantee for further 05 (Five) Years.

Page -589
GLAZED DOORS

Supplying and installation of 12 mm thick frameless toughened clear glass door consisting
hardware as per AAI approved make and 12mm thick toughened clear glass of any required size of
AAI approved manufacturer. Glass to be toughened by special chemical to strengthened by double
impact, all edge to be machine polished and sides also to be toughened. The work also includes
cutting of floor (15mm strip of size 15mm X 15mm) for floor spring of AAI approved manufacturer
heavy floor spring of AAI approved manufacturer to hold the glass at bottom. The work includes
cost of all cut outs/holes wherever required including fixing of hardware consisting of all required
patch fittings for doors with side and upper panels, upper and bottom patches, floor lock with
cylinder and strike plate and SS-316 grade pull handle of size 450mmX22mm complete as per
direction of Engineer-In-Charge.

1.1 MATERIAL
Double door with fan light and side panels consists of the following:
a) Glass door (With 2 leaf’s) over/side panel fitting, with pivot and satin SS covers.
b) Glass door (With 2 leaf’s) over and side panel connector, with satin SS covers.
c) Top patch (2 no’s) fitting with pivot bearing location, with satin SS covers.
d) Bottom patch (2 no’s) fitting with pivot bearing for floor spring, with satin SS covers.
e) Floors lock (2 no’s) –with strike plate and Euro Profile cylinder.
f) Floor Spring (2 no’s)
g) Back to Back SS-316 Pull Handle (4 no’s) 450mm x 22mm diameter.

1.2 FRAMELESS GLASS DOORS.

Frameless glass door shall consist of two 15mm diameter SS short pivot poles and corner lock with
euro profile cylinder. The rugged internal components of lock meet all the requirements of DIN
18251, class 3, satisfying the type test criteria of 2,00,000 latch and 50,000 dead bolt operating
cycles.

The fittings will be mounted on 12 mm thick clear toughened glass door with all necessary
required accessories. The door will also consist of floor spring with all necessary glass mounting
accessories for the self closing feature. Complete as per manufacturer specification. The door shall
also consist of Pull Handle 450mm x 22mm diameter.

Page -590
FAÇADE SYSTEM/STRUCTURAL GLAZING

Designing, Supplying, Testing and fixing factory made fully unitized curtain wall four sided
structural glazing system Duly designed confirming to IS 875 and other relevant IS
codes/specifications, consisting of super durable powder coated aluminium and glass of approved
shade/make, aluminium frame work fabricated out of heavy duty Aluminium extruded profile
powder coated with durable thermosetting super durable polyester powder coating by
electrostatic spraying and hard stoved to not less than 60 micron thickness to comply with BS
6496:1994 (1991) and AAMA 2603-98 standard as per approved shade. All aluminium members
and profile shall be of AC-25grade as specifications. The aluminium members shall be protected
with protections tapes all around the profile for safety against external scratches at site.
(Protection tape shall be removed only at a time of handing over as per the instructions of project
management.). The anchoring /bracing of the glazing to the RCC slabs /beams /colums shall be
done with required number of aluminum brackets with approved dash fasteners of the minimum
12mm dia and depth of minimum 100mm, in the concrete and stainless steel bolts including
providing and fixing aluminium shims of various thickness to adjust the beam level and line
variation. The anchoring system has been design to withstand the dead load of structural wall as
well as stresses due to wind pressure etc. The glazing frame shall be aligned for each vertical
mullion for the entire height and for each transom for the entire width horizontally by laser beam
equipment to ensure 100% x axis and y axis alignment. To make the joint water and air tight the
glazing frame work provided with approved in built ventilation and drainage system. All the joints
of the structural glazing system and the periphery, of glass shall be properly sealed with specified
weather silicon. The details of inbuilt ventilation and drainage system should be submitted by the
contractor before execution.

The scope of work includes designing, fabricating, testing, protection, installation and fixing in
position fully unitized system of structural glazing (with open joints) for linear as well as curvilinear
portions of the building for all heights and all levels to withstand the design loads and wind
pressure. Complete unitized system shall fulfill all the criteria to match requirement of the building
as per seismic zone and location with additional 50% as safety zone.

Silicon/EPDM gasket of suitable profile to accommodate glasses in all vision areas shall be
provided at all glazing area to make the glazing water and air tight. Including the glass to be fixed
at the outer side of the aluminium frame with structural silicon sealant (SG 18/ DC995) and
mechanical support with pressure plates and cover plates(the structural silicon bite size shall not
be less than 8mm/ as per the structural requirement/as per manufacturers recommendation).
Expansion joint gap for mullion shall be minimum 15 to 20mm to be provided where ever
required, filled with expansion joint sealant. All screws, washers used shall be only stainless steel
316 grades and through, Bolts, Nuts and Anchors used shall be only stainless steel of 316 grades
etc. complete as per direction of EIC. (The structural design &drawings shall be provided by
Consultant / approved specialized agency however the executing agency has to submit shop
drawings and mock-up based on same which have to be approved by EIC before start of work.)

Page -591
1) Mullions & Transoms, extruded aluminium sections shall be of 6063-T6 alloy to be as per
structural calculations of Jindal/Bhoruka or approved equivalent.

2) Coating of aluminium section will be powder coated with super durable thermosetting
polyester powder coating by electrostatic spraying and hard stoved to not less that 60
micron thickness to comply with BS 6496-1994 (1991) and AAMA 2603-98 standard of
approved shade as per direction of EIC.

3) Heavy duty, best quality EPDM/Silicon gasket at joints and connection between Aluminium
members.

4) All components should be sealed for water proofing with silicon of wacker, Dow corning of
DC 789 /Sikka or equivalent or water proof membranes with internal/external aluminium
flashing finished to approval. Curtain wall should be seal to hoist structure and allow
movements etc. in its service life. Item includes cost of supplying, installation and fixing of
aluminium frame with structural members, mullions, Transom, sub fame, fixtures etc,
including supply installation and fixing glass including cost of sealants, brackets, fasteners,
screws, sleeve, spacer tape, backer rod, bolts, gasket, fixtures, scaffolding, sales tax/VAT,
excise duty, any other taxes etc. complete in all respect. (The work is to be carried out by a
specialized agency approved by the EIC.)

5) Glass – High performance glass with properties such as Visible Light Transmittance (VLT) 39%
or more, light reflection internal 18 to 20%, light reflection external 12 to 14%, SHGC less
than or equal to 0.24 and U value equal to or less than 1.60 W/m2 degree K etc. in approved
colour and shade.

1.1 TECHNICAL SPECIFICATION

The design of structural glazing should be done as per site condition and as per
specifications to match building criteria as required.

1.2 MATERIAL

a) CLEAR FLOAT GLASS

Float glass used for glazing shall be of approved quality conforming to ASTM C 1016 for
clear and ASTM 1048 for toughened glass and of the thickness specified in the item. The
tolerance in thickness shall be + 0.2 mm for 6/8/10 mm or as required.

b) TEMPERED / TOUGHENED GLASS

Float glass conforming to BS 952 Part – I for clear and of the thickness specified in the item
shall be used for manufacturing toughened glass. Toughening, which shall be carried out
horizontally (without tong-marks), shall conform to ASTM 1048.

Page -592
 All works such as cutting, grinding, drilling etc. on glass shall be carried out prior to
toughening.
Once tempering is done, no work will be allowed on the glass.

c) DOUBLE GLASS UNITS/ INSULATED GLASS UNITS (DGU/IGU)

Double-glazed units (DGU) or insulated laminated glass units (IGU) as per ASTM 774 shall
consist of two parallel glass panes assembled with a metal (aluminium spacer and a dual
seal to form a hermetically sealed unit. The insulation shall be achieved by trapping and
creating of a cavity of dry air between the two panes of glasses.The processing to be done
on specialized machine in a dust free AC plant.
The Aluminium spacer tubes shall contain specified absorbent (desiccant) to absorb
moisture from within the glass panes cavity & the air. The pore size on aluminium spacer
shall be as per manufacturer’s specifications. The aluminium spacer tube on all four sides
shall be filled with desiccant.
The dual seal construction shall have a primary vapour seal made of compressed
POLYISOBUTYLENE(BUTYL) and the outer seal shall be constructed with an elastic sealant
based on structural silicone sealant. The inner seal is to be hot applied and should be
plastic in nature which will fix the spacer – bar to the glass and reduce the moisture vapour
ingress into the dry air cavity to the very minimum level.
The structural silicone outer sealant is cold applied and should be plastic and is to be
chemically reactive material which bonds to the glass and cures to an elastic mass. The
outer sealant should be able to do following functions: -
i) The bonding of glass panes and spacer to one another to from the insulating glass unit
(IGU).
ii) Protection against chemical attack from outside (weather proof).
iii) Resistance against water entry either in fluid or vapour from.
The Aluminium spacer shall be as per design to give a dry air gap of 12/16 mm. The D.G.U.
unit shall have a nominal thickness as designed as per site requirement.
Float glass of international quality conforming to ASTM 774 for clear glass and of the
thickness specified in the item shall be used for making insulated glass. The processing is
done on specialized automatic machines in a dust-free air-conditioned plant.
d) LAMINATED GLASS UNITS
Laminated glass units shall consist of two parallel glass panes glass (toughened clear glass +
Ionoplast structure inter layer lamination + inner toughened clear glass). The lamination
should be able to do following functions:
A. The bonding of glass panes to one another shall be so accurate.
B. Protection against chemical attack from outside (weather proof).
C. Resistance against water entry either in fluid or vapour from.
Page -593
 Laminated glass reduces noise, heat and dust and ultimately consumption of electricity.
Laminated glass should carry 10 years warranty from glass processor for delamination.

Float glass of international quality conforming to BS 952 Part-I for tinted glass and of the
thickness specified in the item shall be used for making conditioned plant. Insulated glass
shall confirm to ASTMC 1036-91.

e) REFLECTIVE TOUGHENED GLASS

Reflective toughened glass used for glazing shall be of approved quality conforming to
ASTM C 1016 for clear and ASTM 1048 for toughened glass and of the thickness specified in
the item.
The tolerance in thickness shall be + 0.2 mm for 6 mm.

f) Silicon / E.P.D.M. GASKET

Heavy duty, best quality of Silicon/EPDM gaskets shall be used at joints and connections
between aluminium members. (EPDM should have its property at-least for minimum 15
years, should not become brittle).

g) BACKER ROD
Backer rod should be closed cell polyethylene, light weight, resilient, non-impregnated,
non-staining and non-bleeding, insert, sealant will not adhere and round with following
specifications:
Water absorption : 0.097 mg/Cm2
Density : 0.028 – 0.30 gm/Cm2
Elongation : 150 -175 %
Thermal conductivity : 0.027 K calmh0C
Stability : Excellent
Resiliency : Excellent
Colour : Clear
Service Temperature : -300C to + 400C

h) EXPANSION JOINT

Building will have an expansion gap of 50-75mm as per structural requirement. In the
curtain wall glazing vertical expansion joint of this width to be provided with adequate
structural / weather proof sealant. Sealant design, appropriate grade etc to be got
approved from the sealant manufacturer. Nothing extra shall be paid on this account. For
aesthetic purpose covering is required for this joint. That also to be done without any extra
cost.

Page -594
1.3 EXECUTION

a) GLAZING WORK
The size of glass panels shall be shown in the drawings and thickness specified in the item.
The glass panes shall be of approved quality and make. They shall have properly squared
corners and straight edges. Damaged or defective glass shall be replaced with new glass at
no additional cost. Each piece of glass shall be delivered with factory labels intact,
indicating glass type, quality and thickness. Labels shall not be removed until installation
has been accepted.

Glazing gasket channels and beads of E.P.D.M/Silicon or neoprene for all glass to be framed
shall be the standard products as specified to fit the frames. Setting blocks shall be of hard
P.V.C. They shall be high enough to provide minimum edges clearance for glass. Glass is to
be protected from breakage immediately upon installation by applying suitable warning
markings.

All components should be sealed for water proofing with silicon of AAI approved make
joint movement minimum + 50% according to ASTMC -920.

Structural silicone of Two part sealant DC 983 or One part sealant DC 995 or structural
sealant from AAI approved make designed to meet test requirements of ASTM C 1184 for
bonding DGU unit with subframe in controlled dust free environment and in conditioned
space.

b) REPLACEMENT OF GLASS
In case of glass breakage during installation & testing, the glass will have to be replaced by
De-glazing the glass at site & the re-glazing of the new glass will have to be done at site
without any extra cost up to defect liability period.

c) FINAL CLEANING
Protective coating and warning markings shall remain undisturbed until final acceptance.
Immediately prior to final inspection, temporary protective covering or coating shall be
removed and surfaces shall be washed with a suitable thinner and left in a finished
condition having approved uniform appearance and free from all marks and blemishes.
Both faces of the glass shall be washed and polished.

d) INSPECTION
As desired by Engineer-in-charge agency should arrange for factory inspection of
Aluminium section and glass to ascertain the quality of material i.e. aluminium and glass as
per manufacturer’s standard / BIS / ASTM standard, including anodizing / P.P.C.,
toughening of glass as per specifications and standards.

1.4 HANDLING & STORAGE

Glass shall be securely and safely crated for delivery, handling and storage. Cushions shall
be provided at edges of glass to prevent damage. Glass faces shall be protected from

Page -595
 scratches and abrasions. It shall be stored in a dry, well-ventilated location, carefully
protected at all times from soiling, atmospheric.

1.5 TEST / FREQUENCY

i) The aluminium shall be of grade 6063-T6 alloy. Testing shall be carried out as per Particular
specifications for alluminium work annexed with tender.

ii) Float glass shall confirm to BS 952 part – 1 for clear glass. The thickness of glass shall be
checked at any stage.

iii) If desired by A.A.I., the system shall be got tested in an AAI approved independent
laboratory at conditions prevalent at site but for minimum 1170 pascal wind load, the max.
deflection in the system should be not more than L/175. Water test and air penetration
according to the centre for Windows and Cladding Technology (CWCT) standard USA at 600
Pascal pressure. The system should be based on rain screen principal and pressure
equalized drainage.

Page -596
Curtain wall Tests:

Performance Test (Off-site & On-site):

Mock-up system shall demonstrate performance for air seal, water seal, structural and seismic
requirement. System performance test shall be mandatory to verify the design performance,
meeting the requirements.
Performance test laboratory with minimum 10 years experience in conducting performance tests
with NABL accredited certificate not less than 6 years. The laboratory shall have façade expertise
to analyse various behavior and test results. Laboratory shall have fully automized data acquisition
system with provision to capture all values directly in test record sheet on completion of each test.
The Dynamic test shall be carried out with dynamic propeller engine. The sequence of test
standards shall be as per AS/NZS-4284 or ASTM E 283, ASTM E 331, AAMA 501.1, ASTM E 330/E
330M, AAMA 501.4 in line with AAMA 501-05. For rails and balustrades ASTM E 935 and ASTM E
shall be followed. No fabrication and installation at the site shall be allowed without successful
completion of the laboratory performance test. On-site test for workmanship verification shall be
carried out in stages for water penetration hose test as per AAMA 501.2.
Sequence of testing and criteria shall be as per clause 3.

1.0 Off-site Test Sequence/Criteria for Curtain Wall & Strip Glazings:

Following off-site lab test are to be carried out for curtain walls and strip glazings and shall be
in accordance with the following test standards:

a) Air Infiltration as per ASTM E 283. Standard Test Method for Determining Rate of Air
Leakage through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure
Differences Across the Specimen.

Positive Test Pressure: 300 Pascal (pressure differential).

Pass Criteria: Air leakage through the test specimen should be within permissible limit. Air
leakage through specimen fix lites shall be permissible within 1.5 m3 /hr/m2 and 2.5 m3
/hr/m from openable crack length.

b) Static Water Penetration as per ASTM E 331.Standard Test Method for Water Penetration
of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure
Difference.

Page -597
 Positive Test Pressure: 600 Pascal (pressure differential).

Pass Criteria: No water leakage during and after testing. Any water contained in the
system should drain outside by gravity without using applied air pressure.

c) Dynamic Water Penetration as per AAMA 501.1. Standard Test Method for Water
Penetration of Windows, Curtain Walls and Doors Using Dynamic Pressure.

Positive Test Pressure: 600 Pascal (pressure differential).

Pass Criteria: No water leakage during and after testing. Any water contained in the
system should drain outside by gravity without using applied air pressure.

d) Strutural Performance @ Design Wind Pressure as per ASTM E 330/ E 330M.Standard

Test Method for Structural Performance of Exterior Windows, Doors, Skylights and Curtain
Walls by Uniform Static Air Pressure Difference.

Positive Test Pressure: 50% &100% design wind pressure.

Negative Test Pressure: 50% &100% design wind pressure.

Pass Criteria: Deflection of structural members and glasses should be within the allowable
limits. No failure of any elements is allowed. Permissible permanent deformation at
structural members shall be L/2000 of span.

e) Seismic Floor Displacement @ Design Displacement as per AAMA 501.4. Static Test
Method For Evaluating Curtain Wall and Storefront Systems Subjected to Seismic and
Wind Induced Interstory Drifts.

Floor Displacement : 0.4 % of greatest floor height but not less than 8 mm.

Pass Criteria: No glass breakage or fall out is allowed. Any damage shall be readily
repairable/adjustable on site with no part replacements required. No wall components
may fall off.

f) Strutural Performance @ 1.5 X Design Wind Pressure as per ASTM E 330/ E 330M.
Standard Test Method for Structural Performance of Exterior Windows, Doors, Skylights
and Curtain Walls by Uniform Static Air Pressure Difference.

Page -598
 Positive Test Pressure: 75% & 150% design wind pressure.
Negative Test Pressure: 75% & 150% design wind pressure.

Pass Criteria: Deformation of structural members should be within the allowable limits. No
failure of any elements is allowed. Permissible permanent deformation at structural
members shall be L/2000 of span.

g) BMU restraint test as per AS/NZS 4284 Testing of building façades.

A tensile load shall be applied to restraint pin at 1.5 KN in all 5 directions.

Pass Criteria: Tie back shall not fall, exhibit distortion.

2.0 Off-site Test Sequence/Criteria for Casement and sliding windows:

Following off-site lab test are to be carried out for windows and shall be in accordance with
the following test standards:

a) Air Infiltration as per ASTM E 283. Standard Test Method for Determining Rate of Air
Leakage through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure
Differences Across the Specimen.

Positive Test Pressure: 300 Pascal (pressure differential).

Pass Criteria: Air leakage through the test specimen should be within permissible limit. Air
leakage through specimen fix lite shall be permissible within 1.5 m3 /hr/m2 and 2.5 m3
/hr/m from openable crack length.

b) Static Water Penetration as per ASTM E 331.Standard Test Method for Water Penetration
of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure
Difference.

Positive Test Pressure: 600 Pascal (pressure differential).

Pass Criteria: No water leakage during and after testing. Any water contained in the
system should drain outside by gravity without using applied air pressure.

Page -599
c) Dynamic Water Penetration as per AAMA 501.1. Standard Test Method for Water
Penetration of Windows, Curtain Walls and Doors Using Dynamic Pressure.

Positive Test Pressure: 600 Pascal (pressure differential).

Pass Criteria: No water leakage during and after testing. Any water contained in the
system should drain outside by gravity without using applied air pressure.

h) Strutural Performance @ Design Wind Pressure as per ASTM E 330/ E 330M.Standard

Test Method for Structural Performance of Exterior Windows, Doors, Skylights and Curtain
Walls by Uniform Static Air Pressure Difference.

Positive Test Pressure: 50% &100% design wind pressure.

Negative Test Pressure: 50% &100% design wind pressure.

Pass Criteria: Deflection of structural members and glasses should be within the allowable
limits. No failure of any elements is allowed. Permissible permanent deformation at
structural members shall be L/2000 of span.

i) Seismic Floor Displacement @ Design Displacement as per AAMA 501.4. Static Test
Method For Evaluating Curtain Wall, Window and Storefront Systems Subjected to Seismic
and Wind Induced Interstory Drifts.

Floor Displacement : 0.4 % of greatest floor height but not less than 8 mm.

Pass Criteria: No glass breakage or fall out is allowed. Any damage shall be readily
repairable/adjustable on site with no part replacements required. No wall components
may fall off.
j) Strutural Performance @ 1.5 X Design Wind Pressure as per ASTM E 330/ E 330M.
Standard Test Method for Structural Performance of Exterior Windows, Doors, Skylights
and Curtain Walls by Uniform Static Air Pressure Difference.

Positive Test Pressure: 75% & 150% design wind pressure.

Negative Test Pressure: 75% & 150% design wind pressure.

Page -600
 Pass Criteria: Deformation of structural members should be within the allowable limits. No
failure of any elements is allowed. Permissible permanent deformation at structural
members shall be L/2000 of span.

3.0 On-site Test Sequence/Criteria for Building Facades:

a) Field water leakage test on actual building-Hose Test as per AAMA 501.2: Hose test for
water leakage shall be carried out confirming to AAMA 501.2 by the independent test
agency at 8-10 locations as desired by the architect / consultant. Initial installation of 4
units by two floor height to be tested to check the workmanship in line with the design
intent and performance. The locations are typical building façade, different corners of the
building, copping, critical roof glazing junctions and inclined glazing corners.

Pass Criteria: There shall be no water leakage.

b) On-site and Off-site Metal Hand Rail/Balustrade Test as per ASTM E 935. Test to be
carried out on site or off site to confirm ASTM E 935 for uniform horizontal load test for
tension and compression load and to check resistance of anchorage for railing system, and
rails.
Pass Criteria: Deflection shall be within permissible limit. No failure of any component is
permitted.

c) On-site and Off-site Metal Hand Rail/Balustrade Test as per ASTM E 2350. Test to be
carried out on site to confirm ASTM E 2350 for impact load test to check resistance of
anchorage for railing system, and rails.

Pass Criteria: No component failure is permitted.

Additional Test for cantilever slab:

a) Vertical Movement Test as per AAMA 501.7. Static Test Method For Evaluating Curtain
Wall, Window and Storefront Systems Subjected to Seismic and Wind Induced Interstory
vertical movements .

Floor Displacement : +/- 6 mm.

Page -601
 Pass Criteria: No glass breakage or fall out is allowed. Any damage shall be readily
repairable/adjustable on site with no part replacements required. No wall components
may fall off.

1.6 Guarantee:-

Contractor should ensure the performance guarantee of the system for a period of 10 years
by submitting a Guarantee Bond (BG) for 5(Five)% value of total Facade System work, for a
period of 05 years and Corporate Guarantee for further 05 (Five) Years.

Page -602
ROOFING

Designing, Providing and Fixing KALZIP/ KINGSPAN RIGIDAL 65/400 "SELF SUPPORTED" CONCEALED FIX
ALLUMINIUM STANDING SEAM ROOFING SYSTEM as per approved make in 0.90 MM THICK AA 3004
aluminum ALLOY, comprising of the following layers:

i) Top Layer 65/400 of Straight / Tapered / Curved profiled sheeting manufactured from Aluminum alloy
AIMn1Mg1 as specified in BSEN 485-2 Quality AA 3004, minimum thickness of 0.9 mm PVDF Finish on
the exposed surface as approved by Engineer-in-Charge. Sheets are to be laid in single length to meet
the requirement of the building roof geometry, fixed on Aluminum clip and which is fixed to Top-Hat /
Liner Sheet with SS-304 screws. The profile should have 3 micro ribs to provide additional strength at
the pan. The support aluminium clip shall be manufactured from extruded aluminium alloy 6061 T6 in
accordance with BSEN 485 part 2. Each aluminium clip shall be coupled with a 5mm thick black
polyamide thermal barrier base pad. The material properties shall be as follows: tensile strength:
minimum 200 N/mm2, Yield strength: min 185 N/mm2.

ii) The insulation shall be 100 mm thick (laid in two layers of 50 mm Glasswool with minimum density 24
kg/m3 or Rockwool with minimum density 60 kg/m3 to achieve minimum U value of 0.26 W/m2 K and
minimum R- Value of insulation -3.70sqm-k/w.

iii) Third Layer: Top Hats Galvanised steel Top hats of min. thickness of 1.6mm and to be installed over the
VCL, cement board, with min. yield strength of 240 Mpa and to be fixed with Steel Fasteners.

iv) Fourth layer (Vapour Control Layer): Scrim reinforced Polyethylene film heavy duty type Vapour control
layer should be laid providing a minimum water Vapour resistance of 336MNs/g and water
permeability of 0.61g/m2/day" having specific weight of 200 gsm.

v) Fifth Layer: Cement Board/ bison Board One layer of 12mm thick cement/bison board layer to be laid
over GI brackets.

vi) Sixth Layer: (Bottom sheet) - Trapezoidal Colour Coated Galvalume 0.50mm TCT (Total Coated
Thickness) profile sheet of 980-1050 mm effective cover width and 28-35 mm height ribs with pan at
200-250 mm centre-to-centre. The feed material is manufactured out of nominal 0.45mm (BMT) Hi-
strength steel with min. 550 MPa yield strength, metallic hot dip coated with Aluminum-Zinc alloy (55%
Aluminium, 45% Zinc) as per AS 1397 Zincalume AZ150 (Min. 150 gms/sq.mt total on both sides) Fixed
to the purlins with self drilling screws.

vii) Item includes designing, supplying, installation and fixing of profiled aluminum sheeting including
system accessories insulation, vapour barrier, liner sheet, cement board, fasteners, gaskets, brackets,
screws, rivets, sealants at all location including sky light, gutter, flashing, welding if any etc, gratings,

Page -603
 inner closure fillers, fixtures, all machineries, scaffolding. The above work is to be carried out by a
specialized agency as per approved by the Engineer-in-Charge.

KEY ROOF PERFORMANCES:

The thermal U value of the roof built-up shall be 0.39 W/mK.

Acoustic requirement: Sound Transmission class (STC) = 40 ± 3.

For designing wind load calculation shall be as per IS 875 and pull out strength of fasteners for the roofing
system to be to Engineer in charge.

Sound transmission class (STC) report shall be submitted from reputed Government accredited labs.
Contractor shall submit System warranty 15 years and Installation warranty 10 year required.

1.1 Supply and Installation Procedure:

Aluminum elements to be supplied in single length with no laps with a sheet element cover width
of 400mm and a standing seam height of 65mm. Sheets are to be laid to meet the requirements of
the building geometry. The aluminum roof elements will be supported by and joined longitudinally
with an electrically operated closure machine over concealed extruded aluminum clips integrated
into the longitudinal element flange thereby allowing for the possibility of transmitting reaction
forces resulting from positive and/or negative loads and also accommodating unobstructed
thermal movements resulting from the specified ambient temperature range. The aluminum clips
shall be capable of transmitting all reaction forces to the purlin without the aid of any other
material, thus resulting in an overall "Self-supporting standing seam roof system. The aluminum
clips shall be capable of transmitting all reaction forces to the purlin through the aluminum saddle,
thus resulting in an overall “Self-supporting standing seam roof system". The aluminum roofing
system must certify by British Board of Agreement and awarded the certificate of compliance with
the Building Regulations. The aluminum clip shall be manufactured from extruded Aluminum Alloy.
Each aluminum clip shall come with a 5mm height black polyamide thermal barrier pad. This
material shall have a minimum tensile strength of 83 Mpa and maximum tensile elongation of 10%
in room temperature.

The roofing system shall be certified by the British Board of Agreement certificate to ensure water
tightness and shall be manufactured by a company accredited with ISO 9001:2000.

1.2 Thermal & Acoustic Performance:- The KALZIP/ KINGSPAN RIGIDAL 65/400 aluminum roofing
system will be designed, and installed to withstand the expansion and contraction forces resulting
from an atmospheric temperature range 5 to 45 degrees Celsius. The complete roofing system will
meet the required thermal performance of maximum 0.039 W/m2K (Bridged)

The acoustic performance shall meet the following criteria and shall be tested by independent
testing facilities to the required standards or equivalent standards.

Page -604
 Airborne Sound Transmission loss of the KALZIP/KINGSPAN RIGIDAL 65/400 system shall be tested
to ASTM E90-97 or equivalent approved standards and shall achieve Sound Transmission Class
(STC) of at least 40 ± 3 Db

1.4 Details at Flashing

a. Flashing: Flashing and capping to the roof will be manufactured from the same quality grade
and finish of material as the roofing elements.

b. Fasteners: Fasteners such as screws and other fastening devices shall be suitable for the
conditions of each application and shall be of austenitic stainless steel to prevent galvanic
action with the components fastened. Where fasteners are not manufactured in stainless steel,
then fasteners of metal compatible with adjoining materials and having a permanent corrosion
resistance finish will be used.

1.5 Accessories

Capping, closure pieces, flashings, trims sills, gutters, fillers, spacers, tapes, sealant, fixing etc.
where not specified shall be types recommended by the manufacturer.

Purpose Mask Cold Formed Metal Accessories:

The material shall be aluminium alloy to match roof sheet.

The thickness/gauge shall be minimum of 0.8mm.

The cladding shall be fixed as per the Manufacturer's recommendations.

1.6. Flashing/Trims

Joints in flashings and trims shall be installed to fully accommodate thermal movement. Flashing
joints generally shall comply with the Cladding Manufacturer's recommendations and
recommendations contained within the Profiled Sheet Metal Roof and Cladding.

1.8. Sealing Laps

The Sheet Manufacturer shall recommend sealant type(s) for the purpose. The position of sealing
laps shall be in straight unbroken lines immediately below fixing positions and parallel to the edges
of sheets. They shall be placed into corrugation and not allowed to stretch or sag in position.

Ensure continuity and effectiveness of seal especially at corners of sheets without over
compressing.

Page -605
1.9 Aluminum gutter:

Providing and fixing of 2 mm thick insulated Aluminum gutter with double side vulcanized rubber
Expansion joints at every 12m length. The gutter built-up consists of High density Rockwool
insulation of 120 kg/m density 50mm thickness, VCL, liner. Necessary down take spout with
diameter upto 150 mm at required intervals & other accessories like Cover plate, end caps, and
welding at joints. The Girth of gutter would be upto 1200mm. Dye Penetration test to be
conducted wherever aluminum welding has been done, complete with all respect. Gutters shall be
fully supported at each joint and at intermediate positions not more that 900mm apart or as per
detailed design & drawing. Spigot ends shall be fixed up the slope with all joints fully watertight.
The gutter shall be manufacture from 2mm thick aluminum solid panel of girth upto 1200mm and
made of grade AA 1100 Alloy in mill finish

The complete system shall be planned, designed and installed to cater proper roof drainage.

1.10 Testing: Manufacturer Test certificate shall be provided for each item with each lot. One test per
lot of top and bottom sheet of roofing shall be carried independently through the approved lab by
AAI. Nothing extra shall be paid on this account.

1.11 Guarantee:

Contractor should ensure the performance guarantee of the system for a period of 10
years by submitting a Guarantee Bond (BG) for 5(Five)% value of total roofing work, for a
period of 05 years and Corporate Guarantee for further 05 (Five) Years.

Page -606
Aluminium Composite Panel Cladding

Designing, fabricating, testing, installing and fixing in position Curtain Wall with Aluminium
Composite Panel Cladding, with open grooves for linear as well as curvilinear portions of the
building, for all heights and all levels etc. including:

a. Structural analysis & design and preparation of shop drawings for pressure equalisation or rain
screen principle as required, proper drainage of water to make it watertight including checking
of all the structural and functional design.

b. Providing, fabricating and supplying and fixing panels of aluminium composite panel cladding
in pan shape in metalic colour of approved shades made out of 4mm thick aluminum
composite panel comprising of Aluminum Skin of Minimum 0.5mm(Alloy Grade AA5005)
coated with KYNAR 500/Hylar 5000 PVDF based fluorocarbon /FEVE Lumiflon paint based
fluro-polymer resin/Exterior Grade Lead free Coating on Top Face Compliance to AAMA 2605
of approved finish +3mm thick non-combustible mineral based polymer core compliance to
Class A2,s1,d0 As per En13501-1 and 2hrs Fire Resistance as per ASTM E119 and NBC
Guidelines 2016 +0.5mm aluminum skin with service coat on Bottom face # 2 using stainless
steel screws, nuts, bolts, washers, cleats, weather silicone sealant, backer rods etc. Overall
weight of the ACP shall not be less than 8.1 kg per sqm.

c. The fastening brackets of Aluminium alloy 6005 T5 / MS with Hot Dip Galvanised with
serrations and serrated washers to arrest the wind load movement, fasteners, SS 316 Pins and
anchor bolts of approved make in SS 316, Nylon separators to prevent bi-metallic contacts all
complete required to perform as per specification and drawing The item includes cost of all
material & labour component, the cost of all mock ups at site, cost of all samples of the
individual components for testing in an approved laboratory, field tests on the assembled
working curtain wall with aluminium composite panel cladding, cleaning and protection of the
curtain wall with aluminium composite panel cladding till the handing over of the building for
occupation.

The Contractor shall provide curtain wall with aluminium composite panel cladding, having all the
performance characteristics all complete , as per the Architectural drawings, as per item
description, as specified, as per the approved shop drawings and as directed by the Engineer-in-
Charge.

MATERIAL

FR-CLASS A2-s1,d0 ALUMINIUM COMPOSITE PANEL

Aluminium composite panel shall be of approved makes and made out of 4mm thick aluminium
composite panel comprising of Aluminium Skin of Minimum 0.5mm (Alloy Grade AA5005) with
PVDF coating on Top Face Compliance to AAMA 2605 of approved finish +3mm thick non-
combustible mineral based polymer core compliance to Class A2,s1,d0 As per En13501-1 and 2hrs
Page -607
Fire Resistance as per ASTM E119 and NBC Guidelines 2016 +0.5mm aluminium skin with service
coat on Bottom face. Overall weight of the ACP shall not be less than 8.1 kg per sqm. Rate shall
include wastage & landing cost on site.

DELIVERY, STORAGE & HANDLING

Ordering: Comply with manufacturer’s ordering instructions and lead time requirements to avoid
construction delays.
Delivery: Deliver materials in manufacturer’s original, unopened, undamaged containers with
identification labels intact.
1. Protection: Protect finish of panels by applying heavy duty removable plastic film during
production.
2. Delivery: Package composite wall panels for protection against transportation damage.
Provide markings to identify components consistently with drawings.
3. Handling: Exercise care in unloading, storing and installing panels to prevent bending,
warping, twisting and surface damage.
4. Storage and Protection: Store materials protected from exposure to harmful weather
conditions and at temperature conditions recommended by manufacturer.
5. Storage: Store panels in well-ventilated space out of direct sunlight.
a. Protect panels from moisture and condensation with tarpaulins or other suitable
weather tight covering installed to provide ventilation.
b. Slope panels to ensure positive drainage of any accumulated water.
c. Do not store panels in any enclosed space where ambient temperature can exceed 49
degrees C.
6. Damage: Avoid contact with any other materials that might cause staining, denting or other
surface damage.

Provision for recessed lighting to be provided.

TESTING AND MOCK UP
Costs of Testing
The contractor shall pay for all costs associated with the performance testing including costs
associated with the supply, fabrication, assembly, erection, maintenance, modification,
dismantling and the removal of the Testing Prototypes from the test site. Include all fees and
charges payable to the Testing Laboratory.

One test for each lot of material (ACP) received at site shall be tested from the lab as approved by
AAI.

Page -608
In the event that test failure necessitate retests, the contractor shall pay the additional laboratory
fees and any other fees and expenses, including the cost of witnessing by the Employer, Employer
Representatives and all other fee, expense and time incurred by the Employer, Employer
Representative as a result of retesting. This applies to all re-testing. All necessary corrections
shall take place in the presence of the Employer’s Representative.

Work shall be carried out by the specialized agency as approved by AAI.

Guarantee:

Contractor should ensure the performance guarantee of the system for a period of 10 years by
submitting a Guarantee Bond (BG) for 5(Five)% value of total ACP work, for a period of 05 years
and Corporate Guarantee for further 05 (Five) Years.

Page -609
GLAZED DOORS

Supplying and installation of 12 mm thick frameless toughened clear glass door consisting
hardware as per AAI Approved make and 12mm thick toughened clear glass of any required size of
as per AAI Approved. Glass to be toughened by special chemical to strengthened by double
impact, all edge to be machine polished and sides also to be toughened. The work also includes
cutting of floor (15mm strip of size 15mm X 15mm) for floor spring of as per AAI Approved heavy
floor spring as per AAI Approved make to hold the glass at bottom. The work includes cost of all
cut outs/holes wherever required including fixing of hardware consisting of all required patch
fittings for doors with side and upper panels, upper and bottom patches, floor lock with cylinder
and strike plate and SS-316 grade pull handle of size 450mmX22mm complete as per direction of
Engineer-In-Charge.

1.1 MATERIAL
Double door with fan light and side panels consists of the following:
a) Glass door (With 2 leaf’s) over/side panel fitting, with pivot and satin SS covers.
b) Glass door (With 2 leaf’s) over and side panel connector, with satin SS covers.
c) Top patch (2 no’s) fitting with pivot bearing location, with satin SS covers.
d) Bottom patch (2 no’s) fitting with pivot bearing for floor spring, with satin SS covers.
e) Floors lock (2 no’s) –with strike plate and Euro Profile cylinder.
f) Floor Spring (2 no’s)
g) Back to Back SS-316 Pull Handle (4 no’s) 450mm x 22mm diameter.

1.2 FRAMELESS GLASS DOORS.

Frameless glass door shall consist of two 15mm diameter SS short pivot poles and corner lock with
euro profile cylinder. The rugged internal components of lock meet all the requirements of DIN
18251, class 3, satisfying the type test criteria of 2,00,000 latch and 50,000 dead bolt operating
cycles.

The fittings will be mounted on 12 mm thick clear toughened glass door with all necessary
required accessories. The door will also consist of floor spring with all necessary glass mounting
accessories for the self closing feature. Complete as per manufacturer specification. The door shall
also consist of Pull Handle 450mm x 22mm diameter.

Page -610
FRAMELESS GLASS AUTOMATIC BI-PARTING SLIDING DOOR SYSTEM

Providing and fixing frameless glass Automatic bi-parting sliding door system of as per AAI
Approved make Automatic biparting sliding door operator with 10 mm thick toughened clear glass
shutters with DC/AC motors, UPS, control panel, trolleys, main profile, cover profile, PWM radar,
rotative selector, photocell, moving door leaf and 10mm thick clear tempered glass, SS patch
fittings, stainless steel handles & locking arrangement etc. Modular design, including internal
aluminum cover the track profile should be separate from main profile for better sound insulation
and vibration with automatic Operator, Microprocessor control panel, self-learning, reversing
when obstruction is encountered, Microprocessor-controlled control unit. It should be Self
learning, with adjustable parameters for opening and closing speed, hold-open time and opening
and closing force. With operator dimensions shall be (H X T X L) - 100 x 180 X 6250 / 4150mm.
Class of protection IP 20. The system shall have constant power supply 230V, 50/60Hz, for various
opening sizes all complete as per design and instructions of Engineer- in-Charge.

1) The doors should be provided with electro-magnetic locks. Automatic control should be
done by two infrared detectors, with a range of operating control options and safety
devices.

2) The panels will consist of 10mm toughened clear glass. (Clear span for Auto Sliding door
(2.00m wide x2.40m high)

1.1 GENERAL :-
The specially designed Automatic Sliding Glazed Door with panic breakout conforming to Indian or
International Standards shall be supplied and fixed. Following minimum standard features shall be
provided:

A pair of bi-parting doors between side screens all fully glazed with fine aluminum frame and
toughened glass for all-glass appearance; both door leaves and side screen panels can be swung
outwards to double the opening width for means of escape.

The doors should be provided with electro-magnetic locks. Automatic control should be done by
two infrared detectors, with a range of operating, control options and safety devices. The system
will also have an emergency stop button.

The system will be integrated in MSH steel girder with external and internal covers. The panels will
consist of thin powder-coated frames with 10mm toughened safety glass.

Aluminum clad steel columns will be used for achieving clear opening height. The system will be
also equipped with Floor guide system, emergency break-out fittings, two pairs of light-barriers
and release devise for sliding panels and side screens. All aluminum profiles will be in E6/C0.

Page -611
Quality Assurance:
Manufacturer must be able to demonstrate compliance with ISO 9000 : 2000 certification and also
fulfils future European standards and regulations, TUV type tested, compliance with EU low-
voltage directives.

1.2 CLEAR TOUGHENED GLASS: -

10mm thick clear float glass conforming to BS 952 Part – I of the thickness specified in the item
shall be used for processing toughened glass. Toughening, which shall be carried out horizontally
(without tong-marks), shall conform to ASTM 1048.

All works such as cutting, grinding, drilling etc. on glass shall be carried out prior to toughening.
Once toughing is done, no cutting, grinding work will be allowed on the glass.

1.3 DOOR OPERATOR:-

Minimum requirements for DOOR OPERATOR shall be as given below:
1 Motor - 1 Nos. / Dc motor
2 Drive - Direct Drive. Without any reduction gear.
3 Microprocessor - 16 bit – Intelligent door
4 Automatic Lock - Bi-stable Electromechanical for Safety and security.
5 Safety stop / Reverse
6 Automatic compensation of friction
7 Fail safe Battery of 1x 24V DC, 700mA
8 Magnetic Encoder
9 Adjustment of all basic parameters via integrated display push button.
10 Self adjusting runs for doors
11 Anodized Aluminium Header frame.
12 Anodized Aluminium hinged operator cover
13 2 trolleys per sliding leaf / 3 large dia wheels per trolley.
14 Insulated and modular Track Rail
15 Night bank control.
16 UVV (Accident Prevention) and VDE (Electrical engineering)
17 System Integration with BMS.
18 Sleek 150/100mm x 180mm CS dimension of header frame.
19 5 years warranty on motors and 1 year on accessories.
20 Microprocessor – controlled functional programmes.
PC based control through cable or modem.
1.4 PERFORMANCE :
1 Opening speed (Incremental setting) - 10 - 70 Cm/s
2 Closing speed (Incremental setting) - 10 – 50 Cm/s
3 Maximum Opening and Closing force - 150 N.
4 Hold open time - 0–180 Seconds
5 Independent Adjustment of Speed and Force – yes
Page -612
1.5 ELECTRICAL FEATURES:
1. Standard power supply - 230V, 50-60 Hz
2. No. and type of motors - 1Xdc motor
3. Direct Drive Transmission - Without reduction Gear.
4. Power consumption during operation - 250W
5. Fuse protection - 4Amp
6. Ambient temperature during operation - 10 to + 65 deg. Celsius.
7. Rechargeable fail safe batteries - 1 x 24 V DC, 700mA.

1.6 SAFETY :
1 Safety Stop / Reverse - Yes – Adjustable
2 Infrared barriers - 1 or 2
3 Glass - 10mm toughened
4 Frame for Glass leaf - 20mm

1.7 REPLACEMENT OF GLASS:-

In case of glass breakage during installation & testing, the glass will have to be replaced by
deglazing the glass at site & the re-glazing of the new glass will have to be done at site without any
extra cost up to defect liability period.

1.8 FINAL CLEANING:-

Protective coating and warning markings shall remain undisturbed until final acceptance.
Immediately prior to final inspection, temporary protective covering or coating shall be removed
and surfaces shall be washed with a suitable thinner and left in a finished condition having
approved uniform appearance and free from all marks and blemishes. Both faces of the glass shall
be washed and polished.

Page -613
MODULAR TOILET CUBICLES SYSTEM

Providing & fixing modular toilet cubicles (model, type ZMS series of as per AAI Approved make,
consisting of high pressure 12mm thick compact laminate board as per IS 2046 and as per fire
retardent BS-476/96 standard with phenolic core panels for partitions of intermediate divider,
doors and pilasters (The cubicle shall have dimensions of 1250mm x 1800mm,1995mm (including
bottom gap 150 mm, but the panel area required for one cabin shall be one longer and the one
shorter side of the cabin including one door) with a door size of 650mm width, the assembly shall
be supported by black satin finish aluminium head rail on top of panels and panels shall fixed on
the floor with a clearance of maximum 150mm using aluminium alloy satin finish adjustable legs
screwed to the floor included accessories with standard - Besco make aluminium, nylon polyamide
accessories, gravity hinges, Aluminium top rail, Privacy thumb turn i/c occupancy indicator, coat
hook, door knob, Adjustable pedestal, Aluminium "U" channel, aluminum door stopper channel,
rubber door stopper lining, screws & wall plug etc complete as per manufacturers specification
and as directed by Engineer in charge.

1.1 MATERIALS
All accessories shall be made of polyamide grade 6 (nylon) and all hardware/fitting shall be made
of anodized Aluminium or Powder-coated aluminum. The door, pilasters & intermediate partitions
shall be 12mm thick High Pressure Laminates (HPL) Compact Board with chamfered edges.

Grade HPL compact board are manufactured from sheet of special Kraft & décor paper,
impregnated with thermosetting synthetic resins which are together under heat & high pressure
(110Kg/cm2 at temperature of about 150°C). HPL compact board has laminates on both sides with
suede finishes melamine. The performance of the board is tested according to Indian standard IS-
2046 (Boiling Water, Fire Rate, Impact, Stain, and Scratch). Compact laminate should be
Greenguard and IGBC certified.

Doors
All doors shall be of single colour, 12mm thick HPL compact board with chamfered edge. Each will
be supported by 3 Nylon Hinges affixed to the pilaster, completed with Nylon Coat Hook and
Nylon Door Knob.

Pilasters
All pilasters shall be of same colour as doors, 12mm thick HPL compact board with Aluminium
Door Stopper profile (incorporated with Rubber Lining to dampen noise) affixed on one vertical
side and completed with Nylon Thumb turn for locking doors. Colours different from doors shall
be made available upon request. The pilaster shall be anchored to the floor using Nylon Adjustable
Leg (base Ø72mm) with threaded rod inserts for stability. The floor clearance is 150mm.

1.2 ACCESSORIES
Page -614
Each Restroom cubicle will be equipped with the following accessories (Colours available in black,
grey or white) Standard – Besco Make Aluminium, Nylon Polyamide 6 accessories).

Top Rail
Heavy-duty Aluminium Top Rail Channel, 77mm x 35mm x 1mm (cross-section dimension, W x H x
Thk), shall be section fixed onto the top of the pilaster for maximum strength, stability and
alignment of the system.

Besco Make Nylon Door Knob of Ø50mm.

Besco Make Nylon Thumbturn with occupancy indicator.
Besco Make Nylon Coat Hook with/without rubber stopper and allow load up to 20kg/15kg
respectively.
Besco Make Nylon Hinges with 3 choices of standard, gravity-to-open or gravity-to-close.
Besco Make Nylon Adjustable Leg with a working range from 145mm to 170mm.

INSTALLATION PROCEDURE:
 Mark out to distribute the cubicle evenly. Mark on wall to mount U channel.
 Drill holes on the U channel. Mark out the drill holes and insert wall plug.
 Insert the U channel by tightening with screws.
 Mount divider furthest from wall and secure both divider and U channel by tightening the
screw.
 Use floor jack to support divider while installing pilaster.
 Prepare the pilaster by installing F-channel and leg on it.
 Mount pilaster to divider and screw to tighten both pilaster and divider.
 Install hinges on pilaster. Prepare the door by installing hinges and hooks and next install
the door knob.
 Continue installing the 2nd divider. Prepare the second pilaster by installing the U-channel.
 Next install the privacy thumb turn follow by the leg. Install the rest of the toilet cubicles.
 The last pilaster are secured to the U-channel attached to the wall.
 Top rail are mounted after all the cubicles are mounted.
 Screw to tighten both top rail and pilaster together and close gap at the end of top rail with
cladding.
 Turn the base of the legs to adjust the height of the cubicle to get a straight horizontal
level. Then drill holes on the floors to insert wall plug and screw to tighten leg on to the
floor.

Page -615
URINAL MODESTY PANELS

Providing & fixing Urinal Modesty Panels made of 12 mm thick compact laminated board as per
AAI Approved make of approved texture/shade having standard dimension of 1200 mm Height x
450 -500 mm Width and made as per IS 2046 (Indian Standard) and as per fire retardant BS-
476/97 standard and should be heat, bacteria, water, chemical, scratch and impact resistant .
The product should have Green Guard Certificate. Including all accessories as per approval and
direction of Engineer-in-Charge .Modesty panels will be fixed to the wall at an height of 500-
600mm from the floor with 304 garde SS right angle bracket, 304 grade SS Screws with satin
finish & Wall Plugs .

The work includes all accessories, machineries, tools etc., complete as per direction of Engineer-
in-charge.

Specification:

Thickness of Compact Laminate : 12 mm

Accessories: Standard – AAI Approved make - 304 Grade accessories) or Equivalent

a) Right Angle Brackets

b) S.S.Screws 304 G & P.V.C Wall Plugs

Page -616
Roller Blinds

Designing, providing and fixing Roller Blinds fabric made up of 30-39% Fiberglass/Polyester & 61-
70% Vinyl with Aluminium Backing / PVC with Aluminium Backing, having specific emissivity
treatment and lead free with Greenguard Guard Gold certification. Fabric should cut UV rays with
97% approximately and should have Fungistatic Treatment: Degree 0, Excellent (EN ISO 846-A) OR
(Antimicrobial properties as per ASTM E 2180, ASTAM, G21, AATCC30 Part 3, ASTM D 3273,
GREENGUARD Mold and Bacteria Standard ASTM 6329: includes Microban antimicrobial additives).

It should have 3% openness (minimum), fabric thickness should be 0.32 - 0.55mm, fabric weight
should be 290 g/m2 - 478 g/m2, Tensile Strength (Warp/Weft): 160/170 daN / 5cm, the fabric
should be Fire retardant as per B1/DIN 4102-1, BS 7837, BS 5867, SCHWERBRENNBAR-Q1-
TR1/ONORM A 3800-1, M1/UNE 23.727-90, VKF 5.2/SN 198898, 1530.3/AS/NZS, G1/GOST 30244-
94, CLASSE 1/UNI 9177-87, CAN ULCS109, METHOD 1 AND 2/NFPA 701, CSFM T19, CLASS A/ASTM
E84 Euroclass: B-s2,d0/EN 13501-1 OR California U.S Title 19 (Small Scale), NFPA701 TM#1 (Small
Scale), NFPA 101 (Class A rating), IBC Section 803.1.1 (Class A Rating), BS 5867 Part 2 Type B
Performance, NFPA 701 TM#2 (Large Scale), CAN/ULC-S 109 (Large and small scale), CAN/CGSB2-
4.162-M80 with 10 years of warranty against any distortion in fabric due to any reason. Roller blind
tube should be made of Aluminum with a diameter of 38 mm, bottom rod should be powder
coated and should come with the end cap to support the fabric, aluminum brackets and a ball chain
or any other sturdy fixing arrangement as per the manufacturer specification all complete..

Roller Tube

Roller Tube shall be of extruded Aluminium alloy 38mm O.D (or as per system dimension) with a
minimum wall thickness of 1.0mm duly anodised.

Clutch

Clutch shall be wrap spring design with high strength fibreglass reinforced polyster assembly and
high carbon steel springs to transmit motion from driving to driven members of clutch mechanism.
Clutch shall operate by directionally with the use of an endless beaded chain. Clutch mechanism
shall be crash proof, prevent slippage and shall raise and lower smoothly to any desired
height.Clutch shall never need adjustment.

Idler

Idler shall be of high strength fibreglass reinforced polyster,consisting of an outside sleeve and
centre shaft. Sleeve shall provide bearing surface for roller tube and rotate freely on centre shaft,
providing smooth, quiet and long wearing operation.

Page -617
Installation Brackets

Brackets shall be of tomised steel powder coated to give superior finish. Bracket shall
accommodate overhead, side or face mounting with clutch assembly on either end of the roller.

Bottom weight

Bottom of the blind shall be provided with aluminium tube powder coated in a colour matching to
the fabric. The fabric shall be enclosed in the suitably created pocket along with the tube. The tube
shall be closed from sides with end caps to give a neat look.

Page -618
GLASS PARTITIONS

Providing and Fixing of Slim Glass internal partition using 12 mm Toughened Glass and
Aluminium profiles of AAI Approved make to a height of maximum 3m. The Fixed glass to be
fixed using AAI Approved make Profiles or equivelent at Top & Bottom & fixed frame cleat. The
profile size shall be 45x25MM to be fixed on to the floor/ ceiling as per the requirements and
the H Junction profile to be used at all Glass to Glass vertical joints and 90 degree L /T Junction
profiles at required necessary areas as per design.

The profile shall be made of 2 mm Gauge thick matt natural anodized Aluminium and having
Minimum anodic coating 20 micron .

GENERAL

DESIGN CRITERIA

The above system shall meet the following design parameters, and will also comply with BS /
Indian Standard Specifications and Codes of Practice.

VISUAL APPEARANCE

Aesthetically the design of the Glazing system should give uniform appearance.

DESIGN LOADINGS

a) The glazing system design shall be capable of accommodating dead load and wind loads
and other movements without reducing its performance or causing permanent damage.
b) The glazing's own dead loads and the loads occurring due to wind forces acting on them
shall be transferred to the structure / ground at its anchorage points.
c) The glazing system shall be designed to withstand a minimum wind pressure in
accordance with IS: 875 in that zone.
d) The vertical movements occurring due to thermal expansion / contraction and structural roof
members deflection shall be accommodated as per the design of the building.

TEMPERATURE DIFFERENCE

The system design shall accommodate a standard temperature range of +100C to +700C

EARTHQUAKE FORCE

The system design shall be capable of incorporating seismic joints, to deal with
earthquakes in that zone.

Page -619
DEFLECTION

The Glazing system shall allow a standard deflection of L/175 and shall also
accommodate variable deflection limits.

MODULE / SIZE OF PANEL

The glazing system shall be as per detailed drawings and details

THERMAL AND ACOUSTIC PROPERTIES

The Glazing system shall achieve and meet the standard thermal and acoustic performance for
glazing in accordance with the industry norms and building regulations.

FIRE AND SMOKE STOPS

The systems design to have provision for incorporating fire and smoke stops.

AIR / WATER PENETRATION RESISTANCE

The Glazing system shall be designed to withstand test pressures as specified in BS and Indian
Standards or ASTM (E283-91 and E330-93)

STATIC / STRUCTURAL PERFORMANCE

The Glazing system shall be capable of withstanding a positive and negative pressure (100%) for
10 seconds and (1.5 x design load) for a further 10 seconds if tested in a test lab.

MATERIAL

CLEAR AND TINTED FLOAT GLASS

Float glass used for glazing shall be of approved quality conforming to BS 952 Part-I for clear
and tinted and BS 6206 for toughened glass and of the thickness specified in the item. The
tolerance in thickness shall be + 0.3 mm for 4 to 6mm and + 0.6mm for 8 to 12mm thick glass.

TOUGHENED GLASS

Toughened glass is 4 to 5 times stronger than its equivalent thickness of normal annealed float
of sheet glass. It offers great resistance to sudden temperature changes and sudden impacts.

Float glass on international quality conforming to BS 952 Part – I for clear and tinted glass and of
the thickness specified in the item shall be used for manufacturing toughened glass. Toughening,
which shall be carried out horizontally (without tong-marks), shall conform to ASTM 1048.

Page -620
All works such as cutting, grounding, drilling etc. On glass shall be carried out prior to
toughening. Once tempering is done, no work will be allowed on the glass.

MATERIAL HANDLING & STORAGE

Glass shall be securely and safely cRated for delivery, handling and storage. Cushions shall be
provided at edges of glass to prevent damage. Glass faces shall be protected from scratches
and abrasions. It shall be stored in a dry, well-ventilated location, carefully protected at all
times from soiling, atmospheric.

GLAZING WORK
The glass panes shall be of the type and thickness specified in the item. Their sizes shall be as
shown in the drawings. The glass panes shall be of approved quality and make. They shall
have properly squared corners and straight edges. Damaged or defective glass shall be
replaced with new glass at no additional cost. Each piece of glass shall be delivered with
factory labels intact, indicating glass type, quality and thickness. Labels shall not be removed
until installation has been accepted.

Glass is to be protected from breakage immediately upon installation by applying suitable

warning markings.

Sealants of high quality, silicone, as specified by the manufacturers shall be used.

REPLACEMENT OF GLASS
In case of glass breakage after installation, the glass will have to be replaced by deglazing the
glass at site & the re-glazing of the new glass will have to be done at site without any extra cost.

STRUCTURAL SEALENT
Structural sealant should have minimum tearing strength 6.0N/mm, sore A hardness 44
(ISO:868), tensile strength (ISO :8339-A) 1.06 N/Sqmm and one part. Joint movement
capability + 25% (As per ASTM C-920), one part natural cure equivalent to SG 18 of Sikka
(Wacker), 995 of Dow Corning or equivalent.

WEATHER SEALENT
The Silicon weather proofing sealant is designed for sealing expansion and control joints, pre-
cast concrete panel joint, non-structural curtain wall mullion joints, stress cracks and joints in
parapet wall. The sealant forms durable, flexible, water tight bonds with most building
materials in any combination, in particular, ceramics, stone, masonry, wood, steel, anodized.

Page -621
Weather sealant should have minimum tearing strength 4.0N/mm, sore hardness 20 (ISO 868),
joint movement capability +15% (s per ASTM C-920), one part natural core equivalent to Sika
Elastosil 305, DOW corning 791P or equivalent.

FINAL CLEANING

Protective coating and warning markings shall remain undisturbed until final acceptance.
Immediately prior to final inspection, temporary protective covering or coating shall be
removed and surfaces shall be washed with a suitable thinner and left in a finished
condition having approved uniform appearance and free from all marks and blemishes. Both
faces of the glass shall be washed and polished.

Page -622
 Structural Steel Painting:

Supplying and applying water based Fire intumescent paint fire tested in accordance with BS
476 Parts 20-22 as approved make @ DFT dependent on HP/a ratio of structural steel with
zinc phosphate primer to give additional anti-corrosive protection having VS of 73% - 83% as
approved applied over abrasive blasted surface and surface preparation up to a standard of
Sa2.5 (ISO 8501-1:1988) or SSPC-SP6 at 75 micron and LEED V4 Compliant for VOC Content
and VOC Emissions polyurethane finish paint as approved having volume solid of 72% - 73%
@ 50 micron of the required shade over Structural Steel Works at all levels including storage,
surface preparation by sand blasting, degreasing, cleaning, drying, providing temporary
staging, scaffolding, testing etc., all complete with all respect as desired and as per
manufacturer specification and direction of Engineer in charge. The above products should
confirm to Green Building norms. Application to be carried out by authorized manufacturer
applicator or any other trained applicator as approved by the manufacturer and direction of
Engineer in charge.

i. For Two hrs fire rating

ii. 1.1 GENERAL

Fireproof Intumescent Coating
st
1 Coat (Primer) Providing & applying Two Component Zinc Phosphate Epoxy Primer
polyamide cured with minimum Volume Solids of 70%.
The minimum recoat interval shall not be more than 2 hrs at 23 Deg C.
The primer shall have a DFT range of 60 – 250 microns achievable in
one coat.DFT - 75 microns.
2nd Coat Providing and applying One component waterborne acrylic thin film
(Waterborne intumescent coating with approximate Volume Solids 69% confirming to
Firproof BS 476 Part 20-21, EN 13381 Part 8.
Intumescent
Coating)
Finishing Coat Providing and applying component chemically curing aliphatic acrylic
(to be applied in polyurethane coating.
a single coat) The coating shall have a VOC not more than 250 gms/ltr.
The coating shall have a minimum Volume Solids of 73% and a DFT
range of 60 – 100 microns achievable in one coat
The coating shall contribute to satisfying the following credit(s):
- Indoor Environmental Quality (IEQ) under LEED® 2009
- Environmental Quality (EQ) and Materials and Resources (MR) under
LEED® v4 DFT – 50 microns

DFT Measurement should be in accordance with SSPC SPA 2. The entire paint system shall
be of same manufacturer.
Page -623
1.2 Surface Preparation & Comments

Abrasive blast cleans to Sa 2.5 (ISO 8501-1:1988) or SSPC-SP6. If oxidation has occurred
between blasting and application, the surface should be re-blasted to the specified visual
standard. Surface defects revealed by the blast cleaning process, should be ground, filled, or
treated in the appropriate manner.

All surfaces to be coated should be clean, dry and free from contamination. Prior to paint
application all surfaces should be assessed and treated in accordance with ISO 8504:1992.
Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning.

1.3 Painting of Structural Steel Work:-

All Paints delivered at site shall be ready mixed in original sealed containers, as packed
by the paint manufacturer.
The structural steel element shall not be painted when its surface temperature is below
4ºC and above 50ºC or when the relative humidity is above 75% and ambient
temperature is 10ºC and below.
For Spray Application:
The spraying equipment shall be compatible with the paint material and provided with
necessary gauges and controls. The equipment shall be cleaned of dirt, dried paint,
foreign matter and solvent before use.

1.4 Summary of Paint Specification:

Anticorrosive Protection for C5 category as per ISO 12944 classifications.

FUNCTION VOC CHEMISTRY TYPE DFT (Dry Film

Compliance Thickness in
microns)
PRIMER <254gm/litre Zinc Phosphate 75 minimum
Fireproof <24gm/litre Waterborne Fire As per the Hp/ A
Intumescent intumescent paint table for the product
Coatings fire tested in
accordance with BS
476 Parts 20-22
FINISH <243gm/litre LEED V4 Compliant 50
for VOC Content and
VOC Emissions
polyurethane

Page -624
1.5 Product Characteristics:

Description Zinc Waterborne Fireproof Polyurethane Paint

Phosphate Intumescent Coating
Primer
Volume 73% (Min) 69% (Min) 72% - 73%
Solids
VOC Less than 254 Less than 24 gm/litre Less than
gm/litre 320gm/litre

Colour Grey White As per RAL

Standard / or as
approved by E-I-C
Typical DFT 75µ (in single As per DFT Loading 50µ
Thickness coat) Tables

Theoretical 9.73 m²/litre 14.6 m²/litre @

Coverage @ 75 µ DFT 50µ DFT
(minimum)

Page -625
Stainless Steel Dustbins

Providing and placing stainless steel Swing Bin ( Dustbins) of Sizes 14"x 28" made of 2mm thick
304 grade Stainless steel sheet all as per manufacturers specification etc complete and as per the
direction of the Engineer-In-Charge.

Modular matting:

Providing and laying 3 M or Euronics or approved equivelent make Modular matting (whipping
& scrapping -moisture & dirt recessed ) for areas like main entry/ exit or wherever required as
per the technical specification and direction of Engineers in charge.

Introduction to Modular Matting System:

The new modular matting system combines high performance with flexible design options and
easy on site installation. This matting system is made up of two tile versions, each incorporating a
2mm drainage foot on the bottom surface. The large open scraper profiles incorporate ‘heel steps’
to prevent heel trapping. Traffic rated at 5000 crossings per day.

The new modular matting system combines high performance with flexible design options and
easy on site installation.
The new modular matting system is made up of 2 tile versions. Each tile is 300x300mm square and
17mm deep incorporating a 2mm drainage foot on the bottom surface. The large open scraper
profiles incorporate ‘heel steps’ to prevent heel trapping.
The Nomad 8900 Aqua Tile combines the scraper elements with large central textile infill of
Nomad Aqua 8500 dual fibre matting. This tile will scrape, remove and hold moisture.

MATERIAL

Material shall be of approved quality and confirming to specification as specified in Description of

item and CPWD Specification 2009 Vol 1&2 with upto date correction slip and relevant IS code.

INSTALLATION TECHNIQUE

Installation shall be done as specified in Description of item and as per manufacturer specification
and direction of Engineer in charge.

Page -626
 TECHNICAL SPECIFICATIONS FOR PAVEMENT WORKS :

1. GRANULAR SUB-BASE (GSB)

Preparation of granular sub-base by providing close graded material (Grade-II),

conforming to specifications mixing in a mechanical mix plant at OMC, carriage of mixed
material by mechanical transport to work site, for all leads and lifts, spreading in uniform
layers of specified thickness with mechanical means including neatly leveling & dressing
on prepared surface and compacting with vibratory power roller to achieve the desired
density, complete and as per direction of Engineer-in-charge.

1.0 Scope
This work shall consist of laying and compacting well-graded material on prepared
sub-grade in accordance with the requirements of these Specifications. The
material shall be laid in one or more layers as sub-base or lower sub-base and
upper sub-base (termed as sub-base hereinafter) as necessary according to lines,
grades and cross-sections shown on the drawings or as directed by the Engineer-in
charge.

The thickness of a single compacted GSB layer shall not be less than 75 mm.
When vibrating or other approved types of compacting equipment are used, the
compacted depth of a single layer of the sub-base course may be increased to 200
mm upon approval of the Engineer-in-charge.

2.0 Materials

2.1 The material to be used for the work shall be natural sand, crushed gravel, crushed
stone, crushed slag, or combination thereof depending upon the grading required.
Use of materials like brick metal, kankar and crushed concrete shall be permitted in
the lower sub-base. The material shall be free from organic or other deleterious
constituents and shall conform to the grading given in Table 1 and physical
requirement given in Table 2. Gradings III and IV shall preferably be used in lower
sub-base. Gradings V and VI shall be used as a sub-base cum drainage layer. The
grading to be adopted for a work shall be as specified in the contract.

If the water absorption of the aggregate determined as per IS: 2386 (Part 3) is
greater than 2 percent, the aggregate shall be tested for Wet Aggregate Impact
Value (AIV)(IS:5640). Soft aggregate like Kankar, brick ballast and laterite shall also
be tested for Wet AIV (IS: 5640).
Page -627
 Table -1. Grading for granular sub-base material

IS Sieve Percent by Weight Passing the IS Sieve

Designation
Grading Grading Grading Grading Grading Grading
I II III IV V VI

75.0 mm 100 - - - 100 -

53.0 mm 80-100 100 100 100 80-100 100

26.5 mm 55-90 70-100 55-75 50-80 55-90 75-100

9.50 mm 35-65 50-80 - - 35-65 55-75

4.75 mm 25-55 40-65 10-30 15-35 25-50 30-55

2.36 mm 20-40 30-50 - - 10-20 10-25

0.85 mm - - - - 2-10 -

0.425 mm 10-15 10 -15 - - 0-5 0-8

0.075mm <5 <5 <5 <5 - 0-3

Table 2: Physical Requirement for Materials for Granular Sub-base.

Aggregate Impact IS:2386(Part 4) or 40 Maximum

Value(AIV)
IS:5640

Liquid Limit IS:2720(Part 5) Maximum 25

Plasticity Index IS:2720(Part 5) Maximum 6

CBR at 98% dry density IS:2720(Part 5) Minimum 30 specified

unless otherwise
(IS:272-(Part 8)
specified in the Contract

Page -628
2.2 Strength of sub-base

It shall be ensured prior to actual execution that the material to be used in the sub-
base satisfies the requirements of CBR and other physical requirements when
compacted and finished.

When directed by the Engineer-in-charge, this shall be verified by performing CBR

tests in the laboratory as required on specimens re-moulded at field dry density
and moisture content and any other tests for the “quality” of materials as may be
necessary.

3 Construction Operations

3.1 Spreading and compacting

The sub base material of grading specified in the Contract and water shall be mixed
mechanically by a suitable mixture equipped with provision for controlled addition
of water and mechanical mixing so as to ensure homogeneous and uniform mix.
The required water content shall be determined in accordance with IS: 2720(Part-
8). The mix shall be spread on the prepared sub grade with mechanical means of
adequate capacity its blade having hydraulic controls suitable for initial adjustment
and for maintaining the required slope and grade during the operation or other
means as approved by the Engineer-in-charge.

The moisture content of mix shall be checked in accordance with IS:2720 (Part-2)
and suitably adjusted so that at the time of compaction it is from 1-2% below the
optimum moisture content.

Manual mixing shall be permitted only where the width of laying is not adequate
for mechanical operations, as in small-sized jobs. The equipment used for mix-in
place construction shall be a rotavator or similar approved equipment capable of
mixing the material to the desired degree. If so desired by the Engineer-in-charge,
trial runs with the equipment shall be carried out to establish its suitability for the
work.

Immediately after spreading the mix, rolling shall be done by an approved roller. If
the thickness of the compacted layer does not exceed 100mm, a smooth wheeled
roller of 80 to 100 KN weight may be used. For a compacted single layer up to
200mm, the compaction shall be done with the help of a vibratory roller of
minimum 80 to 100 KN static weight capable of achieving the required compaction.
Page -629
 Rolling shall commence at the lower edge and proceed towards the upper edge
longitudinally for portions having unidirectional crossfall or on super elevation. For
pavement having crossfall on both sides rolling shall commence at the edges and
progress towards crown.

Each pass of the roller shall uniformly overlap not less than one third of the track
made in the preceding pass. During rolling, the grade and crossfall (camber) shall
be checked and any high spots or depressions, which become apparent, corrected
by removing or adding fresh material. The speed of the roller shall not exceed 5 Km
per hour.

Rolling shall be continued till the density achieved is at least 98% of the maximum
dry density for the material determined as per IS: 2720 (Part 8). The surface of any
layer of material on completion of compaction shall be well closed, free from
movement under compaction equipment and from compaction planes, ridges,
cracks or loose material. All loose, segregated or otherwise defective areas shall be
made good to the full thickness of layer and re-compacted.

4 Surface Finish and Quality Control of Work

4.1 General

All works performed shall conform to the lines, grades, cross-sections and
dimensions shown on the drawings or as directed by the Engineer-in-Charge,
subject to the permitted tolerances described herein-after.

4.2 Horizontal Alignment:

Horizontal alignment shall be reckoned with respect to the centre line of the
carriageway as shown on the drawings. The edges of the carriageway as
constructed shall be correct within a tolerance of ±10 mm therefrom. The
corresponding tolerance for edges of the pavement and lower layers of pavement
shall be ±25 mm.

4.3 Surface levels:

The top level of the granular sub-base shall not vary from those calculated with
reference to the longitudinal & cross profile of the pavement shown in the
Drawings or as directed by Engineer-in-Charge, beyond the tolerances mentioned
as follow:

Page -630
 S. No. Sub-base Tolerances

1 Flexible pavement ±10 mm

2 Concrete pavement ±6 mm

4.4 Surface Regularity:

The maximum allowable difference between pavement surface and underside of

a 3 m straightedge when placed parallel with or at right angles to the centre line of
pavement at points decided by the Engineer –in-charge shall not exceed 8 mm.

4.5 Rectification:

Where the surface regularity fall outside the specified tolerances, the Contractor
shall be liable to rectify the same upto the satisfaction of Engineer-in-Charge.
Where the surface is high, it shall be trimmed and suitably compacted. Where the
same is low, the deficiency shall be corrected to scarifying the lower layer and
adding fresh material and recompacting to the required density.

4.6 Quality Control:

The following quality control tests shall be carried out at frequencies specified
against each for Granular Sub-base:-

Test Test Method Frequency (min.)

S.No.

1 Gradation IS: 2720 (Part –VI) One test per 200 m3

2 Atterberg limits IS: 2720 (Part-V) One test per 200 m3

3 Moisture Content prior IS: 2720 (Part-II) One test per 250 m2
to compaction

4 Density of compacted IS: 2720 (Part- One test per 500 m2

layer XXVIII)

5 Deleterious IS: 2720 (Part-XXVII) As required

constituents

Page -631
 6 C.B.R. (On set of 3 IS: 2720 (Part-XVI) As required
specimens)

7 Control of Grade, - Regularly

camber thickness and
surface finish

5 Arrangement of Traffic

No vehicular traffic of any kind shall be allowed on the finished granular sub-base
surface till it has dried and the next course laid. In exceptional cases, construction
traffic may be allowed with approval of the Engineer-in-Charge for short durations
once the course is completely dry provided vehicles move over the full width
avoiding any rutting or uneven compaction. The Contractor will take all
precautionary measures to prevent any damage to the finished surface till next
layer is laid over it.

Page -632
2. WET MIX MACADAM (WMM)

Providing, laying, spreading and compacting graded stone aggregate (size range 53 mm
to 0.075 mm) to wet mix macadam (WMM) specification including premixing the
material with water at OMC in mechanical mix plant, carriage of mixed material by
mechanical transport to site, for all leads & lifts, laying in uniform layers with mechanical
paver finisher in sub- base /base course on well prepared surface and compacting with
vibratory roller of 8 to 10 tonne capacity to achieve the desired density, complete as per
specifications and directions of Engineer-in-Charge.

1.1 Scope

This work shall consist of laying and compacting clean, crushed, graded aggregate
and granular material, premixed with water, to a dense mass on a prepared sub
grade/sub-base/base or existing pavement as the case may be in accordance with
the requirements of these Specifications. The material shall be laid in one or
more layers as necessary to lines, grades and cross-sections shown on the
approved drawings or as directed by the Engineer-in-charge.

The thickness of a single compacted Wet Mix Macadam layer shall not be less than
75 mm. When vibrating or other approved types of compacting equipment are
used, the compacted depth of a single layer of the sub-base course may be
increased to 200 mm upon approval of the Engineer-in-charge.

1.2 Materials

1.2.1 Aggregates

1.2.1.1 Physical requirements:

Coarse aggregate shall be crushed stone. The aggregates shall conform to the
physical requirements set forth in Table below:

PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WET MIX MACADAM FOR

SUB-BASE / BASE / BASE COURSE.

Test Test Method Requirements

* Los Angeles Abrasion IS : 2386 (Part 4) 40 per cent (Max.)

value

Page -633
 or * Aggregate Impact IS : 2386 (Part 4) or 30 per cent (Max.)
value IS:5640

Combined Flakiness and IS : 2386 (Part 1) 30 per cent (Max.) **

Elongation indices
(Total)

* Aggregate may satisfy requirements of either of the two tests.

** To determine this combined proportion, the flaky stone from a

representative sample should first be separated out. Flakiness index is
weight of flaky stone metal divided by weight of stone sample. Only the
elongated particles are to be separated out from the remaining (non-flaky)
stone metal. Elongation index is weight of elongated particles divided by
total non-flaky particles. The value of flakiness index and elongation index
so found are added up.

If the water absorption value of the coarse aggregate is greater than 2 per cent, the
soundness test shall be carried out on the material delivered to site as per I S : 2386
(Part 5).

1.2.1.2 Grading requirements

The aggregate shall conform to the grading given in table below:

Section 1.02 GRADING REQUIREMENTS OF AGGREGATES FOR WET MIX

MACADAM

IS Sieve designation Per cent by weight passing the IS sieve

53 mm 100
45 mm 95 – 100
26.5 mm -–
22.40 mm 60 – 80
11.20 mm 40 – 60
4.75 mm 25 – 40
2.36 mm 15 – 30
600 micron 8 -- 22
75 micron 0 -- 5

Page -634
 Materials finer than 425 micron shall have Plasticity Index (PI) not
exceeding 6.

The final gradation approved within these limits shall be well graded from coarse to
fine and shall not vary from the low limit on one sieve to the high limit on the
adjacent sieve or vice versa.

1.3 Construction operations

1.3.1 Preparation of Base

The surface of the sub grade/sub-base/base to receive the wet mix macadam
course shall be prepared to the specified lines and crossfall (camber) and made free
of dust and other extraneous material. Any ruts or soft yielding places shall be
corrected in an approved manner and rolled until firm surface is obtained if
necessary by sprinkling water.

1.3.2 Provision of lateral confinement of aggregates:

While constructing wet mix macadam, arrangement shall be made for the lateral
confinement of wet mix. This shall be done by laying materials in adjoining
shoulders along with that of wet mix macadam layer and following the sequence of
operations as follows:

The sequence of operations shall be such that the construction of paved shoulder is
done in layers each matching the thickness of adjoining pavement layer. Only after
a layer of pavement and corresponding layers in paved and earth shoulder portion
have been laid and compacted, the construction of next layer of pavement and
shoulder shall be taken up.

Where the materials in adjacent layers are different, these shall be laid together
and the pavement layer shall be compacted first. The corresponding layer in paved
shoulder portion shall be compacted thereafter, which shall be followed by
compaction of earth shoulder layer. The adjacent layers having same material shall
be laid and compacted together.

1.3.3 Preparation of mix:

Wet Mix Macadam shall be prepared in an approved mixing plant of suitable

capacity having provision for controlled addition of water and forced/positive
mixing arrangement like pug mill or pan type mixer of concrete batching plant. For
small quantity of wet mix work, the Engineer-in-charge may permit the mixing to be
done in concrete mixers.

Page -635
 Optimum moisture for mixing shall be determined in accordance with IS : 2720
(Part 8) after replacing the aggregate fraction retained on 22.4 mm sieve with
material of 4.75 mm to 22.4 mm size. While adding water, due allowance shall be
made for evaporation losses. However, at the time of compaction, water in the wet
mix shall not vary from the optimum value by more than agreed limits. The mixed
material should be uniformly wet and no segregation shall be permitted.

1.3.4 Spreading of mix:

Immediately after mixing, the aggregates shall be spread uniformly and evenly
upon the prepared sub grade/sub-base/base in required quantities. In no case
should these be dumped in heaps directly on the area where these are to be laid
nor shall their hauling over a partly completed stretch be permitted.

The mix shall be spread either by a paver finisher or motor grader. For portions
where mechanical means cannot be used, manual means as approved by the
Engineer-in-charge shall be used. The motor grader shall be capable of spreading
the material uniformly all over the surface. Its blade shall have hydraulic control
suitable for initial adjustments and maintaining the same so as to achieve the
specified slope and grade.

The paver finisher shall be self-propelled, having the following features:

(i) Loading hoppers and suitable distribution mechanism

(ii) The screed shall have tamping and vibrating arrangement for initial
compaction to the layer as it is spread without rutting or otherwise marring
the surface profile.
(iii) The paver shall be equipped with necessary control mechanism so as to
ensure that the finished surface is free from surface blemishes.

The surface of the aggregate shall be carefully checked with templates and all high
or low spots remedied by removing or adding aggregate as may be required. The
layer shall be tested by depth blocks during construction. No segregation of larger
and fine particles shall be allowed. The aggregates as spread shall be of uniform
gradation with no pockets of fine materials.

1.3.5 Compaction:

After the mix has been laid to the required thickness, grade and crossfall/camber,
the same shall be uniformly compacted, to the full depth with suitable roller. If the
thickness of single compacted layer does not exceed 100 mm, a smooth wheel
roller of 80 to 100 kN weight shall be used. For a compacted single layer up to 200
Page -636
mm, the compaction shall be done with the help of vibratory roller of minimum
static weight of 80 to 100 KN or equivalent capacity roller. The speed of the roller
shall not exceed 5 km/h.

In portions having unidirectional cross fall / super elevation, rolling shall commence
from the lower edge and progress gradually towards the upper edge. Thereafter,
roller shall progress parallel to the centre line of the road, uniformly over-lapping
each preceding track by at least one-third width until the entire surface has been
rolled. Alternate trips of the roller shall be terminated in stops at least 1 m away
from any preceding stop.

In portions in camber, rolling shall begin at the edge with the roller running forward
and backward until the edges have been firmly compacted. The roller shall then
progress gradually towards the centre parallel to the centre line of the road
uniformly overlapping each of the preceding track by at least one-third width until
the entire surface has been rolled.

Any displacement occurring as a result of reversing of the direction of a roller or

from any other cause shall be corrected at once as specified and / or removed and
made good.

Along forms, kerbs, walls or other places not accessible to the roller, the mixture
shall be thoroughly compacted with mechanical tampers or a plate compactor.
Skin patching of an area without scarifying the surface to permit proper bonding of
the added material shall not be permitted.

Rolling shall not be done when the sub grade is soft or yielding or when it causes a
wave-like motion in the sub-base/base course or sub grade. If irregularities
develop during rolling which exceed 12 mm when tested with a 3m straight edge,
the surface shall be loosened and premixed material added or removed as required
before rolling again so as to achieve a uniform surface conforming to the desired
grade and crossfall. In no case the use of unmixed material shall be permitted to
make up the depressions.

Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material as determined by the method outlined in IS :
2720 (Part – 8).

Page -637
 After completion, the surface of any finished layer shall be well closed, free from
movement under compaction equipment or any compaction planes, ridges, cracks
and loose material. All loose, segregated or otherwise defective area shall be made
good to the full thickness of the layer and re-compacted.

1.3.6 Setting and drying:

After final compaction of wet mix macadam course, the pavement shall be allowed
to dry for 24 hours.

1.4 Opening to Traffic

No vehicular traffic of any kind shall be allowed on the finished wet mix macadam
surface till it has dried and the wearing course laid.

1.5 Surface Finish and Quality Control of Work

1.5.1 Surface Regularity: The maximum allowable difference between pavement surface
and underside of a 3m straightedge when placed parallel with or at right angles to
the centre line of pavement at points decided by the Engineer-in-Charge shall not
be more exceed 8 mm.

1. 5.2 Surface level: The tolerance in surface level for wet mix macadam shall not vary
±10 mm for machine laid and ±15 mm for manually laid with reference to the
longitudinal and cross-profile of the pavement shown on the drawing or as directed
by Engineer-in-Charge.

1.5.3 Quality Control:

The following quality control tests shall be carried out at frequencies specified
against each for Wet Mix Macadam.

S.No. TEST Test Method Frequency

i) Los Angeles Abrasion IS:2386 (Part IV) One test per 200
Value/ Aggregate Impact cum. of aggregate.
Value
ii) Grading of mixed IS:2386 (Part I) One test per 100
aggregate cum. of aggregate.
iii) Flakiness Index IS:2386 (Part I) One test per 200
cum. of aggregate.
iv) Plasticity Index IS:2720 (Part V) One test per 200
cum. of aggregate.

Page -638
 v) Moisture content prior to One test per 200
compaction cum. of aggregate.
vi) Density of compacted IS:2720(Part-28) One test per 500
layer sqm.

1.5.4 The materials supplied and the works carried out by the Contractor shall conform
to the relevant technical specifications and as approved by the Engineer-in-Charge.

For ensuring the requisite quality of construction, the materials and works shall be
subjected to quality control tests, as described above. The testing frequencies set
forth are the desirable minimum and the Engineer-in-Charge shall have the full
authority to carry out tests as frequently as he may deem necessary to satisfy
himself that the materials and works comply with the appropriate specifications.

Test procedures for the various quality control tests are indicated in the respective
Section of these Specifications or for certain tests within this Section. Where no
specific testing procedure is mentioned, the tests shall be carried out as per the
prevalent accepted engineering practice to the directions of the Engineer-in-
Charge.

1.6 Rectification of Surface Irregularity

Where the surface irregularity of the wet mix macadam course exceeds the
permissible tolerances or where the course is otherwise defective due to sub grade
soil getting mixed with the aggregates, the full thickness of the layer shall be
scarified over the affected area, reshaped with added premixed material or
removed and replaced with fresh premixed material as applicable and recompacted
in accordance with Clause 1.3 above. The area treated in the aforesaid manner
shall not be less than 5 m long and 2 m wide. In no case, the depressions shall be
filled up with unmixed and ungraded material or fines.

Page -639
3. DRY LEAN CEMENT CONCRETE

Providing and laying dry lean cement concrete with coarse and fine aggregate
conforming to IS:383, the size of coarse aggregate not exceeding 26.5 mm,
aggregate cement ratio not exceed 15:1, aggregate gradation after blending to be
as per specification, cement content not to be less than 150 kg/cum, optimum
moisture content to be determined during trial length construction, concrete
strength not to be less than 10 MPa at 7 days, mixed in a batching plant as per
mix design, transported to site, laid with a paver with electronic sensor,
compacting with 8-10 tonne vibratory roller, finishing and curing etc. complete as
per specification and direction of the Engineer-in-Charge.

1. Scope

1.1 The work shall consist of construction of (zero slump) dry lean concrete sub-base
for cement concrete pavement in accordance with the requirements of these
specifications and shall conform. to the lines, grades and cross-sections shown on
the drawings or as directed by the Engineer-in-Charge. The work shall include
furnishing of all plant and equipment, materials and labour and performing all
operations, in connection with work, as approved by the Engineer-in-Charge.

1.2 The design parameters of dry lean concrete sub-base, i.e. width, thickness, grade of
concrete, details of joints, if any, etc. shall be as stipulated in the drawings or as
directed by Engineer-in-Charge.

2. Materials

2.1 Source of Materials: The contractor shall indicate to the Engineer-in-Charge the
source of all materials with relevant test data to be used in the dry lean concrete
work sufficiently in advance and the approval of the Engineer-in-Charge for the
same shall be obtained before start of the work. If the contractor later proposes to
obtain the materials from a different source during execution of work, he shall
notify the Engineer-in-Charge for his approval before such materials are to be used.

2.2 Cement: Any of the following types of cement may be used with the prior approval
of Engineer-in-Charge.
S. No. Type Conforming to
i) Ordinary Portland Cement IS: 8112

ii) Portland Slag Cement IS: 455

iii) Portland Pozzolana Cement IS: 1489-Part- I
Page -640
 If the sub-grade is found to consist of soluble sulphates in a concentration more
than 0.5 percent, the cement used shall be sulphate resistant and shall conform to
IS: 6909.

2.2.1 Supply of Cement shall be obtained either in bulk form or as per clause 3.1.2.5 of
CPWD specifications Vol-I, 2009. Cement shall be subjected to acceptance tests
prior to its use. Nothing extra shall be paid on this account.

2.3 Aggregates

2.3.1 Aggregates for lean concrete shall be natural material complying with IS: 383. The
aggregates shall not be alkali reactive. The limits of deleterious materials shall not
exceed the requirements set out in table 1 of IS: 383. In case the aggregates are not
free from dirt, the same may be washed and drained for at least 72 hours before
batching, as directed by the Engineer-in-Charge.

2.3.2 Coarse aggregate: Coarse aggregates shall consist of clean, hard, strong, dense,
non-porous and durable pieces of crushed stone or crushed gravel and shall be
devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or
splinters pieces. The maximum size of coarse aggregate shall not exceed 26.5mm
for lean concrete. No aggregate which has water absorption more than 2 percent
shall be used in the concrete mix. The aggregate shall be tested for soundness in
accordance with 15:2386 (Part-5). After 5 cycles of testing, the loss shall not be
more than 12 percent if sodium sulphate solution is used or 18 percent if
magnesium sulphate solution is used. The Loss Angeles Abrasion value shall not
exceed 35. The combined flakiness and elongation index of aggregate shall not be
more than 35 percent.

2.3.3 Fine aggregate: The fine aggregates shall consist of clean natural sand or crushed
stone sand or a combination of the two and shall conform to 15:383. Fine
aggregate shall be free from soft particles, clay, shale, loam, cemented particles,
mica and organic and other foreign matter. The fine aggregates shall have a sand
equivalent value of not less than 50 when tested in accordance with the
requirement of 15:2720 (Part 37).

2.3.4 The material after blending shall conform to the grading as indicated in Table 1.

Table 1: Aggregate gradation for Dry Lean Concrete

Sieve Designation Percentage passing the

sieve by weight
26.50 mm 100

Page -641
 19.00 mm 75-95
9.50 mm 50-70
4.75 mm 30-55
2.36 mm 17-42
600 micron 8-22
300 micron 7-17
150 micron 2-12
75 micron 0-10

2.4 Water: Water used for mixing and curing of concrete shall be clean and free from
injurious amounts of oil, salt, acid, vegetable matter or other substances harmful to
the finished concrete. It shall meet the requirements stipulated in IS: 456.

2.5 Storage of materials

2.5.1 Cement:

The Contractor shall provide adequate storage facilities to prevent deterioration of

cement during storage due to climate and other causes. Wherever bulk storage
containers are used, their capacity should be sufficient to cater to the requirement
at site. The containers shall be cleaned at least once every 3 months. Cement
remaining in stores for more than one and half month from the date of
manufacture must be retested before use and to be rejected, if it fails to conform
to any of the requirements of the specifications.

2.5.2 Aggregates:

a) Stock piles shall be made immediately on receipt of aggregates at site of

work. Aggregates shall be stacked separately according to the nominal sizes
of coarse aggregates. For fine aggregates, separate stacks shall be made.
b) Aggregates shall be stacked on a hard surface so as to exclude the possibility
of soil or grass being mixed up. When stacked in close proximity, the stock
piles shall be separated by bulk heads to prevent the different sizes of
aggregates from mixing together. Special care shall be taken to clean and
wash the last layer of aggregates in contact with ground surface before use.
c) Before batching, the aggregates shall have been stock piled for at least 24
hours to allow for draining of water, if any. The Contractor shall make
adequate provision for stock piling aggregates to the extent sufficient to
meet the needs of the work taking into account the availability of supplies
and rates of delivery etc. and nothing extra shall be paid for necessary
double handling and transport of materials from stock piles to mixing plant
etc.
Page -642
3. Proportioning of Materials for the Mix

3.1 The mix shall be proportioned with a maximum aggregate cement ratio of 15:1. The
water content shall be adjusted to the optimum as per clause 3.2 for facilitating
compaction by rolling. The strength and density requirement of concrete shall be
determined in accordance with clause 6 and 7 by making trial mixes.

3.2 Moisture Content: The right amount of water for the lean concrete in the main
work shall be decided so as to ensure full compaction under rolling and shall be
assessed at the time of rolling the trial area. Too much water will cause the lean
concrete to be heaving up before the wheels and to be picked up on the wheels of
the roller and too little will lead to inadequate compaction, a low in-situ strength
and an open-textured surface.

The optimum water content shall be determined and demonstrated by rolling

during trial area construction and the optimum moisture content and degree of
compaction shall be got approved from the Engineer-in-Charge. While laying the
main work, the lean concrete shall have a moisture content between the optimum
and optimum + 2 per cent, keeping in view the effectiveness of compaction
achieved and to compensate for evaporation losses.

3.3 Cement Content: The cement content in dry lean concrete shall be such that the
strength specified in clause 3.4 is achieved. For the purpose of tendering, the
cement content may be assumed as 150 Kg per cum of finished DRLC.
If the actual quantity of cement required as per laboratory mix design varies from
the quantity assumed above, necessary cost adjustment for deviation in the
quantity of cement as per mix design, if any, shall be made. The cost adjustment
for the extra/short use of cement to be used as a result of laboratory test shall be
inclusive of contractor profit & over heads @ 15% and plus labour cess @ 1%. The
rate of cement applicable shall be the Base price of cement as issued by DG (W) or
concerned Zonal Chief Engineer, CPWD or as decided by ED (Engg) if above rates
not declared by CPWD as on the last stipulated date of receipt of tender i/c
extension if any or the purchase price whichever is lower. However, under no
circumstances the cement content shall fall below 150 Kg per cum.

3.4 Concrete Strength: The average compressive strength of each consecutive group of
5 cubes made shall not be less than 10 MPa at 7 days. In addition, the minimum
compressive strength of any individual cube shall not be less than 7.5 MPa at 7
days. The design mix complying with the above clauses shall be got approved from
the Engineer-in-Charge and demonstrated in the trial length construction.

Page -643
4. Construction

4.1 General

The pace and programme of the dry lean concrete sub-base construction shall be
matching suitably with the programme of construction of the cement concrete
pavement over it. The dry lean concrete sub-base shall be overlaid with concrete
pavement only after 7 days after sub-base construction.

4.2 Batching and Mixing

4.2.1 ‘A' system approach should be adopted for construction of pavement, and the
method statement for carrying out the work, detailing all the activities including
indication of time cycle, equipment, personnel etc. shall be got approved from the
Engineer-in- Charge before the commencement of work. The above shall include
the type, capacity and make of batching and mixing plant beside the hauling
arrangement and paving equipment. The capacity of paving equipment, batching
plant as well as all the ancillary equipment shall be adequate for a paving
requirement for day's work.

4.2.2 Batching and mixing of the concrete shall be done at a central batching and mixing
plant of capacity not less than 30 Cum/hr with automatic controls, located at
suitable place which takes into account sufficient space for stock piling of cement,
aggregate and stationary water tanks. This shall be however, situated at an
approved distance, duly considering the properties of the mix and transport
arrangements available with the contractor.

4.2.3 Proportioning of a material shall be done in the batching plant by weight, each type
of material being weighed separately. The cement from the bulk stock may be
weighed separately from the aggregates and water shall be measured by volume.
Wherever properly graded aggregate of uniform quality cannot be maintained as
envisaged in the mix design the grading of aggregates shall be controlled by
appropriate blending techniques. The capacity of batching and mixing plant shall be
at-least 25 higher than the proposed capacity for the laying/ paving equipment.

4.2.4 The batching plant shall include preferably four bins, weighing hoppers, and scales
for the fine aggregate and for each size of coarse aggregate. If cement is used in
bulk (after opening bags on platform) a separate scale for cement shall, be
included. The weighing hoppers shall be properly sealed and vented to preclude
dust during operation. Approved safety devices shall be provided and maintained
for the protection of all personnel engaged in plant operation, inspection and
testing. The batch plant shall be equipped with a suitable non-resettable batch
counter which will correctly indicate the number of batches proportioned.
Page -644
4.2.5 Bins preferably with four adequate separate compartments shall be provided in the
batching plant.

4.2.6 Batching plant shall be equipped to proportion aggregates and bulk cement by
means of automatic weighing devices using load cells. The weighing device shall
have an accuracy within + 1 in respect of quantity of cement and water and + 2 in
respect of aggregates and accuracy shall be checked at least once a month.

4.2.7 Mixers shall be pan type, reversible type with single or twin shaft or any other
mixer capable of combing the aggregates, cement and water into a thoroughly
mixed and uniform mass within the specified mixing period and of discharging the
mix without segregation. Each stationary mixer shall be equipped with an approved
timing device which will automatically lock the discharge lever when the drum has
been charged and release it at the end of the mixing period. The device shall be
equipped with a bell or other suitable warning device adjusted to give a clearly
audible signal each time the lock is released. In case of failure of the timing device
the mixer may be used for the balance of the day while it is being repaired provided
that each batch is mixed for 90 seconds or as per the manufacturer's
recommendation. The mixer shall be equipped with a suitable non-resettable batch
counter which shall correctly indicate the number of batches mixed.

4.2.8 The mixer shall be cleaned at suitable intervals. The pickup and throw over blades
in the drum or drums shall be repaired or replaced when they are worn down
20mm or more. The contractor shall have available at the job site a copy of the
manufacturers design, showing dimensions and arrangements of blades in
reference to original height and depth or provide permanent marks on blade to
show points of 20mm wear from new conditions. Drilled holes of 5 mm diameter
near each end and at mid point of each blade are recommended. Batching plant
shall be calibrated for the each ingredients upto its maximum quantity being used
in the mix at site in the beginning and thereafter at suitable interval not exceeding
one month.

4.2.9 Air-conditioned centralized computer control cabin shall be provided for automatic
operation of the equipment.
4.2.10
The design feature of the batching plant should be such that it can be shifted
quickly.

4.3 Transporting

Plant mix lean concrete shall be discharged immediately from the mixer,
transported directly to the point where it is to be laid and protected from the
weather by covering with ·tarpaulin during transit. The concrete shall be
Page -645
 transported by tipping trucks, sufficient in number to ensure a continuous supply
of material -to feed the laying equipment to work at a uniform speed and in an
uninterrupted manner. The lead of the batching plant to the paving site shall be
such that the travel time available from mixing to paving as specified in Para 4.S.2
will be adhered to. Tipping truck shall not have old concrete sticking to it. Each
tipping truck shall be washed with water jet before next loading as and when
required after inspection.

4.4 Placing

Lean concrete shall be laid by a paver with electronic sensor on the sub base layer
or as specified. The equipment shall be capable of laying the material in one layer
in an even manner without segregation, so that after compaction the total
thickness is as specified. The paving machine shall have high amplitude tamping
bars to give good initial compaction to the sub-base. One day before placing of the
dry lean cement concrete sub-base the surface of the granular sub-base/drainage
layer shall be given a fine spray of water and rolled with a smooth wheeled roller.

The Dry Lean Concrete shall be laid in such a way that it is at least 750mm wider on
each side than the proposed width including paved shoulders of the concrete
pavement. The extra widening beyond 750 mm width on either side shall be
decided based on the specification of the paver, such that the crawler moves on
the Dry Lean Concrete and the cost of extra width beyond 750 mm on either side,
if any, shall be borne by the Contractor. For small works, the laying of concrete
with paver may be dispensed with. Where laying of PQC is done by manual
method, the extra 750 mm width Dry Lean Concrete on either side for crawler
movement is not required.

4.5 Compaction

4.5.1 The compaction shall be carried out immediately after the material is laid and
leveled. In order to ensure thorough compaction, rolling shall be continued on the
full width till there is no further visible movement under the roller and the surface
is well closed. The minimum dry density obtained shall be 98 per cent of that
achieved during trial length construction in accordance with clause 6. The densities
achieved at the edges i.e. 0.5 m from the edge shall not be less than 96 per cent of
that achieved during trial construction.

4.5.2 The spreading, compacting and finishing of the lean' concrete shall be carried out as
rapidly as possible and the operation shall be so arranged as to ensure that the
time between mixing of the first batch of concrete in any transverse section of the
layer and the final finishing of the same shall not exceed 90 minutes when the
concrete temperature is between 25 and 30 degree Celsius and 120 minutes if less
Page -646
 than 25 degree Celsius. The period may be reviewed by Engineer-in-Charge in the
light of the results of the trial run but in no case shall it exceed 2 hours. Work shall
not proceed when the temperature of the concrete exceeds 30 degree Celsius. If
necessary, chilled water or addition of ice may be resorted to for bringing down the
temperature. It is desirable to stop concreting when the ambient temperature is
above 35 degree Celsius. After compaction has been completed, roller shall not
stand on the compacted surface for the duration of the curing period except during
commencement of next day's work near the location where work was terminated
the previous day.

4.5.3 Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 KN static

weight are suitable for rolling dry lean concrete. In case any other roller is
proposed, the same shall be got approved from Engineer-in-Charge, after
demonstrating its performance. The number of passes required to obtain maximum
compaction depends on the thickness of the dry lean concrete, the compatibility of
the mix, 'and the weight and type of the roller and the same as well as the total
requirement of rollers for the job shall be determined during trial run by measuring
the in-situ density and the scale of the work to be undertaken.

4.5.4 A preliminary pass without vibration to bed the Dry Lean Concrete down shall be
given followed by the required number of passes to achieve the desired density
and, a final pass without vibration to remove roller with vibration marks and to
smoothen the surface.

Special care and attention shall be exercised during compaction near joints, kerbs,
channels, side forms and around gullies and manholes. In case adequate
compaction is not achieved by the roller at these points, use of plate vibrator shall
be made, if so directed by the Engineer-in-Charge.

4.5.5 The final lean concrete surface on completion of compaction shall be well closed,
free from movement under roller and free from ridges, low spots cracks, loose
material, pot holes, ruts or other defects. The final surface shall be inspected
immediately on completion and all loose, segregated or defective areas shall be
corrected by using fresh lean concrete material laid and compacted. For repairing
honeycombed/hungry surface, concrete with aggregate of size 10 mm and below
shall be spread and compacted as per specification. It is necessary to check the
level of the rolled surface for compliance. Any level/thickness deficiency shall be
corrected after applying concrete with aggregate of size 10 mm and below after
roughening the surface. Strength test shall be carried out, and if deficiency in
strength is noticed, at least three (evenly spread) cores of minimum 100 mm dia.
per 5000 sqm shall be cut to check deficiency in strength. The holes resulting from
cores shall be restored by filling with concrete of the specified strength and
compacted by adequate rodding.
Page -647
4.5.6 Segregation of concrete in the tipping truck shall be controlled by moving the
dumper back and forth while discharging the mix into the same or by any
appropriate means. Paving operation shall be such that the mix does not segregate.

4.6 Joints

Construction and longitudinal joints shall be provided as per the drawings.

Transverse butt type joint shall be provided at the end of the construction in a day.
Longitudinal construction joint shall be provided only when full width paving is not
possible. Transverse joints in Dry Lean concrete shall be staggered from the
construction butt type joint in concrete pavement by 800-1000 mm.

Longitudinal joint in Dry Lean Concrete shall be staggered by 300-400 mm from the
longitudinal joint of concrete pavement.

At longitudinal or transverse construction joints, unless vertical forms are used, the
edge of compacted material shall be cut back to a vertical plane where the correct
thickness of the properly compacted material has been obtained.

4.7 Curing

After two to three hours i.e. when concrete has started setting /hardening, the
exposed surfaces shall be kept damp with moist gunny bags, sand or any other
material approved by the Engineer-in-Charge or by sprinkling water. 24 hours after
compaction, the exposed surface shall be kept continuously in damp or wet
condition by ponding or by covering with a layer of sacking, canvas, hessian or
similar materials and kept constantly wet for at least 7 days from the date of laying
where Ordinary Portland Cement is used and this period of curing shall be 10 days
from the date of laying when Portland Pozzolana Cement /Portland slag cement is
used.

5. Trial Mixes

The contractor shall make trial mixes of dry lean concrete with moisture contents
like 5.0, 5.5, 6.0, 6.5 and 7.0 per cent using specified cement content and the
specified aggregate grading but without violating the requirement of aggregate-
cement ratio specified in clause 3.1. Optimum moisture and density shall be
established by preparing cubes with varying moisture contents. Compaction of the
mix shall be done in three layers with vibratory hammer fitted with a square or
rectangular foot (as in appendix 'A-1'). After establishing the optimum moisture, a
set of six cubes shall be cast at that optimum moisture for the determination of
compressive strength on third and the seventh day. Trial mixes shall be repeated if
the strength is not satisfactory either by increasing cement content. After the mix
Page -648
 design is approved, the Contractor -shall construct a trial section in accordance with
clause 6.0.

If during the construction of trial area/patch, the optimum moisture content

determined as above is found to be unsatisfactory, the contractor may make
suitable changes in the moisture content to achieve the satisfactory mix. The cube
specimens prepared with the change mix content should satisfy the strength
requirement. Before production of the mix, natural moisture content of the
aggregate should be determined on a day-to- day basis so that the moisture
content could be adjusted. The mix finally designed should neither stick to the
rollers nor become too dry resulting in raveling of surface.

6. Trial Length

6.1 After finalizing the mix design, trial length/area as decided by the Engineer-in-
Charge shall be prepared.

6.2 After the construction of the trial length, the in-situ density of the freshly laid
material shall be determined by sand replacement method. Three density holes
shall be made at locations equally spaced along a diagonal that bisects the trial
length average of these densities shall be determined. These main density holes
shall not be made in the strip 500 mm from the edges. The average density
obtained from the three samples collected shall be the reference density and is
considered as 100 per cent. The field density of regular work will be compared with
this reference density in accordance with clauses 4.5.1 and A.2 of Appendix 'A-1'.

6.3 The hardened concrete shall be cut over 3m width and reversed to inspect the
bottom surface for any segregation taking place. The trial length shall be
constructed after making necessary changes in the gradation of the mix to
eliminate segregation of the mix. The lower surface shall not have honey combing
and the aggregates shall not be held loosely at the edges.

6.4 The main work shall not start until the trial length has been approved by the
Engineer- in-Charge. After approval has been given, the materials, mix proportions,
moisture content, mixing, laying, compaction plant and construction procedures
shall not be changed without the approval of the Engineer-in-Charge.

7. Tolerance for Surface Regularity, Level, Thickness, Density and Strength

7.1 Surface Regularity: The maximum allowable difference between pavement

surface and underside of a 3 m straightedge when placed parallel with or at right
angles to the centre line of pavement at points decided by the Engineer-in-Charge
Page -649
 shall not be more exceed 10 mm for dry lean concrete.

7.2 Surface level: The tolerance in surface level for dry lean concrete shall not vary ±6
mm with reference to the longitudinal and cross-profile of the pavement shown on
the drawing or as directed by Engineer-in-Charge.

7.3 Thickness, density and strength shall be as per Appendix 'A-1'.

7.4 Quality control test on the materials and the work and minimum frequencies shall
be as under:

S. Test Test Method Minimum desirable

No. frequency
1 Quality of Cement IS:269/488/1489 As required
2 Los angeles abrasion value / IS: 2386 (Part IV) One test per 200m3
Aggregate Impact value

3 Aggregate gradation IS: 2386 (Part I) One test per 100m3

4 Aggregate moisture content / IS: 2386 (Part III) As required

water absorption

5 Wet analysis of mix IS: 1119 As required

6 Control of grade, camber Regularly

thickness and surface finish

7 Cube strength of material IS: 516 One test per 1000 Sqm
mixed at site (3 samples) or part thereof

7.5 Rectification:

The defective length of the Dry Lean Concrete course shall be removed to full
depth and replaced with material conforming to the specification. Before relaying
the course, the disturbed subgrade or layer below shall be corrected by leveling,
watering and compacting.

8. Traffic

No heavy vehicles shall be permitted on the lean concrete sub-base after its
construction. Light vehicles if unavoidable may, however, be allowed after 7 days
of its construction with prior approval of the Engineer-in-Charge.

Page -650
 Appendix 'A-1'
Dry Lean Concrete

A. l Sampling and Testing of Cubes

Samples of dry lean concrete for making cubes shall be taken from the uncompacted
material from different locations immediately before compaction at the rate of 3 samples
for each 1000 Sqm or part thereof laid each day. The sampling of mix shall be done from
the paving site.

Test cubes of 150mm size shall be made immediately from each mix sample.

Cubes shall be made in accordance with the methods described in 15:516 except that the
cubes shall be compacted by means of a vibratory hammer with the moulds placed on a
level and rigid base. The vibrating hammer shall be electric or pneumatic type fitted with a
square or rectangular foot having an area of between 7500 to 14000 Sqm. The compaction
shall be uniformly applied for 60 + 5 seconds with a downward force of between 300 N and
400 N on to each of the three layers of the lean concrete material placed into the mould.
The surface of each compacted layer shall be scarified before the next layer is added to
give key for the next layer. The final layer shall be finished flush with the top of the cube
mould.

The dry lean concrete shall be cured in accordance with 15:516.

A.2 In-Situ Density

The dry density of the laid material shall be determined from three density holes at
locations equally spaced along a diagonal that bisects each 2000 sqm or part thereof laid
each day and shall comply with the requirements as per Clause 4.5.1. This rate of testing
may be increased at the discretion of the Engineer in case of doubt or to determine the
extent of defective area in the even of non-compliance. Density holes at random may be
made to check the density at edges.

A.3 Thickness

Section 1.03 The average thickness of the sub-base layer as computed by the level data
of sub-base and subgrade or lower sub-base shall be as per the thickness specified in the
contract drawings. The thickness at any single location shall not be 8mm less than the
specified thickness. Such areas shall be corrected as stated in Clause 4.5.5. Areas which
cannot be repaired should be replaced over full width. The extent of deficient area should
be decided based on cores.

Page -651
 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

Item: Providing and laying Pavement Quality Concrete (PQC) produced in a batching
and mixing plant having a Characteristic flexural strength i.e. flexural strength of 4.1
MPa at 28 days using Ordinary Portland cement of 43/53 grade or Portland Pozzolana
Cement or Portland Slag cement conforming as per relevant IS codes, to be mixed at
site, with 0.5% Super plasticizer by mass of cementitious material, fine aggregate,
graded stone aggregates of 40 mm nominal size in appropriate proportion as per
specification and job mix formula, laid in panels as per drawings/design as approved by
the Engineer-In-Charge using Slip Form Paver or Fixed form paver including anti friction
layer, joint filler board, making necessary provision for expansion, dummy and
construction joint including filling with Polysulphide sealant of approved make, curing
and making profile, complete as per direction of Engineer-in-Charge and specifications.
The item for execution shall include all operations making pavement for intended use
but not limited to following:

(i) Polyethylene sheet (White in color) of thickness 400 micron conforming to IS: 2508
with 6mm thick fine sand layer.
(ii) Providing and laying in position for expansion joint, 25mm thick pre-cut Synthetic
joint filler board of approved make conforming to IS:1838(part 3)-2011, 45 mm
from top (to be removed at the time of filling of Polysulphide sealant).
(iii) Mechanically cutting dummy joints 3mm wide x 1/3rd thickness of slab which is
subsequently widened to 10mm for the top 25mm depth and construction joints
10mm wide x 25mm deep as per specification.
(iv) Providing and laying in position Polysulphide sealant of approved make conforming
to BS-5212-1990 or IS: 11433-1995 in expansion/ construction / dummy joints
including rounding off edges, applying 2 coats of approved primer compatible with
the brand of Polysulphide and preparing the surface and applying masking tape
along the edge of joint to prevent accidental spillage of sealant on top surface and
to give neat finish to the sealant and removing the masking tape after application
of sealant etc. as per the details below:

(a) Expansion Joints of size 25 mm wide and 10 mm deep over 30mm dia expanded
closed-cell Polyethylene foam back-up/backer rod of minimum density 22
Kg/Cum, as per manufacturer’s specifications and sketch at Appendix-‘A’.
(b) Construction Joints of size 10 mm wide and 10 mm deep over 12mm dia
expanded closed-cell Polyethylene foam back-up/backer rod of minimum
density 22 Kg/Cum, as per manufacturer’s specifications and sketch at
Appendix-‘A’.
(c) Dummy Joints of size 10 mm wide and 10 mm deep over 12 mm dia expanded
closed-cell Polyethylene foam back-up/backer rod of minimum density 22
Kg/Cum, as per manufacturer’s specifications and sketch at Appendix-‘A’.
(v) Making profile as per DGCA CAR, panel drawing showing dummy, construction,
expansion joints location.
Note:
(i) Areas inaccessible to paving equipment shall be constructed by manual/hand guided
method. Areas in which manual/hand guided methods of construction become

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indispensable shall be got approved by the Engineer-in-Charge in writing in advance.

(ii) The quantity of cement, type of cement and super plasticizer for one Cum. of
finished concrete specified are for tendering purpose only. The contractor shall
quote his rates assuming quantity of OPC cement as 360 Kg/Cum or 400 Kg of
Portland Pozzolana Cement/ Portland Slag cement. In addition, if the actual quantity
of cement & super plasticizer required as per laboratory mix design varies from the
quantity assumed above, necessary cost adjustment for deviation in the quantity
of cement and super plasticizer as per mix design, if any, shall be done as per the
rate of cement and super plasticizer in actual supply voucher from
manufacturer/authorized dealer at the time of execution. In the case of authorized
distributor, the rate may be authenticated by the manufacturer. The rate of cement
and super plasticizer exclusive of GST shall only be considered for payment.

1.0 MATERIALS

1.1 CEMENT

a) Ordinary Portland Cement 43 Grade conforming to IS: 269-2015.

b) Ordinary Portland cement 53 grade conforming to IS: 269-2015.

Following extra precautions shall be taken:
(i) Proper mix design may be done to account for shrinkage/micro
cracking due to higher heat of hydration.
(ii) The temperature of aggregate, water and cement should be
maintained at the lowest practical levels, so that temperature of
concrete is below 300 C at the time of placement.
(iii) Aggressive curing of concrete to avoid cracking shall be done keeping
surface continuously wet by providing wet hessian cloth etc, before
continuous curing i.e. after 24 hours of laying.
(iv) Use of 53 grades OPC shall be avoided in case of hot weather
concreting.
c) Factory Produced Portland Pozzolana Cement (Flyash based) conforming to
IS: 1489 (Part-I)-2015.
d) Portland Slag Cement conforming to IS:455-2015.
e) Sulphate Resisting Portland cement conforming to IS: 12330 (If soluble salt
like sulphate in subgrade is more than 0.5%).

Note:

i) High alumina cement is not permitted to be used.

ii) Agency should submit copies of purchase voucher to the Engineer-in- Charge
and original to be produced for verification.

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1.1.1 Supply of Cement shall be obtained either in bulk form or as per clause
3.1.2.5 of CPWD specifications Vol-I, 2009. Tests on cement shall be done
as per clause 16.1 under quality control and nothing extra shall be paid on
this account.

1.1.2 SUPER PLASTICIZER

Super Plasticizer conforming to IS: 9103 may be used to improve the

workability of concrete.

1.2 WATER

Water for mixing and curing concrete will ordinarily be obtained from a source
which is used for drinking. Where water from such a source is not available,
the contractor shall ensure that it is clean and free from injurious quantities
of acid, alkalies, salts, alcohol, silt, oil, organic matter etc. and conforms
to IS: 456 (latest revision). In order to ensure that the water does not contain
impurities in injurious proportions, the contractor shall get the water tested in
one of the approved testing laboratories at his own expense. Nothing extra
shall be paid on this account. In such cases, the provisions laid down in clause
5.4 of IS: 456 (latest revision) shall be binding. Test on water should be
repeated whenever there is change in the source.

1.3 COARSE AGGREGATES

These shall be natural materials conforming to IS: 383(latest revision) but

with Los Angeles Abrasion value not more than 30 per cent. These shall
be crushed or broken from hard stones obtained from approved quarry.
These shall be clean, strong, durable of fairly cubical shape and free from
soft, f r i a b l e , thin e l o n g a t e d and l a m i n a t e d / disintegrated pieces.
These shall also be free from dirt, organic, deleterious and any other foreign
matter and adherent coatings and shall satisfy the physical requirement laid
down in clause 16.1 under quality control. Nothing extra shall be paid for
testing of material. Manufactured aggregate shall also be allowed subject to
meeting the requirement of IS 383.

1.3.1 Some aggregates may contain ferrous sulfides and iron oxides which can cause
stains on exposed concrete surfaces. In areas where staining has been a problem
or is suspected, the Engineer should verify that producers and aggregate suppliers
have taken steps to prevent the inclusion of any ferrous sulfides or iron oxides in
aggregate to be used in the project.

If there is a concern that these may exist, an indicator to identify staining

particles is to immerse the aggregate in a lime slurry. If staining particles are
present, a blue-green gelatinous precipitate will form within 5 to 10 minutes,

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rapidly changing to a brown color on exposure to air and light. The reaction
should be complete in 30 minutes. If no brown gelatinous precipitate forms,
there is little chance of reaction in concrete.

1.4 FINE AGGREGATE

The fine aggregate shall be coarse sand consisting of clean natural sand or crushed
stone sand or a combination of the two and shall conform to IS: 383 and clause
3.3.4 of IRC 15-2017 and shall satisfy the physical requirement laid down in
clause 16.1 under quality control. Nothing extra shall be paid for testing of
material. Fine aggregate shall be free from soft particles, clay, shale, loam,
cemented particles, mica, organic and other foreign matter. Manufactured fine
aggregate shall also be allowed subject to meeting the requirement of IS 383.

1.5 COMBINED GRADING OF AGGREGATES

The grading of all aggregates (coarse and fine aggregates) to be used on specific
job shall be determined in the material testing laboratory (approved by AAI/Govt.
Institutions i.e., IITs, NITs, Govt. Engg. Colleges) or in-house by Department
of Structure as directed by the Engineer-In-Charge. The coarse and fine
aggregates shall be mixed in suitable proportions so that the grading of
the mixed aggregates shall be in the range indicated in the table below:

I.S. Sieve Size %age passing by weight

45 mm 100
22.4 mm 55-60
11.2 mm 45-50
5.6 mm 35-40
2.8 mm 30-35
1.4 mm 20-25
710 micron 15-20
355 micron 8 -14
180 micron 0-5

If the combined aggregate grading calculated thereof does not meet the specified
grading requirements, appropriate adjustment shall be made in the proportions of
different aggregate fractions. Any deviation to the overall grading shall be
made only with the specific approval of Engineer-In-Charge and nothing
extra shall be paid for such adjustment. Design of mix shall be redone if there
is a change in the source of coarse or fine aggregates or type of cement as
per Para 1.1. Nothing extra shall be paid for such testing and designing.

1.6 ANTI-FRICTION LAYER

1.6.1 Anti-friction layer shall be provided between the concrete slab and the DRLC

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surface. Before placing the anti-friction layer, the sub-base shall be swept clean
of all the extraneous materials and a layer of 6mm fine sand shall be laid. On
sand layer, polyethylene sheet (white in colour) of thickness 400 micron
conforming to IS: 2508, with overlaps of not less than 300mm longitudinally
and 300mm transversely shall be laid. Any damaged sheeting shall be replaced
at the contractor’s expenses. The anti-friction layer shall be nailed to the lower
layer with concrete nails.

1.6.2 COMPOSITION

1.6.2.1 Natural Compound

1.6.2.1.1 The compound used for manufacturing natural film shall consist only of
polyethylene resins complying with 1.7.2.1.2. Any additives, such as anti-
oxidants, to impart additional qualities to the films, such as slip, may be
added in quantity to the resins, as agreed to between the supplier and the
purchaser.

1.6.2.1.2 The polymers for the natural film shall have a melt flow index between 0.10
to 15.0 g/10 min. The density for the compound from which the film is made
shall be between 0.913 to 0.923 g/ml at 27°C (0.915 to 0.925 g/ml at
23°C ).

1.6.3 Appearance - The film shall be uniform in colour, texture and finish. The
material shall be substantially free from pin-holes and undispersed raw
materials, streaks and particles of foreign matter. There shall be no other visible
defects, such as holes, tears or blisters. The edges shall be free from nicks and
cuts visible to unaided eye. The natural films shall be free from pin-holes.

1.6.4 Odour - The film shall be free from any objectionable odour.

1.6.5 Density - The density of the film, when determined in accordance with A-l of IS
2508 or Method 5 of IS: 8543 (Part l/Set 2)-1979 shall be as prescribed in
1.7.2.1.2. However, in case of dispute, the latter shall be the preferred method.

1.66 Melt Flow Index The melt flow index of the film when determined in
accordance with 7 of IS: 2530-19637 shall be as prescribed in 1.7.2.1.2.

1.6.7 Tensile Strength at Break - The tensile strength at break when tested as
prescribed in A-4 of IS 2508 for all thicknesses of polyethylene film shall be not
less than 11.77 MN/m2 ( 120 kgf/ cm2 ) in lengthwise direction and 8.33 MN/m2
( 25 kgf /cm2 ) in crosswise direction.

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2.0 HANDLING AND STORAGE OF MATERIALS

2.1 CEMENT

The Contractor shall provide adequate storage facilities to prevent deterioration

of cement during storage due to climate and other causes. Wherever bulk
storage containers are used, their capacity should be sufficient to cater to the
requirement at site. The containers shall be cleaned at least once every 3
months. Cement remaining in stores for more than one and half month from
the date of manufacture must be retested before use and to be rejected, if it
fails to conform to any of the requirements of the specifications.

2.2 AGGREGATES

a) Stock piles shall be made immediately on receipt of aggregates at

site of work. Aggregates shall be stacked separately according to the
nominal sizes of coarse aggregates. For fine aggregates, separate stacks
shall be made.

b) Aggregates shall be stacked on a hard surface so as to exclude the

possibility of soil or grass being mixed up. When stacked in close
proximity, the stock piles shall be separated by bulk heads to prevent the
different sizes of aggregates from mixing together. Special care shall be
taken to clean and wash the last layer of aggregates in contact
with ground surface before use.

c) Before batching, the aggregates shall have been stock piled for at
least 24 hours to allow for draining of water, if any. The Contractor shall
make adequate provision for stock piling aggregates to the extent
sufficient to meet the needs of the work taking into account the
availability of supplies and rates of delivery etc. and nothing extra
shall be paid for necessary double handling and transport of materials
from stock piles to mixing plant etc.

d) Grading of coarse and fine aggregate shall be checked as per clause 16.1
under quality control to ensure that the suppliers are maintaining
the uniform grading as approved for samples used in the mix design.

3.0 MIX DESIGN

3.1 The concrete mix shall be got designed by the Contractor in the material testing
laboratory (approved by AAI/Govt. institutions i.e., IITs, NITs, Govt. Engg.
Colleges) or in-house by Department of Structure as directed by the Engineer-In-
Charge so as to obtain the target average flexural strength. The margin
over characteristic strength is as below:

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Characteristic flexural strength (beam) at 28 days, (fcr) = 4.1 MPa

Normal variate for the desired confidence level, (Z) = 1.65
Assumed value of Standard Deviation, (s) = 0.4 MPa
Target average flexural strength at 28 days, f’cr = fcr + 1.65 x s
f’cr = 4.1 + 1.65 x 0.4
= 4.76 MPa
Say, 4.8 MPa
Water cementatious ratio by weight = 0.45 (Maximum)

Slump = 25 ± 15 mm for slip/fixed form paver

= 40 ± 10 mm for manual method

Any change in the source of materials or mix proportions including change of

brand of cement proposed by the Contractor during the course of work shall be
assessed by making laboratory trial mixes and same shall be incorporated in
work with written approval of concerned Engineer-In-Charge.

In case services of Department of Structure, AAI is utilized for mix design and
other testing if any, contractor shall be charged extra as per prevalent charges
and same shall be deducted from contractor bills. Contractor quoted rates shall
be deemed to be inclusive of same and nothing extra shall be payable.

3.2 The quantity of cement, type of cement and super plasticizer for one Cum. of
finished concrete specified in the item are for tendering purpose only. Necessary
cost adjustment shall be done as per formula laid down below:

3.2.1 OPC 43/53 grade of Cement:

If the actual quantity of OPC 43/53 grade of Cement required as per laboratory
mix design varies from 360 Kg/Cum, necessary cost adjustment for deviation in
the quantity of OPC 43/53 grade of Cement shall be done as per the rate of OPC
43/53 grade of Cement in actual supply voucher from manufacturer/authorized
dealer at the time of execution. In the case of authorized dealer the rate may
be authenticated by the manufacturer. The rate of OPC 43/53 grade of Cement
exclusive of GST shall only be considered for payment. In no case quantity of
OPC 43/53 grade of cement shall fall below 330 Kg/Cum. Extra
payable/deductible rate shall be calculated in following manner:

Cost of OPC 43/53 grade of Cement above/below 360Kg/Cum : ‘X’

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Add 1% Water Charges on ‘X’

Add 15% CP & OH on total adding 1% water charges

Add 1% labour Cess on total after adding 15% CP & OH : Say ‘A’

3.2.2 Portland Pozzolana Cement or Portland Slag cement:

If the actual quantity of Portland Pozzolana Cement or Portland Slag cement

required as per laboratory mix design varies from 400 Kg/Cum, necessary cost
adjustment for deviation in the quantity of Portland Pozzolana Cement or
Portland Slag cement shall be done as per the rate of Portland Pozzolana Cement
or Portland Slag cement in actual supply voucher from manufacturer/authorized
dealer at the time of execution. In the case of authorized dealer the rate may
be authenticated by the manufacturer. The rate of Portland Pozzolana Cement
or Portland Slag cement exclusive of GST shall only be considered for payment.
In no case quantity of Portland Pozzolana Cement or Portland Slag cement shall
fall below 330 Kg/Cum. Extra payable/deductible rate shall be calculated in
following manner:

Cost of Portland Pozzolana Cement or Portland Slag cement above/below

400Kg/Cum : ‘X’

Add 1% Water Charges on ‘X’

Add 15% CP & OH on total adding 1% water charges

Add 1% labour Cess on total after adding 15% CP & OH : Say ‘A’

3.2.3 SUPER PLASTICIZER

If the actual percentage of Super plasticizer by mass of cementitious material

varies from 0.5%, Extra payable/ deductible rate shall be calculated in following
manner:

Extra/ less cost of super plasticizers over or below 0.5% of cementitious material
: ‘X’

Add 1% Water Charges on ‘X’

Add 15% CP & OH on total adding 1% water charges

Add 1% labour Cess on total after adding 15% CP & OH : Say ‘A’

The rate of super plasticizers shall be as per actual supply voucher from
manufacturer/authorized dealer at the time of execution. In the case of

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authorized dealer the rate may be authenticated by the manufacturer. The rate
of super plasticizer exclusive of GST shall only be considered for payment.

3.3 At the time of tendering, the Contractor, after taking into account the type
of aggregates, plant and method of laying he intends to use, shall allow in his
tender for aggregate/cement and water cement ratios which he considers will
achieve the specified strength. These ratios shall, however, not exceed the
ratios stipulated in para 3.1 and shall produce a workability, which shall enable
concrete to be properly compacted to its full depth and finished to the surface
tolerance specified.

3.4 No concrete shall be laid nor any payment made thereof unless the concrete
mix design is submitted by the Contractor and is approved by the concerned
Engineer-In-Charge and communicated in writing. This mix design shall be
provisional and subject to obtaining satisfactory results with trial mixes. Final
approval shall be issued only after getting the satisfactory test report from
trial mixes.

3.5 Laboratory charges for mix design, cost of materials, its cartage and other
incidental expenses shall be borne by the Contractor.

3.6 Guidelines for Cement Concrete Mix Design for Pavements can be followed as
per IRC: 44 -2017 and SP: 23-1982.

4.0 FIELD TRIAL MIXES

4.1 Preliminary trial mixes shall be made and tested. Trial mixes shall also be made if
a change is intended subsequently in the source of supply of materials/quality of
materials or in the proportions of the materials to be used.

4.2 Samples of concrete shall be taken at the concrete batching plant and work
beams made, cured and tested in accordance with IS: 1199 and IS: 516, as
per clause 4.3 given below.

4.3 Representative samples of materials to be used shall be taken and trial mix using
the proposed proportions shall be made, two samples each on three different days.
Each sample shall consist of 6 beam specimens, three for testing at 7 days
and three at 28 days and a total of 36 beams shall be made in three days. The
workability of each of these six trial mixes shall be determined. The test strength
of the sample shall be the average strength of 3 specimens but individual variation
should not be more than +15%. Otherwise, new trial mix corresponding to the
initially approved sample will have to be made. The proposed mix proportion
shall not be accepted if the average of 28 days beam strength of 6 trial mixes is
not satisfying the provisions as per para 16.4.1. The mix shall be suitably modified
if the strength do not meet the criteria as specified.

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4.4 The mix design shall be got approved from concerned Engineer-In-Charge. The
design mix, thus approved shall be intimated to the Contractor by the Engineer-
in-Charge with full data and clear understanding that the mix proportion specified
is provisional subject to the verification of level of control at the site.

4.5 30 beams and 30 cubes shall be cast for deriving the relationship between flexural
strength and compressive strength i.e. K-value, by the Engineer-In-Charge and the
same shall be got approved from concerned General Manager Engg (Project)/work.
This K-value shall be used for calculation of required core strength in clause 16.4.3.

4.6 During the progress of work, samples of concrete shall be taken at the concrete
batching plant and work beams made, cured and tested in accordance with IS:
1199 and IS: 516. Acceptance criteria for this shall be as per para 16.4.1.

4.7 All samples for tests shall be taken in the presence of the Engineer-in- charge and
the contractor or their authorized representatives.

5.0 SLUMP TEST

5.1 Slump tests shall be carried out as per IS: 1199 (latest revision). A slump test
shall be carried out as per clause 16.1 under quality control or more and
frequently, if directed by the Engineer-in-Charge. Any batch from which slump test
is being made shall not be transferred to the place of laying till the slump test has
been completed and result approved. Not only the batch which gives a slump in
excess of that specified shall be rejected but the concrete already laid immediately
preceding the batch tested up to the nearest last transverse joint may be
rejected by the Engineer-in- Charge or his representative, if he is satisfied
that such preceding batches were sub-standard in this respect. The decision of
the Engineer- in-Charge in this respect shall be final and binding on the
contractor. Such rejected concrete shall be removed by the Contractor
immediately and replaced with proper concrete at his own cost and expense.

6.0 BATCHING AND MIXING OF CONCRETE

6.1 A system approach should be adopted for construction of pavement, and the
method statement for carrying out the work, detailing all the activities
including indication of time cycle, equipment, personnel etc. shall be got
approved from the Engineer-in-Charge before the commencement of work. The
above shall include the type, capacity and make of batching and mixing plant
beside the hauling arrangement and paving equipment. The capacity of paving
equipment, batching plant as well as all the ancillary equipment shall be adequate
for a paving requirement for day’s work.

6.2 Batching and mixing of the concrete shall be done at a central batching and mixing
plant of adequate capacity as per work program with automatic controls, located

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at suitable place which takes into account sufficient space for stock piling of
cement, aggregate and stationary water tanks. This shall be however, situated
at an approved distance, duly considering the properties of the mix and transport
arrangements available with the contractor.

6.3 Proportioning of a material shall be done in the batching plant by weight,

each type of material being weighed separately. The cement from the bulk
stock may be weighed separately from the aggregates and water shall be
measured by volume. Wherever properly graded aggregate of uniform
quality cannot be maintained as envisaged in the mix design the grading of
aggregates shall be controlled by appropriate blending techniques. The capacity
of batching and mixing plant shall be at-least 25% higher than the proposed
capacity for the laying/ paving equipment.

6.4 The batching plant shall include preferably four bins, weighing hoppers, and scales
for the fine aggregate and for each size of coarse aggregate. If cement is used
in bulk (after opening bags on platform) a separate scale for cement shall
be included. The weighing hoppers shall be properly sealed and vented to
preclude dust during operation. Approved safety devices shall be provided and
maintained for the protection of all personnel engaged in plant operation,
inspection and testing. The batch plant shall be equipped with a suitable non
resettable batch counter which will correctly indicate the number of batches
proportioned.

6.5 Bins preferably with four adequate separate compartments shall be provided in
the batching plant.

6.6 Batching plant shall be equipped to proportion aggregates and bulk cement by
means of automatic weighing devices using load cells. The weighing device shall
have an accuracy within + 1% in respect of quantity of cement and water
and + 2% in respect of aggregates and accuracy shall be checked at least once a
month.

6.7 Mixers shall be pan type, reversible type with single or twin shaft or any other
mixer capable of combing the aggregates, cement and water into a thoroughly
mixed and uniform mass within the specified mixing period and of discharging the
mix without segregation. Each stationary mixer shall be equipped with an
approved timing device which will automatically lock the discharge lever when
the drum has been charged and release it at the end of the mixing period.
The device shall be equipped with a bell or other suitable warning device adjusted
to give a clearly audible signal each time the lock is released. In case of failure of
the timing device the mixer may be used for the balance of the day while
it is being repaired provided that each batch is mixed for 90 seconds or as
per the manufacturer’s recommendation. The mixer shall be equipped with a
suitable non resettable batch counter which shall correctly indicate the number
of batches mixed.

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6.8 The mixer shall be cleaned at suitable intervals. The pickup and throw over blades
in the drum or drums shall be repaired or replaced when they are worn down
20mm or more. The contractor shall have available at the job site a copy of the
manufacturers design, showing dimensions and arrangements of blades in
reference to original height and depth or provide permanent marks on blade to
show points of 20mm wear from new conditions. Drilled holes of 5mm diameter
near each end and at mid-point of each blade are recommended. Batching plant
shall be calibrated for the each ingredients upto its maximum quantity being
used in the mix at site in the beginning and thereafter at suitable interval
not exceeding one month.

6.9 Air-conditioned centralized computer control cabin shall be provided for automatic
operation of the equipment.

6.10 The design feature of the batching plant should be such that it can be shifted
quickly.

6.11 Concrete mixed as above is not to be modified by the addition of water or

otherwise in order to facilitate handling or for any other purpose.

7.0 PAVING EQUIPMENT

7.1 The concrete shall be placed with Slip Form Paver/Fixed form paver (with
independent units to spread, consolidate from the mould, screed and float-finish,
texture and cure) or Manual method as per the item/as approved by Engineer-in-
Charge. If the concrete is to be laid by slip form paver, the paver shall be equipped
with electronic controls to control the line and grade from either one side or both
sides of the machine.

7.2 Vibrators shall operate at a frequency and spacing recommended by the

manufacturer. The variable vibration setting shall be provided in the machine.

7.3 The contractor shall provide adequate no. of concrete saws with
sufficient no. of diamond edge saw blades. The saw machine shall be either
electric or petrol/ diesel driven type. A water tank with flexible hose and pump
shall be made available for this activity on priority basis. The contractor shall have
at least one standby saw in good working condition. The concreting work shall not
commence if the saws are not in working condition.

7.4 Guide wires for Slip form Paver

7.4.1 Guide wire shall be provided along both sides of the slab. Each guide wire shall
be at a constant height above and parallel to the required edge of the slab
as described in the contract/drawing within a vertical tolerance of + 2 mm.
Additionally, one of the wires shall be kept at a constant horizontal distance from

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the required edge of the pavement as indicated in the contract /drawing with
in a lateral tolerance of +10mm.

7.4.2 The guide wires shall be supported on stakes 5-6 meters apart by connectors
capable of fine horizontal and vertical adjustment. The guide wire shall be
tensioned on the stakes so that a 500 grams weight shall produce a deflection or
not more than 20mm when suspended at the midpoint between any pair of stakes.
The ends of guide wire shall be anchored to fixing point or winch and not on the
stakes.

7.4.3 The stakes shall be positioned and the connectors maintained at their correct
height and alignment 12 hrs. on the day before concreting takes place until 12
hrs. after finishing of the concrete. The guide wires shall be checked and tensioned
on the connectors at any section at least 2 hrs. before concreting that section.

7.4.4 The contractor shall submit to the Engineer-In-Charge for his approval of line and
level, the stakes and connectors which are ready for use in the length of pavement
to be constructed next day. Such approval shall be obtained at least 12 hrs.
before commencement of paving operation. Any deficiencies noted by the
Engineer-in-Charge shall be rectified by the contractor who shall then
reapply for approval of the affected stakes. Work shall not proceed until the
Engineer-in-Charge has given his approval. It shall be ensured the stakes and
guide wires are not affected by the construction equipment when concreting is
in progress.

7.5 Side Forms and Rails for Fixed form paver

7.5.1 All side forms shall be of mild steel channels of depth equal to the thickness
of pavement or slightly less to accommodate the surface irregularity of the
sub base. The forms can be placed in series of steel packing plates or shims to
take care of irregularity of sub base. They shall be sufficiently robust and rigid
to support the weight and pressure caused by a paving equipment.

7.5.2 Side forms for use with wheeled paving machines shall incorporate metal rails
firmly fixed at a constant height below the top of the forms. The forms and rail
shall be firmly secured in position by not less than 3 stakes/pins for every 3
meter length so as to prevent movement in any direction. Forms and rails shall
be straight within a tolerance of 3 mm in 3 meter and when in place shall not
settle in excess of 1.5 mm in 3 meter while paving is being done. Forms shall
be cleaned and oiled immediately before each use.

7.5.3 The forms shall be bedded on a continuous bed of low moisture content lean
cement mortar or concrete and set to the line and levels shown on the
drawings within tolerances of + 10 mm and + 2 mm respectively. The bedding
shall not extend under the slab and there shall be no vertical step between

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adjacent forms of more than 2 mm. The forms shall be got inspected by the
Engineer-in-Charge for his approval 12 hrs. before construction of the slab and
shall not be removed until at least 12 hrs. Afterwards. No concreting shall
commence till form work has been approved by the Engineer-in-Charge.

7.5.4 At all times sufficient forms shall be used and set to the required alignment for
required length of pavement immediately in advance of the paving operations,
or the anticipated length of pavement to be laid within the next 24 hrs.

7.5.5 Forms shall be fixed in advance as per specifications. Before any paving is done
the site shall be shown to the Engineer-in-Charge in order to verify the
arrangement for paving as per the relevant clauses of this specification. The
mixing and placing of concrete shall progress only at such a rate as to permit
proper finishing, protecting and curing of the pavement.

7.6 Steel Forms for Manual Method

7.6.1 Manual method may be adopted where execution with slip form paver is not
feasible. All side forms shall be of mild steel. The steel forms shall be of mild
steel sturdy channels sections and their depth shall be equal to the thickness
of the pavement.

7.5.2 The side forms shall have a length of at least 3.0 meters except on curves
of less than 45 meters radius where shorter length may be used. When set to
grade and stacked in place the maximum deviation of the top surface of any
section from a straight line shall not exceed 2 mm in the vertical plane and 5 mm
in the horizontal plane. The method of connection between sections shall be such
that the joint formed shall be free from difference in level, play or movement in
any direction. The use of bent, twisted or worn out forms will not be permitted.
At least three stake pickets for each 3.0 m of form and the bracing and support
must be ample to prevent springing of the forms under the pressure of concrete
or the weight or thrust of machinery operating on the forms.

7.5.3 The supply of forms shall be sufficient to permit their remaining in place for 12
hrs. after the concrete has been placed or longer, if in the opinion of the Engineer–
in-Charge, it is necessary.

7.5.4 The top line of the forms is not to vary from the correct level or alignment
and the levels and alignment of the forms are to be checked and corrected as
necessary immediately prior to the placing of concrete. The top edges and faces
of the forms are to be carefully cleaned and maintained in clean condition.

7.5.5 While removing the steel forms, care shall be taken to withdraw them gradually.
Any damages to the bull nosed edges shall be made good while the concrete
is still green, as directed by the Engineer–in- Charge.

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7.5.6 Setting of forms shall be according to the slab plan subject to the approval
of the Engineer-in-Charge and concreting shall not commence until the setting
of forms is approved.

7.5.7 Forms shall be set at least 50 meters length in advance of the point where
the concrete is being laid and shall not be removed until at least 12 hrs. of the
placing of concrete or longer if in the opinion of Engineer- in-Charge, it is
necessary. After setting, the working faces shall be thoroughly oiled using
approved oil but before concrete is placed against them.

7.5.8 Sufficient rigidity shall be obtained to support the forms in such a position
during the entire operation of compaction and finishing that they will not at
any time deviate more than 3 mm from a straight edge 3 meters in length.
Forms which show a variation from the required rigidity or the alignment and levels
shown on the plans, shall be reset or removed, as directed. The length and
number of pins or stakes shall be such as to maintain the forms at the correct line
and grade. All forms shall be cleaned and oiled each time before they are used.

8.0 HAULING AND PLACING OF CONCRETE

8.1 Freshly mixed concrete from the central batching and mixing plant shall be
transported to the paver site by means of tippers/transit mixers of sufficient
capacity and approved design in sufficient numbers to ensure a constant supply
of concrete. Cover shall be used for protection of concrete against the weather.
While loading the concrete, truck shall be moved back and forth under the
discharge chute to prevent segregation. The tipping trucks shall be capable of
maintaining the mixed concrete in a homogeneous state and discharging the same
without segregation and loss of cement slurry. The feeding to the paver is to be
regulated in such a way that paving is done in an uninterrupted manner with a
uniform speed throughout the day’s work. Tipping truck shall be washed at a
regular frequency as prescribed by the Engineer-in-Charge to ensure that no
leftover mix of previous loading remains stuck.

8.2 Concrete mixed in central mixing plant shall be transported to the site without
delay and the concrete which in the opinion of Engineer-in-Charge, has been
mixed too long before laying will be rejected and shall be removed from the
site. The total time taken from the addition of water to the mix until the
completion of surface finishing and texturing shall not exceed 120 minutes
when concrete temperature is less than 250C and 90 minutes when concrete
temperature is between 250C to 300C. Tippers/transit mixers delivering concrete
shall not run on completed slabs until after 28 days of placing of concrete.

8.3 In all cases the temperature of the concrete shall be measured at the point of
discharge from the delivery vehicle.

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8.4 The addition of water to the surface of the concrete to facilitate the
finishing operations will not be permitted except with the approval of the Engineer-
in-Charge when it shall be applied as a mist by means of approved
equipment.

8.5 If considered necessary by the Engineer-in-Charge, the paving

equipment shall be provided with approved covers to protect the surface of the
slab under construction from direct sunlight and rain or hot wind.

8.6 As soon as the side forms are removed, edges of the slabs shall be
corrected wherever irregularities have occurred by using fine concrete composed
of 1:1:2, cement: sand: coarse aggregate (10 mm down) with water cement
ratio not more than 0.4 under the supervision of Engineer-in-Charge.

8.7 If the requirement for surface regularity fails to be achieved on two consecutive
working days then normal working shall cease until the cause of the excessive
irregularity has been identified and remedied.

8.8 Construction by Slip Form Paver: The slip form paving train shall consist of
power machines which spreads compacts and finishes the concrete in a continuous
operation.

8.8.1 The slip form paving machine shall compact the concrete by internal vibration
and shape it between the side forms with either a conforming plate or by vibrating
and oscillating finishing beams. The concrete shall be deposited without
segregation in front of slip form paver across the whole width and to a height
which at all times in excess of the required surcharge. The deposited concrete
shall be struck off to the necessary average and differential surcharge by means
of the strike off plate or a screw auger device extending across the whole width
of the slab. The equipment for striking-off the concrete shall be capable of being
rapidly adjusted for changes of the average and differential surcharge necessitated
by change in slab thickness or cross fall.

8.8.2 The level of conforming plate and finishing beam shall be controlled automatically
for the guide wires installed by sensors attached at the four corners of the
slip form paving machine. The alignment of paver shall be controlled
automatically from the guide wire by at least one set of sensors attached to the
paver. The alignment and level of ancillary machines for finishing, texturing and
curing of the concrete shall be automatically controlled relative to the guide wire
or to the surface and edge of an adjoining hardened slab.

8.8.3 Slip form paving machines shall have vibrators of variable output with a maximum
energy output of not less than 2.5 KW per meter width of slab per 300 mm
depth of slab for a laying speed upto 1.5 m per minute or pro-rata for higher
speeds. The machine shall be of sufficient mass to provide adequate reaction

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during spreading and paving operations on the traction units to maintain forward
movements during the placing of concrete in all situations.

8.8.4 If the edges of the slip formed slab slump to the extent that the surface of the top
edge of the slab does not comply with the requirements, then special measures
approved by the Engineer-in-Charge shall be taken to support the edges to the
required levels and work shall be stopped until such time as the contractor can
demonstrate his ability to slip form the edges to the required levels. The slumped
edge shall have to be corrected by adding fresh concrete after roughening the
surface.

8.8.5 Upon the instructions of the Engineer-in-Charge, contractor shall scrape the
concrete surface when in plastic state with a 3.0 m long tube float fixed with a
long and stable handle before texturing. Tube float shall be of an alloy steel
tube of 50-60 mm diameter with a long and stable handle. The length of
the tube float shall preferably be longer than half the length of slab i.e., half
the distance between two transverse contractions joints. This operation shall
be done to minimize surface irregularity caused due to varied causes like frequent
stoppage of work, surface deformation due to plastic flow etc. The tube float shall
be placed at the center of the slab parallel to longitudinal joint and pulled slowly
and uniformly towards the edges. After the use of the float tube, it shall be
frequently cleaned before further use. The slurry removed shall be discarded. This
activity shall be advanced laterally by providing an overlap of half the length of
two float. The removal of the cement slurry from the surface shall be sufficient
enough such that the texture is formed on a firm surface and is more durable.
This operation however, shall be carried out after removing bleeding water.

8.8.6 In the case of construction by slip form paver, areas inaccessible to paving
equipment shall be constructed by manual/hand guided method. Areas in which
manual/hand guided methods of construction become indispensable shall be got
approved by the Engineer-in-Charge in writing in advance. Work shall be carried
out by skilled personnel as per methods approved by the Engineer-in-Charge. For
construction by hand guided method in the limited area, no cost adjustment will
be made.

8.9 Construction by Fixed Form Paver: The fixed form paving train shall consist
of separate powered machines which spread compact and finish the concrete in
a continuous operation. The paving train moves on the rails fixed on both sides
of the pavement and compacting/finishing is simultaneously carried with the
equipment fitted with paving train which moves on the rails.

8.9.1 The concrete shall be discharged without segregation into a hopper of the
spreader which is equipped with means for controlling its rate of deposition on
to the sub-base. The spreader shall be operated to strike off concrete upto a
level requiring a small amount of cutting down by the distributor of the spreader.

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The distributor of spreader shall strike of the concrete to the surcharge adequate
to ensure that the vibratory compactor thoroughly compacts the layer. If
necessary poker vibrator shall be used adjacent to the side forms and edges of
the previously constructed slab.

8.9.2 The vibratory compactor shall be set to strike off the surface slightly high so
that it is cut down to the required level by the oscillating beam. The machine
shall be capable of being rapidly adjusted for changes in average and differential
surcharge necessitated by changes in slab thickness or cross fall. The final
finisher shall be capable to finish the surface to the required level and
smoothness as specified, care being taken to avoid bringing up of excessive
mortar to the surface by over working.

8.9.3 In the case of construction by fixed form paver, areas inaccessible to paving
equipment shall be constructed by manual/hand guided method. Areas in which
manual/hand guided methods of construction become indispensable shall be got
approved by the Engineer-in-Charge in writing in advance. Work shall be carried
out by skilled personnel as per methods approved by the Engineer-in-Charge.
For construction by hand guided method in the limited area, no cost adjustment
will be made.

8.10 SURFACE TEXTURE

8.10.1 Surface of the pavement shall be finished for the newly constructed concrete
pavements such that texturing equipment shall not tear or unduly roughen the
concrete surface during the operation. The texture shall be uniform in appearance
and approximately 2.0mm in depth. Brush shall be applied when the water sheen
has practically disappeared and the surface of concrete shall be brush-textured in
a direction at right angles to the longitudinal axis of the carriageway to get
satisfactory texture.

8.10.2 The texture depth shall be determined by the Sand Patch Test as described
below. This test shall be performed at least once for each day’s paving and
wherever the Engineer-In-Charge consider it necessary at times after construction
as under:

Five individual measurement of the texture depth shall be taken at least

2m apart anywhere along a diagonal line across a lane completed between points
50m apart along the pavement. No measurement shall be taken within 300mm
of the longitudinal edges of a concrete slab constructed in one pass.

8.10.4 Measurement of Texture Depth – Sand Patch Method

The following apparatus shall be used:

i) A cylindrical container of 25 ml internal capacity.

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ii) A flat wooden disc 64mm diameter with a hard rubber disc, 1.5mm
thick, stuck to one face, the reverse face being provided with
a handle.

iii) Dry natural sand with a rounded particle shape passing a

300micron IS sieve and retained on a 150 micron IS sieve.

Method: The surface to be measured shall be dried, any extraneous mortar and
loose material removed and the surface swept clean using a wire brush both at
right angles and parallel to the carriageway. The cylindrical container shall be
filled with the sand, tapping the base 3 times to the surface on ensure compaction,
and striking off the sand level with the top of cylinder. The sand shall be poured
into a heap on the surface to be treated. The sand shall be spread over to
surface, working the disc with its face kept flat in a circular motion so that the
sand is spread into a circular patch with the surface depressions filled with
sand to the level of peaks. The diameter of the patch shall be measured to the
nearest 5mm. The texture depth of concrete surface shall be calculated from
31000/(D x D) mm where D is the diameter of patch in mm.

8.10.5 Texture depth shall not be less than a minimum required when measurement are
taken as given in table nor greater than a maximum average of 1.25 mm.
TABLE : TEXTURE DEPTH

S Time Test Number of Required Texture

No. measurements Depth (mm)

Specifie
Tolerance
d value

1. Between 24 Hrs. and 7 days after

An average of 5
the construction of the slab or until 1.00 ±0.25
Measurements
the slab is first used by vehicles.

2. Not later than 6 weeks before the An average of 5

1.00 ±0.25
pavement is opened to traffic. Measurements

8.10.6 After the application of the brushed texture, the surface of the slab shall have a
Uniform appearance.

8.10.7 Where the texture depth requirements are found to be deficient, the Contractor
shall make good the texture across the full lane width over length directed by the
Engineer-in-Charge, by texturing the hardened concrete surface in an approved
manner.

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9.0 CONSTRUCTION BY MANUAL/HAND GUIDED METHOD:

The pavement shall be constructed using side forms. The acceptance criteria
regarding level, thickness, surface regularity, texture, finish strength
of concrete and all other quality control measures shall be the same as in
the case of machine laid down.

9.1 Placing of Concrete:

9.1.1 Concrete shall be deposited between the forms. Where a certain amount of
redistribution is necessary, it shall be done with shovels and not with rakes. The
concrete shall be compacted with the needle vibrator and vibrating screeds. Use
of vibrator near side forms is essential to eliminate honey combing. To effect
adequate compaction, the concrete shall be placed with appropriate surcharge
over the final slab thickness. The amount of surcharge will depend upon the
mode of placement of concrete and shall be determined by trial. In general, the
required surcharge is about 20% of the required slab thickness.

9.1.2 The concrete is to be deposited and spread to such a depth that when compacted
and finished, the slab thickness indicated will be obtained at all points and the
surface will not at any point be below the level specified for the finished
surface.

9.2 Compaction of Concrete

9.2.1 Compaction shall be carried out by electrically operated needle and screed
vibrators as stipulated hereafter. Needle vibrators should be used all over
the area for obtaining initial compaction of concrete. These should be of
diameter not less than 4.5 cm and if the vibrators are pneumatic, the pressure
must not be below 4 kg/sq.cm. If electrically operated, they should have a
minimum frequency of 3500 impulses per minute. Minimum number of petrol
driven vibrators as specified by the Engineer-in-Charge with minimum frequency
of 3500 impulses per minute shall be provided at each work head as a standby
arrangement. The screed and internal vibrator shall conform to I.S.:2505 and
I.S.: 2506 respectively.

9.2.2 There should be at least three needle vibrators working in one bay. A vibrating
screed consisting of a steel or timber section weighing not less than 15 kg per
meter with a tamping edge of not less than 7 cm width and having a vibrator
mounted thereon shall follow needle vibrators to obtain full compaction. The
face of the wooden tamping edge of the screed shall be lined with M.S.
plate rigidly fixed by means of counter sunk screws. Where screed vibrators
are used for compaction, a standby unit shall always be maintained ready for
use, should the other one go out of order. Where electrically driven vibrators are
employed, a stand by pneumatic unit shall be kept ready for use in case of power

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failure. At the discretion of the Engineer-in-Charge, for compaction at edges and

joints, vibrators may be supplemented by hand tamping and rodding for securing
satisfactory results. Under no circumstances, honey combing of concrete at joints
or elsewhere shall be permitted.

9.2.3 When using screed vibrator for compaction, it should not be dragged over
the concrete. During the initial passes, it shall be lifted to the adjacent forward
position in the steps. Subsequently, it shall be slowly slided over the surface
with its axis slightly tilted away from the direction of sliding and the
operation repeated until a close, dense surface is obtained.

9.2.4 Work men shall not be allowed to walk on freshly laid concrete. All
operations shall be carried out from suitable wooden bridges spanning the lane-
width.

9.2.5 IMPORTANT PRECAUTION: The vibration process shall be restricted just upto
the stage of appearance of water/ cement slurry on the surface. After
reaching this point vibration should be discontinued. It should be ensured that
no over-vibration is resorted, as it leads to formation of thin cement slurry
layer over the top surface which tends to peel off with passage of time by
movement of traffic.

9.3 Finishing of Concrete

9.3.1 Immediately after compacting of concrete and the construction of joints but
before the concrete has hardened and while the concrete is still in a plastic state,
the pavement surface shall be inspected for irregularities with a profile
checking template and minor irregularities and score marks shall be eliminated
by removing surplus material or by adding and working in freshly mixed concrete
if necessary by means of long handled floats and scraping straight edges followed
by further compaction and finishing. The long handled floats may be used to
smoothen and fill in open textured area in the pavement surface, but the final
finishing is to be done with scraping straight edges.

9.3.2 The scraping straight edges are to be 3 meters long with flexible handles
long enough to reach the other side of the slab when operated from one side of
the pavement. They are to be placed parallel to the forms at the side of the
pavements and worked backwards and forwards uniformly across the width of the
slab. After this operation has been completed and the surface has been brought
to the required finish, the straight edge is to be moved forward but not more than
half its length and the process repeated.

9.3.3 The straight edge testing and refloating is to continue until the entire surface:

a) Is free from observable departure from the straight edge.

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b) Conforms to the required levels and cross-section.

c) Conforms to the specified surface finish when the concrete has
hardened.
9.3.4 The foregoing work is to be carried out while the concrete is still plastic and
workable and in such time sequence so as to ensure the removal of water and
laitance from the surface.

9.4 BELTING

Just b e f o r e t h e c o n c r e t e b e c o m e s n o n -plastic, the s u r f a c e

s h a l l b e belted with two ply canvas belt not less than 20 cm wide and
at least 1 meter longer than the width of the slab. Hand belts shall have
suitable handles to permit controlled uniform manipulation. The belt shall be
operated with short strokes transverse to the center line of pavement and
with a rapid advance parallel to the concrete line.

9.5 BROOMING

9.5.1 After belting and as soon as surplus water, if any, has risen to the surface,
the pavement shall be given a broom finish with an approved steel or fiber
broom not less than 45 cm wide. The broom shall be pulled gently over
the surface of the pavement from edge to edge. Adjacent strokes shall be
slightly overlapped. Brooming shall be perpendicular to the centre line of the
pavement and so executed that the corrugations formed will be uniform in
character and width and not more than 2.0 mm deep.

9.5.2 Brooming shall be completed before the concrete reaches such a stage that the
surface is likely to be torn or unduly roughened by the operation. The
broomed surface shall be free from porous or rough spots, irregularities,
depressions and small pockets such as may be caused by accidental
disturbing of particle of coarse aggregates embodied near the surface.
The rate of the contractor for the item of quality controlled concrete pavement
includes the provision for belting and brooming operations and nothing
extra shall be paid on this account.

9.6 EDGING

After belting/ brooming has been completed but before the initial setting
of concrete, the edges of the slab shall be carefully finished with an
edging tool of 6 mm radius, and the pavement edges shall be left
smooth and true to line.

9.7 HONEY COMBING

As soon as the side forms are removed, any minor honey combed areas

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shall be filled with mortar composed of one part of cement and two
parts of fine aggregate. Major honey combed areas or segregated
concrete or other defective work or areas damaged by removal of the
forms or concrete damaged by rain or due to any other reason
whatsoever shall be considered as defective work and shall be removed and
replaced by the contractor at his own expense. The total area of honey
combed surface not exceeding 2.5 sq.cm. each, shall not exceed 4% of the
area of the slab side. Engineer in charge’s decision as to whether the
concrete is defective or not shall be final and binding.

10.0 SURFACE ACCURACY

10.1 After the concrete has sufficiently hardened after about 12 hours and not
later than 24 hours, the surface shall be tested again for high spots. All high spots
shall be marked and those exceeding 3 mm shall be ground down
immediately as directed by the Engineer-in-Charge after obtaining his written
permission. Care shall be taken to see that the grinding does not in any way
damage the concrete surface.

10.2 The final surface finish is to be such that when tested with a
profilograph/ roughness indicator/or a 3 meter long straight edge or an equivalent
mechanical unevenness indicator placed anywhere within the same or adjoining
slab in any direction on the surface, there shall be no variation greater than 3mm.

10.3 If the surface irregularities exceeding 3 mm still remains despite

grinding if permitted, as per para 10.1 the concrete shall be removed to its full
depth and replaced. The area of concrete to be removed shall be complete slab
between the nearest joints. Where the defective slab is less than 4.5 meter from
the construction joint, the whole area upto the construction joint shall be removed
to the full depth. The concrete so removed shall not be reused in the work.
Fresh concrete shall be laid in the manner already described in these
specifications and shall again be subjected to test for surface accuracy and
other quality control measures. Nothing extra shall be paid for all these
operations.

10.4 Every slab shall bear an impression not exceeding 3 mm in depth comprising
the number allotted to the slab and the date on which it is laid. This impression
shall be formed by the Contractor when the concrete is green so as to leave
permanent mark on setting.

11.0 CURING OF CONCRETE

Initial curing shall be done by application of curing compound or by

manual method as per clause 16.37.13.5 of CPWD specifications Vol-II, 2009.
However nothing extra shall be paid for curing by application of curing
compound.

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11.1 Initial Curing by application of Curing Compound:

11.1.1 Immediately after the surface texturing, the surface and sides of the slab shall
be cured by the application of approved resin-based aluminized reflective
curing compound or white pigmented curing compound which hardens into an
impervious film or membrane with the help of a mechanical sprayer.

11.1.2 Curing compounds shall contain sufficient flake aluminium in finely divided
dispersion to produce a complete coverage of the sprayed surface with a
metallic finish. The compound shall become stable and impervious to evaporation
of water from the surface of the concrete within 60 minutes of application
and shall be of approved type. The curing compounds shall have a water
retention efficiency index not less than 90 percent in accordance with BS
Specifications No.7542 or as per ASTM C-309-81 Type 2.

11.1.3 The curing compound shall not react chemically with the concrete and the film or
membrane shall not crack, peel or disintegrate within three weeks after
application. Immediately prior to use, the curing compound shall be
thoroughly agitated in its containers. The rate of spread shall be in accordance
with the manufacturer’s instructions checked during the construction of the trial
length and subsequently whenever required by the Engineer-in-Charge. The
mechanical sprayer shall incorporate an efficient mechanical device for continuous
agitation and mixing of the compound during spraying. Arrangements should be
made to spray the curing compound on the sides of the slab. The curing
compound shall be sprayed in two applications to ensure uniform spread. In
addition to spraying of the curing compound, the fresh concrete surface
shall be protected for at least 3 hours by covering the finished concrete
pavements with tents supported on mobile truss during adverse weather
conditions as directed by the Engineer-in-Charge.

11.2 FINAL CURING

Final curing shall be done either by spreading of wet hessian and moisturing it
regularly or by ponding method as given below. However, nothing extra
s h a l l be paid for curing by spreading wet hessian method. All joints
shall be filled in with temporary filler like sand etc. in order to prevent
the edges of joints from being damaged and entry o f clay m a t e r i a l s
i n t o t h e joints d u r i n g final curing.

11.2.1 Final curing by spreading of wet hessian method

After two or three hours after application of curing compound, the pavement shall
be covered including sides by moist hessian (minimum of two layers) and the same
shall then be kept damp for a minimum period of 14 days after which time
the hessian may be removed. During the curing period, the hessian shall be

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kept continuously moist.

All damaged/torn hessian shall be removed and replaced by new

hessian on a regular basis.

11.2.2 Final curing by ponding method

After two to three hours after application of curing compound or upon

removal of the burlap as the case may be, the slab shall be thoroughly wetted
and cured by ponding as follows:

Exposed edges of the slab shall be banked with a substantial berm of earth.
Upon the slab shall then be laid a system of transverse and longitudinal
height of clay about 50 mm high immediately covered with a blanket of
sandy soil free from stones to prevent the drying up and cracking of
clay. The rest of slab within these boundaries shall then be covered with
sufficient sandy soil so as to produce blanket of earth not less than 40mm
deep after wetting. The earth covering shall be thoroughly wetted while it
is being place on the surface and against the sides of the slab and kept
thoroughly saturated with water for 21 days and thoroughly
nd
wetted down during the morning of the 22 day and shall
thereafter remain in place until the concrete has attained the
required strength and permission is given by the Engineer-in-
Charge. Thereafter the covering shall be removed and the pavement
cleaned and swept. If the earth covering becomes displaced during the
curing period, it shall be replaced to the original depth and restarted.

11.2.3 The contractor shall be liable at his cost to replace any concrete damaged
as a result of incomplete curing or cracked on a line other than that of a joint
as per procedure in IRC:SP-83.

11.2.4 The Contractor shall employ his own security personnel to prevent workmen,
cattle straying etc., on the pavement concrete.

11.2.5 Concrete shall not be subjected to any load or weight of any plant until at least 28
days after laying, except for cutting the joints as directed by the Engineer-in-
Charge.

12.0 CONTRACTION/DUMMY JOINTS

12.1 The spacing of transverse and longitudinal joints shall be 4.5 to 5 meter or
as shown in the drawing. It shall be 10 mm wide and shall extend vertically
from the surface of the slab to a depth equal to one-third depth of
slab. The joint shall be formed by cutting with a joint cutting machine. The
initial cut or slot of not less than 3mm wide is to be formed by sawing

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the concrete with a joint cutting machine of approved design as soon

as the concrete hardens. Normally in summer when ambient
temperature is more than 30°C, initial cutting may be carried after 4-
8 hrs. of laying and in winter when ambient temperature is less
than 30°C, initial cut may be done at 8-12 hrs. of laying. Top 25mm of
this joint groove shall be subsequent widened to 10mm, after 14-16 days of
casting concrete pavements. The details of Contraction/dummy joint shall be
as given in Appendix –‘A’.

12.2 Before cutting the dummy joints, all necessary precautions shall be taken to ensure
that the joint alignment is marked straight and true as per the drawings. The joint
cutting machine will be handled only by an experienced person thoroughly familiar
with this type of work. The joint should be cut along this alignment only. Any error
in the joint cutting alignment shall be rectified by the Contractor at his own
expense as directed by the Engineer-in-Charge, preferably using epoxy
concrete as approved.

12.3 The groove shall be inserted with 12mm dia closed-cell Polyethylene foam
back-up rod, 13mm below from the surface of the concrete and filling with
Polysulphide Sealant conforming to grade B.S.: 5212-1990 or IS:11433-1995.
Prior to filling with Polysulphide, the joints shall be cleaned by compressed
air up to full depth and primed properly with appropriate Polysulphide primer up
to back-up rod and masking tape shall be applied along the edges of joint to
prevent spillage of sealant on top surface to give neat finish to sealant. The
masking tape shall be removed after the sealant has been applied and tooled.

12.4 All joints shall be sealed as soon as practicable after 28 days of placing of slabs.
Joints shall be sealed flush with the adjacent pavement surface. The pavement
shall be opened to traffic only after joint sealing over the entire pavement has
been completed. To prevent tackiness or pick up under traffic, the exposed
surfaces of the sealing compound shall be dusted with hydrated lime, if
directed by Engineer-in-Charge, for which nothing extra shall be paid to the
Contractor.

12.5 Each lot sealant shall be supported with manufacturers test certificate. However
one sample per 1000 kg. of sealant received at site or part thereof shall be
collected by the Engineer-in-Charge or his authorized representative and sent
for testing to any Government/ AAI approved Laboratory.

The contractor shall note that as testing charges of sealant seem to be high,
they shall confirm the testing charges and quote their rates accordingly.
Nothing extra over and above the quoted rates is payable on this account and
no plea on what so ever ground will be entertained later on.

12.6 In case of sudden rain or storm, the work can be concluded at the dummy

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joints but these will then be formed as construction joints.

12.7 Before sealing of joints, it may be ensured that the transverse joints on each side
of the longitudinal joint shall be in line with each other and of the same type and
width. Any concrete or other foreign matter must be removed from the groove
before sealing.

13.0 CONSTRUCTION JOINTS

13.1 Construction joints shall be provided as shown in the drawing and also at places
whenever day’s operations start and stops or where concreting is stopped due to
unforeseen circumstances. The joints shall be straight and vertical through the
full depth of the slab.

13.2 At all construction joints, bulk head shall be used to retain the concrete and care
shall be taken in striking off and finishing the surface to the top face of the
bulkhead. When work is resumed, the surface of concrete laid subsequently,
shall conform to the grade and cross section of previously laid pavement.
Where semi-mechanized method of construction is used, the concrete along the
face of all joints shall be compacted with an internal vibrator inserted in the
concrete and worked along the joint to ensure a concrete free from
honeycombing. In case of mechanized construction, working and vibration/RPM
of all the fixed vibrators shall be checked. There shall be two additional needle
vibrators to compact the concrete near bulk head.

13.3 The Sealing of joints shall be done in the same manner as for contraction
joints, by cutting a groove of 10mm wide and 25mm deep as shown in Appendix
‘A’.

14.0 EXPANSION JOINTS

14.1 Expansion joints are essential where cement concrete pavement

is designed to abut with structures like bridges, culverts, etc. and
at junction of building and pavement. Expansion joint shall also
b e provided at the intersection of runway, taxiway and Apron.
The expansion joint shall be straight, extend through the full depth of the slab
and shall be of the shape and dimensions shown on the drawing. The slab
edges adjacent to the joint shall be formed truly vertical.

14.2 Where semi-mechanized method of construction is used, the concrete along the
face of all joints shall be compacted with an internal vibrator inserted in the
concrete and worked along the joint to ensure a concrete free from
honeycombing. In case of mechanized construction, working and vibration/RPM
of all the fixed vibrators shall be checked. There shall be two additional needle
vibrators to compact the concrete near bulk head.

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14.3 Synthetic expansion joint filler board as per specification shall be used to fill the
gap between adjacent slabs at expansion joint. The joint groove shall be filled
with Polysulphide conforming to grade B.S.: 5212-1990 or IS: 11433-1995.
Prior to filling with Polysulphide, the joints shall be cleaned by compressed air
up to full depth and primed properly with appropriate Polysulphide primer up to
back-up rod and masking tape shall be applied along the edges of joint to
prevent spillage of sealant on top surface to give neat finish to sealant. The
masking tape shall be removed after the sealant has been applied and tooled. The
details of expansion joint shall be as given in Appendix –‘A’.

15.0 APPLICATION OF POLYSULPHIDE JOINT SEALING COMPOUND

15.1 Materials

15.1.1 Sealant: It shall be cold Polysulphide sealant of approved make conforming

to BS: 5212-1990 or IS: 11433-1995.

15.1.2 Back-up Rod/Backer Rod: Type of material shall be Expanded closed

cell Polyethylene foam and shall conform to ASTMC-5249-95 or ASTMD
3575.

15.1.3 Primer: It shall be applied on the concrete faces of the joints. It shall be single
component primer suitable for use with Polysulphide joint sealant, as approved by
the Engineer-in-Charge.

15.1.4 Joint Filler Board: The joint filler shall be Synthetic joint filler board of approved
make. It shall be 25mm thick within a tolerance of +1.5mm and of a firm
compressible material and complying with the requirements of IS:1838 (Part
3):2011 with a compressibility more than 25%. It shall be provided to the
full width between the side forms. If two pieces are joined to make up full
width, the joint shall be taped such that no slurry escapes to the joint. The
physical requirement of filler shall be as per the table given below:

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S.No Characteristics
1 Resistance to handling
2 Recovery
3 Compression
Method of
Requirement test, Ref.
to IS
Filler strips shall not be
deformed or broken by twisting, -
bending or other types of
ordinary handling when exposed
to atmospheric condition (see
note)
90% min. 10566
a) Load required to compress
the specimen to 50% of its
original thickness before the
test shall be (i) 7 kgf/cm2, min. -do-
(ii) 53 kgf/cm2, max.

4 Extrusion Amount of extrusion of the -do-

free edge shall not exceed
6mm
5 Water Absorption 1%, max. -do-

6 Density 100 + 10 kg/m3, min. -do-

7 Weathering a) shall show no sign of

disintegration,
delamination or separation
after the test -do-
b) shall satisfy the
requirement of recovery,
Note: Pieces of joint filler that have been damaged shall be rejected.

In order to ensure that sides of the PQC pavement in the portion of

above expansion joint filler board do not get dirty and this space does not
accumulate pieces of aggregates and other foreign materials, precaution is
required to be taken as indicated in note 1 given below.

Note:

1. Expansion joint filler board should be provided upto the top of finished
pavement surface. At the time of filling the joint with sealant material and back-
up rod/baker rod, the required depth of joint filler board from the top upto the
bottom of back-up rod/baker rod should be cut & removed. For easy removal of
top filler board and to avoid damage to the filler board, a pre-cut in the expansion
joint filler board shall be provided at a suitable depth so that back-up rod/baker

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rod & sealant could be filled after removal of the top cut portion of the filler board.
Nothing extra shall be paid for the filler board from top upto the bottom of back-
up rod/baker rod.

2. As the period for the test will be around three weeks, advance planning is
required to avoid any delay on this account.

15.2 PROCEDURE

15.2.1 Preparation of Surface: All the joint surfaces to which the sealant is to be
applied should be clean, dry and free from any loose material, dirt, dust,
scale, protective lacquer, grease.

15.2.2 Expansion joint filler material must be checked to ensure that it is tightly
packed and no gaps or voids exist at the base of the joint slot.

15.2.3 Sealant should be prepared as per manufacturer’s specifications.

15.2.4 Before sealant is applied, primer shall be applied to secure better adhesion
between sealant and the concrete surface. The surface shall be allowed to dry for
at least 30 minutes but no longer than 3 hours before the sealant is applied.

15.2.5 To prevent accidental spillage of sealant on the top surface and to give a neat
finish, masking tape should be applied along the edge of joint before the sealant
material is filled.

15.2.6 Immediately after filling the joints, the sealant should be tooled either with a
stainless steel or wooden spatula of the size of the joint to give a smooth surface.
While tooling, the spatula should be wetted with a wetting agent like soap water.
Masking tape shall be removed immediately after the sealant has been tooled.
By tooling, the sealant is compressed with the result that air bubbles if any, are
broken up and the sealant becomes free of voids and there is a proper
adhesion of the sealant to the sides of the joints.

15.3 Sealant of approved make shall be filled only after complete curing of concrete
i.e., after 28 days. Sealant shall be applied slightly to a lower level than the slab
with a tolerance of 1+0.5mm as shown in Appendix –‘A’
15.4 Sealant of approved make shall be filled up for a depth as specified in item. The
rate of application of sealant may be calculated on the basis of the following
formula:

Number of 1 Kilogram tins required = 0.0015 x L x W x D

where L = Length of joint in meters
W = Width of joint in mm.

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D = Depth of joint in mm.

15.5 Manufacturer’s certificate shall be produced for establishing that the sealant is not
more than six months old or the shelf-life of the sealant. For storage, preparation
of sealant, health and safety precautions etc., manufacturer’s specifications shall
be applicable.

15.6 A typical sketch showing details of filling of joints is enclosed as

Appendix -‘A’.

16.0 QUALITY CONTROL

16.1 The following quality control tests shall be carried out at frequencies
specified against each, as per the table given below:

S.No Test Test Method Frequency Acceptance

Criteria
I Cement
Physical and IS:4031, Once for each As per
chemical tests IS:4032 source of supply relevant
and every 200 code as per
tonnes or part Para 1.1
thereof. Cement
remaining in
stores for more
than one and half
month from the
date of
manufacture must
be retested before
use and to be
rejected, if it fails
to conform to any
of the
requirements of
the specifications.
Each brand of
cement brought
to site shall be
tested as per
this frequency.
Besides, the
Contractor
also will
submit daily

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S.No Test Test Method Frequency Acceptance

Criteria
test report on
cement
released by
the
manufacturer.

II Coarse aggregate
a) Flakiness IS:2386 (Part- Before approval Not more
Index I) of the quarry than 25%
and at every
subsequent
change in the
source of
supply and
one test for
every
2 0 0 0 cum
of
aggregate
b) Impact value
or IS:2386 (Part- - do- Not more
Los Angeles IV) than 30%
abrasion value
c) Water IS:2386 (Part -do- Not more
Absorption III) than 3%.
d) Deleterious IS:2386 (Part Before approval As per
materials II) of the quarry table -2 of
and at every IS: 383
subsequent
change in the
source of
supply.
e) Moisture IS:2386 (Part Regularly as This data
content III) required shall be used
subject to a for
minimum of correcting

one test per the water

day demand of
the mix on a
daily basis

f)Grading IS: 2386 (Part– One test per As per

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S.No Test Test Method Frequency Acceptance

Criteria
I) day on each Table - 7
size of of IS: 383
aggregates
g) Soundness IS 2386 ( Part Before approval
(i) Loss with V) of the quarry
Sodium and at every Max. 12%
Sulphate for subsequent
5 cycles change in the
(ii) Loss with source of Max. 18%
Magnesiu supply
m Sulphate
with 5
cycles
(h) Presence of As per clause Before approval No presence
ferrous 1.3.1 of the quarry of ferrous
sulphide and and at every sulphide and
iron oxide subsequent iron oxide
change in the
source of
supply.
III Fine Aggregates
a) Silt Content CPWD One test Not more
Specificatio per 2 00 than 8%
n cum and
2009 Vol. I, part
Page thereof
78, Appendix –
C
b) Grading IS : 2386 (Part- -do- Fineness
III) modulus
between
2.5 to 3.9
c) Water IS : 2386 (Part- -do- Not more
Absorption III) than 3%
d) Deleterious IS: 2386 (Part- Before approval As per
materials II) of the quarry table 1 of
and at every IS 383
subsequent
change in the
source of
supply.

e)Moisture IS:2386 (Part- Regularly as This data

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S.No Test Test Method Frequency Acceptance

Criteria
content III) required shall be used
subject to a for correcting
minimum of the water
two test per demand of
day. the mix on a
daily basis.
IV Combined Grading of Aggregates
a) Grading IS: 2386 (Part- 1 test per As per Para
I) 150 cum 1.5
a nd part
thereof
V Concrete
a) Slump test of IS : 1199 At least once As per Para
concrete in 50 batches 3.1
at each mixer
or more
frequently if
directed by the
EIC.
b) Flexural IS : 516 One test As per Para
strength consisting of six 16.4
beam
specimens and
6 cubes. Three
specimens shall
be tested after
7 days and
another three
shall be tested
after 28 days
for every
200 Cum of
Concrete &
part thereof
c) Surface As prescribed Regularly As per Para
accuracy 10
VI Polyethylene IS:2508 One test per As per
sheet Density lot IS:2508
Tensile strength
at break
Melt flow Index

16.2 Equipment as per list at Appendix–‘B’ shall be provided by the

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Contractor in the field testing laboratory. Nothing extra shall be paid to him on
this account. Records as required shall be maintained at site.

All test details in support of mix design shall be maintained as part of records
of the contract and shall be signed both by the contractor and the Engineer-
in-Charge or their authorized representatives. The contractor shall provide
all labour, materials and equipment required for all tests to be carried out, at
his own cost.

16.3 The Engineer-in-Charge reserves the right to test any concrete laid
regarding quality, soundness, compaction, thickness strength and finish of the
concrete at any time before the expiry of the “Defects Liability period”
notwithstanding that necessary tests had been carried out and found
satisfactory at the time of execution.

16.4 QUALITY CONTROL AND STANDARD OF ACCEPTANCE OF

STRENGTH OF CONCRETE

16.4.1 Samples of concrete shall be collected at the point of discharge on the pavement
and beams cast as controlled specimens and tested in accordance with IS:
516 and IS: 1199. The concrete will be said to comply with the specified
flexural strength, when the following conditions are met with.

(a) The mean strength determined from any group of four consecutive
samples (each sample containing 3 beam specimen i.e. 4x3 =12
beam specimens) at 28 days should exceed the specified characteristic
flexural strength by at least 0.3 MPa i.e., 4.4 MPa.

(b) The strength of any specimen is not less than the specified
characteristic flexural strength minus 0.1 MPa i.e., 4.0 MPa.

16.4.2 Should the concrete fail to pass the specification for strength as
described above, the contractor may, all at his own expense elect to cut cores
(diameter of the core not less than 150mm) as per the direction of Engineer-in-
Charge where the requirements are not met with. The points from where cores
are to be taken and the number of cores required shall be at the discretion
of the Engineer-in-Charge and shall be representative of the whole of concrete
concerned. In no case, however, shall fewer than 3 cores be tested.

16.4.3 Cores shall be prepared and tested as described in IS 516. Concrete in the
member represented by a core test shall be considered acceptable if the
average of the results of crushing strength tests of the cores shall not be
less than 0.8x0.85 times the corresponding Characteristic compressive strength
of cubes and no individual core has a strength less than 0.8x0.75 times the
corresponding Characteristic compressive strength of cubes where height to

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diameter ratio of the core is 2. Where height to diameter ratio of

the core is not 2 necessary corrections shall be made in calculating
crushing strength of cubes as per clause 12.21.1 of IRC:15-2017.

Sample calculation for required core strength is placed below for core cut
with height to diameter ratio of core is 2:

Flexural strength fcr = K

fcr = 4 . 1 MPa

4.1 = K

K - value as derived in clause 4.5

fck = 16.81/K2

Average core strength required = 0.8x0.85x fck MPa

Individual core strength required = 0.8x0.75x fck MPa

16.4.4 If however, the tests on cores also confirm that the concrete is not
satisfying the strength requirements, then the concrete corresponding to the
area from which the cores were cut should be replaced, i.e., over an
area extending between two transverse joints where the defects could
be isolated or over larger area as decided by the Engineer-in-Charge.

16.4.5 All defective and sub-standard work which includes concrete slab of
sub-standard strength as established in above para shall be liable to rejection
and shall be replaced by the contractor at his expense. Acceptance
criteria for cracked concrete slabs shall be as follows (ref. clause 12.33 of IRC-
15-2017):

i) Fine crazy cracks (Plastic shrinkage cracks) with cumulative length of 3000
mm in a slab can be accepted after repair as per IRC:SP-83. Beyond
cumulative length of 3000 mm, it shall be rejected.
ii) Slabs with cracks running transversely or longitudinally penetrating to full
depth and length of the slab are to be rejected.
iii) Slabs with any type of cracks which are penetrating to more than half the
depth shall be rejected. (ref. clause 12.33 of IRC-15-2017).
iv) When due to operational or any other reason, such replacement does
not become possible (decision of Engineer-in-charge in this respect

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being final and binding on the contractor), the cost of removal and
replacement of such rejected work shall be recovered from
the contractor whether such rejected work is subsequently replaced by
the Deptt. or not.

17.0 WEATHER LIMITATIONS

17.1 Concreting during rains: To prevent damage to freshly laid concrete during
monsoon, or sudden rains, the Contractor shall provide an adequate
supply of tarpaulins or other water-proof material. Any concrete
damaged by rain shall be removed and replaced by the Contractor at
his own cost as directed by the Engineer-in-Charge. If need be, necessary
provisions shall be made to support the water- proof material clear of
the newly-laid concrete surface to prevent smoothening or any damage due to
the contact with tarpaulin. The whole unit should be weighted down
appropriately to prevent from blown off by winds. The rate quoted shall include
all these.

17.2 Concreting in hot weather: No concreting shall be done when the concrete
temperature is above 30°C. Besides, in adverse conditions like high
temperature, low relative humidity, excessive wind velocity, imminence
of rains etc. if so desired by the Engineer-in-charge, tents on mobile trusses
may be provided over the freshly laid concrete for a minimum period of
3 hours as directed by the Engineer-in-charge. The temperature of the concrete
mix on reaching the paving site shall not be more than 30°C. To bring down
the temperature, if necessary, chilled water or ice flakes should be made use
of. No extra payment shall be made for this arrangement.

17.3 Concreting in cold weather: No concreting shall be done when the

concrete temperature is below 5°C.

18.0 MEASUREMENTS

18.1 For the purpose of ascertaining the quantity of concrete in the

pavement length, breadth and thickness shall be measured as detailed below:
a) Length
i) Between the end of a pavement to the center line
of the construction / expansion joints.
ii) Between the center lines of consecutive construction/
expansion joints.
b) Width
i) Between the edge of a pavement and the center line
of the construction joints.
ii) Between the center lines of construction joints and expansion joints.

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iii) Between the center lines of construction joints and expansion joints.
iv) Between the center lines of consecutive construction joints.

c) Thickness
Levels shall be taken before and after construction, at the grid of points 5
metre centre-to-centre longitudinally in straight reaches for each panel
and 2.5 metre centre-to-centre at curves. The shall also be taken
transversely, at 0.75 metre from either edge of the and the remaining
locations shall be at equi-distance but not more than 2 metre in the
balance portion of panel. The average thickness of the pavement course
in any panel shall be the arithmetic mean of the difference of levels before
and after construction at all the grid points falling in that panel, provided
that the thickness of finished work shall be limited to those shown on the
drawings or approved by the Engineer-In- Charge in writing. As
supplement to level measurements, the Engineer shall have the option to
take cores/ make holes to check the depth of construction. The holes
made and the portions cut for taking cores shall be made good by the
Contractor by laying fresh mix/material including compacting as required
at his-own cost immediately after the measurements are recorded.

The finished concrete courses to be paid on volume basis by multiplying

length , breadth and thickness as measured above and its volume shall
be calculated in Cubic metres correct to two places of decimal.
Measurements of concrete slabs shall be recorded in aforesaid
manner jointly by the Engineer-in-Charge or his authorized subordinate
and the Contractor or his authorized agent.

19.0 RATE

19.1 The rate of the item for concrete in pavement shall include the cost of all
materials and labour including charges for machinery tools & plants, making
profile including taking levels including all cartages and lift required in all
the operations described above complete in all respects for a successful
completion of the job. The rate also includes cost of mix design from outside
laboratory, trial mix, all costs of setting up of laboratory at site and carrying out
the quality control measures/tests enumerated above by the Contractor at
his own cost in the presence of Engineer-in-Charge or his authorized
representative, and submission of test results on completion of tests to the
Engineer-in-Charge thereof.

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APPENDIX-A

EXPANSION JOINT

CONTRACTION /DUMMYJOINT

CONSTRUCTION JOINT

DETAILS OF FILLING OF JOINTS IN RIGID PAVEMENTS

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APPENDIX-B
List of minimum equipment to be provided in the field testing
laboratory by the contractor at his own cost.

1. Sieve analysis for combined grading of aggregates

Sets of I.S. Sieves of sizes 63mm, 45mm, 22.4mm, 11.2mm, 5.6mm,
2.8 mm, 1.4 mm, 710 micron, 355 micron and 180 micron.

2. Sieve analysis for coarse aggregates

Sets of I.S. Sieves of sizes 63mm, 40mm, 20mm, 12.5mm, 10mm,
4.75mm, 2.36mm.

3. Sieve analysis of fine aggregate

Sets of I.S. Sieves of sizes 10mm, 4.75mm, 600 micron, 300
micron and 150 micron
4. Silt content of sand
Graduated glass cylinders 500 C.C. capacity.

5. Bulkage of sand
a) Graduated glass cylinders 250 C.C. capacity
b) Graduated glass cylinders 500 C.C. capacity

6. Slump test
a) Slump cones
b) Slump rods 3/8" dia. 24" long bullet pointed.
c) Steel plates 24" x 24"
d) Steel scales

7. For making beam specimens for flexural strength

a) Beam moulds size 70x15x15cm (minimum 18 nos.)
b) Cube moulds size 15x15x15cm (minimum 18 nos.)
c) Tamping rods.
d) Table vibrator (size 1m x 1m)

8. Testing flexural strength of concrete:

100 tonne capacity equipment for compressive strength and 5-10
tonne equipment for flexural strength testing electrically operated.

9. Other miscellaneous items

a) Electronic weighing scale of different capacity
b) Glass measuring jar
c) Beakers
d) Towels, glass plates etc.
e) Apparatus for testing flakiness index, Impact value and Los Angeles
Abrasion value of coarse aggregates.

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Item: Providing and laying Pavement Quality Concrete (PQC) produced in a batching
and mixing plant having a Characteristic flexural strength i.e. flexural strength of 4.1
MPa at 28 days using Combination of 260 Kg of OPC 43/53 grade and 100 Kg of Ground
Granulated Blast Furnace Slag (GGBS), conforming as per relevant IS codes, to be
mixed at site, with 0.5% Super plasticizer by mass of cementitious material, fine
aggregate, graded stone aggregates of 40 mm nominal size in appropriate proportion as
per specification and job mix formula, laid in panels as per drawings/design as approved
by the Engineer-In-Charge using Slip Form Paver or Fixed form paver including anti
friction layer, joint filler board, making necessary provision for expansion, dummy and
construction joint including filling with Polysulphide sealant of approved make, curing
and making profile, complete as per direction of Engineer-in-Charge and specifications.
The item for execution shall include all operations making pavement for intended use
but not limited to following:

(vi) Polyethylene sheet (White in color) of thickness 400 micron conforming to IS: 2508
with 6mm thick fine sand layer.
(vii) Providing and laying in position for expansion joint, 25mm thick pre-cut Synthetic
joint filler board of approved make conforming to IS:1838(part 3)-2011, 45 mm
from top (to be removed at the time of filling of Polysulphide sealant).
(viii) Mechanically cutting dummy joints 3mm wide x 1/3rd thickness of slab which is
subsequently widened to 10mm for the top 25mm depth and construction joints
10mm wide x 25mm deep as per specification.
(ix) Providing and laying in position Polysulphide sealant of approved make conforming
to BS-5212-1990 or IS: 11433-1995 in expansion/ construction / dummy joints
including rounding off edges, applying 2 coats of approved primer compatible with
the brand of Polysulphide and preparing the surface and applying masking tape
along the edge of joint to prevent accidental spillage of sealant on top surface and
to give neat finish to the sealant and removing the masking tape after application
of sealant etc. as per the details below:

(d) Expansion Joints of size 25 mm wide and 10 mm deep over 30mm dia expanded
closed-cell Polyethylene foam back-up/backer rod of minimum density 22
Kg/Cum, as per manufacturer’s specifications and sketch at Appendix-‘A’.
(e) Construction Joints of size 10 mm wide and 10 mm deep over 12mm dia
expanded closed-cell Polyethylene foam back-up/backer rod of minimum
density 22 Kg/Cum, as per manufacturer’s specifications and sketch at
Appendix-‘A’.

(f) Dummy Joints of size 10 mm wide and 10 mm deep over 12 mm dia expanded
closed-cell Polyethylene foam back-up/backer rod of minimum density 22
Kg/Cum, as per manufacturer’s specifications and sketch at Appendix-‘A’.
(x) Making profile as per DGCA CAR, panel drawing showing dummy, construction,
expansion joints location.
Note:
(j) Areas inaccessible to paving equipment shall be constructed by manual/hand guided

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method. Areas in which manual/hand guided methods of construction become

indispensable shall be got approved by the Engineer-in-Charge in writing in advance.

(ii) The quantity of cement, GGBS and super plasticizer for one Cum. of finished
concrete specified are for tendering purpose only. The contractor shall quote his
rates assuming quantity 260 Kg of OPC 43/53 grade and 100 Kg of Ground
Granulated Blast Furnace Slag (GGBS). In addition, if the actual quantity of cement,
GGBS & super plasticizer required as per laboratory mix design varies from the
quantity assumed above, necessary cost adjustment for deviation in the quantity
of cement, GGBS and super plasticizer as per mix design, if any, shall be done as
per the rate of cement, GGBS and super plasticizer in actual supply voucher from
manufacturer/authorized dealer at the time of execution. In the case of authorized
distributor, the rate may be authenticated by the manufacturer. The rate of
cement, GGBS and super plasticizer exclusive of GST shall only be considered for
payment.

1.0 MATERIALS

1.1 CEMENT & GGBS

Ordinary Portland cement 43/53 grade conforming to IS: 269-2015 mixed at

site with Ground Granulated Blast-Furnace Slag conforming to IS 16714:2018
(70% cement and 30% GGBS). Minimum cement content shall be 250 Kg/cum.

When Ordinary Portland cement 53 grade is used, following extra precautions

shall be taken:
(v) The temperature of aggregate, water and cement should be
maintained at the lowest practical levels, so that temperature of
concrete is below 300 C at the time of placement.
(vi) Aggressive curing of concrete to avoid cracking shall be done keeping
surface continuously wet by providing wet hessian cloth etc, before
continuous curing i.e. after 24 hours of laying.
(vii) Use of 53 grades OPC shall be avoided in case of hot weather
concreting.
Note:
iii) Agency should submit copies of purchase voucher to the Engineer-in-
Charge and original to be produced for verification.

1.5.1 Supply of Cement shall be obtained either in bulk form or as per clause
3.1.2.5 of CPWD specifications Vol-I, 2009. Tests on cement shall be done
as per clause 16.1 under quality control and nothing extra shall be paid on
this account.

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1.5.2 SUPER PLASTICIZER

Super Plasticizer conforming to IS: 9103 may be used to improve the

workability of concrete.

1.6 WATER

Water for mixing and curing concrete will ordinarily be obtained from a source
which is used for drinking. Where water from such a source is not available,
the contractor shall ensure that it is clean and free from injurious quantities
of acid, alkalies, salts, alcohol, silt, oil, organic matter etc. and conforms
to IS: 456 (latest revision). In order to ensure that the water does not contain
impurities in injurious proportions, the contractor shall get the water tested in
one of the approved testing laboratories at his own expense. Nothing extra
shall be paid on this account. In such cases, the provisions laid down in clause
5.4 of IS: 456 (latest revision) shall be binding. Test on water should be
repeated whenever there is change in the source.

1.3 COARSE AGGREGATES

These shall be natural materials conforming to IS: 383(latest revision) but

with Los Angeles Abrasion value not more than 30 per cent. These shall
be crushed or broken from hard stones obtained from approved quarry.
These shall be clean, strong, durable of fairly cubical shape and free from
soft, f r i a b l e , thin e l o n g a t e d and l a m i n a t e d / disintegrated pieces.
These shall also be free from dirt, organic, deleterious and any other foreign
matter and adherent coatings and shall satisfy the physical requirement laid
down in clause 16.1 under quality control. Nothing extra shall be paid for
testing of material. Manufactured aggregate shall also be allowed subject to
meeting the requirement of IS 383.

1.3.1 Some aggregates may contain ferrous sulfides and iron oxides which can cause
stains on exposed concrete surfaces. In areas where staining has been a problem
or is suspected, the Engineer should verify that producers and aggregate suppliers
have taken steps to prevent the inclusion of any ferrous sulfides or iron oxides in
aggregate to be used in the project.

If there is a concern that these may exist, an indicator to identify staining

particles is to immerse the aggregate in a lime slurry. If staining particles are
present, a blue-green gelatinous precipitate will form within 5 to 10 minutes,
rapidly changing to a brown color on exposure to air and light. The reaction
should be complete in 30 minutes. If no brown gelatinous precipitate forms,
there is little chance of reaction in concrete.

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1.4 FINE AGGREGATE

The fine aggregate shall be coarse sand consisting of clean natural sand or crushed
stone sand or a combination of the two and shall conform to IS: 383 and clause
3.3.4 of IRC 15-2017 and shall satisfy the physical requirement laid down in
clause 16.1 under quality control. Nothing extra shall be paid for testing of
material. Fine aggregate shall be free from soft particles, clay, shale, loam,
cemented particles, mica, organic and other foreign matter. Manufactured fine
aggregate shall also be allowed subject to meeting the requirement of IS 383.

1.5 COMBINED GRADING OF AGGREGATES

The grading of all aggregates (coarse and fine aggregates) to be used on specific
job shall be determined in the material testing laboratory (approved by AAI/Govt.
Institutions i.e., IITs, NITs, Govt. Engg. Colleges) or in-house by Department
of Structure as directed by the Engineer-In-Charge. The coarse and fine
aggregates shall be mixed in suitable proportions so that the grading of
the mixed aggregates shall be in the range indicated in the table below:

I.S. Sieve Size %age passing by weight

45 mm 100
22.4 mm 55-60
11.2 mm 45-50
5.6 mm 35-40
2.8 mm 30-35
1.4 mm 20-25
710 micron 15-20
355 micron 8 -14
180 micron 0-5

If the combined aggregate grading calculated thereof does not meet the specified
grading requirements, appropriate adjustment shall be made in the proportions of
different aggregate fractions. Any deviation to the overall grading shall be
made only with the specific approval of Engineer-In-Charge and nothing
extra shall be paid for such adjustment. Design of mix shall be redone if there
is a change in the source of coarse or fine aggregates or type of cement as
per Para 1.1. Nothing extra shall be paid for such testing and designing.

1.6 Ground Granulated Blast furnace Slag (GGBS)

1.6.1 GGBS shall be manufactured by drying and grinding of granulated blast furnace
slag. It may contain not more than 1.0 percent of additives not found harmful,
for the purpose of improving its surface characteristics. GGBS from JSW/Tata
Steel Ltd/Ultratech shall only be permitted to use subject to the meetings the
requirements as given in IS 16714: 2018

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1.6.2 Chemical, Physical requirements and Glass Content shall comply with the
requirements as given in IS 16714: 2018 ‘Ground Granulated Blast Furnace Slag
for Use in Cement, Mortar and Concrete — Specification’.

1.6.3 PACKING

1.6.3.1 The GGBS shall be packed in any of the following bags:

a) Jute sacking bag conforming to IS 2580,

b) Multi-wall paper sacks conforming to IS 11761
c) HDPE/PP woven sacks conforming to IS 11652, or
d) Any other approved composite bag.

1.6.3.2 It may also be supplied in drums or in bulk.

1.6.3.3 In case of supply in bags or bulk form, each consignment shall carry test
certificate. GGBS supplier shall submit test certificate of each batch. The
information provided in the test certificate shall comply with this standard and
it shall cover all the requirements of IS 16714 : 2018 ‘Ground Granulated Blast
Furnace Slag for Use in Cement, Mortar and Concrete — Specification’.

1.6.4 MARKING

1.6.4.1 Each bag/drum of GGBS shall be legibly and indelibly marked with the
following:
a) Manufacturer’s name and his registered trademark;
b) The words ‘Ground Granulated Blast Furnace Slag’;
c) Net quantity, in kg;
d) The words ‘Use no Hooks’ on the bags;
e) Batch/control unit number in terms of week, month and year of packing;
and
f) Address of the manufacturer.

1.6.4.2 Similar information shall be provided in the delivery advices accompanying the
shipment of GGBS in bulk form.

1.6.5 BIS Certification Marking

The GGBS may also be marked with the Standard Mark.

1.6.6 SAMPLING

1.6.6.1 The methods and procedure of sampling shall be in accordance with 5.1 to 5.7
of IS 3535. (NOTE - For the purpose of sampling, wherever reference to cement
has been made in IS 3535, it may be read as GGBS).

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1.6.6.2 The samples shall be taken within three weeks of the delivery and all the tests
shall be commenced within one week of sampling.

1.6.6.3 When it is not possible to test the samples within one week, the samples shall
be packed and stored in air-tight containers till such time that they are tested
not later than three months.

1.6.8 CRITERIA FOR CONFORMITY

GGBS sample drawn in accordance with 1.6.6 shall be tested and shall comply
with all requirements of IS 16714 : 2018.

1.6.9 TESTS
The sample or samples of GGBS for tests shall be taken as 1.6.6 and shall be
tested in the manner prescribed in the relevant clauses of IS 16714 : 2018
‘Ground Granulated Blast Furnace Slag for Use in Cement, Mortar and Concrete
— Specification’.

1.7 ANTI-FRICTION LAYER

1.7.1 Anti-friction layer shall be provided between the concrete slab and the DRLC
surface. Before placing the anti-friction layer, the sub-base shall be swept clean
of all the extraneous materials and a layer of 6mm fine sand shall be laid. On
sand layer, polyethylene sheet (white in colour) of thickness 400 micron
conforming to IS: 2508, with overlaps of not less than 300mm longitudinally
and 300mm transversely shall be laid. Any damage sheeting shall be replaced
at the contractor’s expenses. The anti-friction layer shall be nailed to the lower
layer with concrete nails.

1.7.2 COMPOSITION

1.7.2.1 Natural Compound

1.7.2.1.1 The compound used for manufacturing natural film shall consist only of
polyethylene resins complying with 1.7.2.1.2. Any additives, such as anti-
oxidants, to impart additional qualities to the films, such as slip, may be
added in quantity to the resins, as agreed to between the supplier and the
purchaser.

1.7.2.1.2 The polymers for the natural film shall have a melt flow index between 0.10
to 15.0 g/10 min. The density for the compound from which the film is made
shall be between 0.913 to 0.923 g/ml at 27°C (0.915 to 0.925 g/ml at
23°C ).

1.7.3 Appearance - The film shall be uniform in colour, texture and finish. The
material shall be substantially free from pin-holes and undispersed raw

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materials, streaks and particles of foreign matter. There shall be no other visible
defects, such as holes, tears or blisters. The edges shall be free from nicks and
cuts visible to unaided eye. The natural films shall be free from pin-holes.

1.7.4 Odour - The film shall be free from any objectionable odour.

1.7.5 Density - The density of the film, when determined in accordance with A-l of IS
2508 or Method 5 of IS: 8543 (Part l/Set 2)-1979 shall be as prescribed in
1.7.2.1.2. However, in case of dispute, the latter shall be the preferred method.

1.7.6 Melt Flow Index The melt flow index of the film when determined in
accordance with 7 of IS: 2530-19637 shall be as prescribed in 1.7.2.1.2.

1.7.7 Tensile Strength at Break - The tensile strength at break when tested as
prescribed in A-4 of IS 2508 for all thicknesses of polyethylene film shall be not
less than 11.77 MN/m2 ( 120 kgf/ cm2 ) in lengthwise direction and 8.33 MN/m2
( 25 kgf /cm2 ) in crosswise direction.

2.0 HANDLING AND STORAGE OF MATERIALS

2.1 CEMENT

The Contractor shall provide adequate storage facilities to prevent deterioration

of cement during storage due to climate and other causes. Wherever bulk
storage containers are used, their capacity should be sufficient to cater to the
requirement at site. The containers shall be cleaned at least once every 3
months. Cement remaining in stores for more than one and half month from
the date of manufacture must be retested before use and to be rejected, if it
fails to conform to any of the requirements of the specifications.

2.2 GGBS

GGBS shall be stored in silos protected from entry of moisture and free from
dampness to minimize internal condensation. GGBS packed in bags shall be kept
away from ground contact to avoid damage.

2.3 AGGREGATES

a) Stock piles shall be made immediately on receipt of aggregates at

site of work. Aggregates shall be stacked separately according to the
nominal sizes of coarse aggregates. For fine aggregates, separate stacks
shall be made.

b) Aggregates shall be stacked on a hard surface so as to exclude the

possibility of soil or grass being mixed up. When stacked in close
proximity, the stock piles shall be separated by bulk heads to prevent the

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different sizes of aggregates from mixing together. Special care shall be

taken to clean and wash the last layer of aggregates in contact
with ground surface before use.

c) Before batching, the aggregates shall have been stock piled for at
least 24 hours to allow for draining of water, if any. The Contractor shall
make adequate provision for stock piling aggregates to the extent
sufficient to meet the needs of the work taking into account the
availability of supplies and rates of delivery etc. and nothing extra
shall be paid for necessary double handling and transport of materials
from stock piles to mixing plant etc.

d) Grading of coarse and fine aggregate shall be checked as per clause 16.1
under quality control to ensure that the suppliers are maintaining
the uniform grading as approved for samples used in the mix design.

3.0 MIX DESIGN

3.1 The concrete mix shall be got designed by the Contractor in the material testing
laboratory (approved by AAI/Govt. institutions i.e., IITs, NITs, Govt. Engg.
Colleges) or in-house by Department of Structure as directed by the Engineer-In-
Charge so as to obtain the target average flexural strength. The margin
over characteristic strength is as below:

Characteristic flexural strength (beam) at 28 days, (fcr) = 4.1 MPa

Normal variate for the desired confidence level, (Z) = 1.65
Assumed value of Standard Deviation, (s) = 0.4 MPa
Target average flexural strength at 28 days, f’cr = fcr + 1.65 x s
f’cr = 4.1 + 1.65 x 0.4
= 4.76 MPa
Say, 4.8 MPa
Water cementatious ratio by weight = 0.45 (Maximum)

Slump = 25 ± 15 mm for slip/fixed form paver

= 40 ± 10 mm for manual method

Any change in the source of materials or mix proportions including change of

brand of cement proposed by the Contractor during the course of work shall be
assessed by making laboratory trial mixes and same shall be incorporated in
work with written approval of concerned Engineer-In-Charge.

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In case services of Department of Structure, AAI is utilized for mix design and
other testing if any, contractor shall be charged extra as per prevalent charges
and same shall be deducted from contractor bills. Contractor quoted rates shall
be deemed to be inclusive of same and nothing extra shall be payable.

3.2 The quantity of cement, type of cement, GGBS and super plasticizer for one
Cum. of finished concrete specified in the item are for tendering purpose only.
Necessary cost adjustment shall be done as per formula laid down below:

3.2.1 OPC 43/53 grade of Cement:

If the actual quantity of OPC 43/53 grade of Cement required as per laboratory
mix design varies from 260 Kg/Cum, necessary cost adjustment for deviation in
the quantity of OPC 43/53 grade of Cement shall be done as per the rate of OPC
43/53 grade of Cement in actual supply voucher from manufacturer/authorized
dealer at the time of execution. In the case of authorized dealer the rate may
be authenticated by the manufacturer. The rate of OPC 43/53 grade of Cement
exclusive of GST shall only be considered for payment. In no case quantity of
OPC 43/53 grade shall fall below 250 Kg/cum. Extra payable/deductible rate
shall be calculated in following manner:

Cost of OPC 43/53 grade of Cement above/below 260Kg/Cum : ‘X’

Add 1% Water Charges on ‘X’

Add 15% CP & OH on total adding 1% water charges

Add 1% labour Cess on total after adding 15% CP & OH : Say ‘A’

3.2.1 GGBS:

If the actual quantity of GGBS required as per laboratory mix design varies from
100 Kg/Cum, necessary cost adjustment for deviation in the quantity of GGBS
shall be done as per the rate of GGBS in actual supply voucher from
manufacturer/authorized dealer at the time of execution. In the case of
authorized dealer the rate may be authenticated by the manufacturer. The rate
of GGBS exclusive of GST shall only be considered for payment. In no case
quantity of GGBS shall exceed 30% of total weight of OPC 43/53 grade of
cement and GGBS. Extra payable/deductible rate shall be calculated in following
manner:

Cost of GGBS above/below 100 Kg/Cum : ‘X’

Add 1% Water Charges on ‘X’

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Add 15% CP & OH on total adding 1% water charges

Add 1% labour Cess on total after adding 15% CP & OH : Say ‘A’

The rate of GGBS exclusive of GST shall only be considered for payment.

3.2.4 SUPER PLASTICIZER

If the actual percentage of Super plasticizer by mass of cementitious material

varies from 0.5%, Extra payable/ deductible rate shall be calculated in following
manner:

Extra/ less cost of super plasticizers over or below 0.5% of cementitious material
: ‘X’

Add 1% Water Charges on ‘X’

Add 15% CP & OH on total adding 1% water charges

Add 1% labour Cess on total after adding 15% CP & OH : Say ‘A’

The rate of super plasticizers shall be as per actual supply voucher from
manufacturer/authorized dealer at the time of execution. In the case of
authorized dealer the rate may be authenticated by the manufacturer. The rate
of super plasticizer exclusive of GST shall only be considered for payment.

3.3 At the time of tendering, the Contractor, after taking into account the type
of aggregates, plant and method of laying he intends to use, shall allow in his
tender for aggregate/cement and water cement ratios which he considers will
achieve the specified strength. These ratios shall, however, not exceed the
ratios stipulated in para 3.1 and shall produce a workability, which shall enable
concrete to be properly compacted to its full depth and finished to the surface
tolerance specified.

3.4 No concrete shall be laid nor any payment made thereof unless the concrete
mix design is submitted by the Contractor and is approved by the concerned
Engineer-In-Charge and communicated in writing. This mix design shall be
provisional and subject to obtaining satisfactory results with trial mixes. Final
approval shall be issued only after getting the satisfactory test report from
trial mixes.

3.5 Laboratory charges for mix design, cost of materials, its cartage and other
incidental expenses shall be borne by the Contractor.

3.6 Guidelines for Cement Concrete Mix Design for Pavements can be followed as
per IRC: 44 -2017 and SP: 23-1982.

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4.0 FIELD TRIAL MIXES

4.1 Preliminary trial mixes shall be made and tested. Trial mixes shall also be made if
a change is intended subsequently in the source of supply of materials/quality of
materials or in the proportions of the materials to be used.

4.2 Samples of concrete shall be taken at the concrete batching plant and work
beams made, cured and tested in accordance with IS: 1199 and IS: 516, as
per clause 4.3 given below.

4.3 Representative samples of materials to be used shall be taken and trial mix using
the proposed proportions shall be made, two samples each on three different days.
Each sample shall consist of 6 beam specimens, three for testing at 7 days
and three at 28 days and a total of 36 beams shall be made in three days. The
workability of each of these six trial mixes shall be determined. The test strength
of the sample shall be the average strength of 3 specimens but individual variation
should not be more than +15%. Otherwise, new trial mix corresponding to the
initially approved sample will have to be made. The proposed mix proportion
shall not be accepted if the average of 28 days beam strength of 6 trial mixes is
not satisfying the provisions as per para 16.4.1. The mix shall be suitably modified
if the strength do not meet the criteria as specified.

4.4 The mix design shall be got approved from concerned Engineer-In-Charge. The
design mix, thus approved shall be intimated to the Contractor by the Engineer-
in-Charge with full data and clear understanding that the mix proportion specified
is provisional subject to the verification of level of control at the site.

4.5 30 beams and 30 cubes shall be cast for deriving the relationship between flexural
strength and compressive strength i.e. K-value, by the Engineer-In-Charge and the
same shall be got approved from concerned General Manager Engg (Project)/work.
This K-value shall be used for calculation of required core strength in clause 16.4.3.

4.6 During the progress of work, samples of concrete shall be taken at the concrete
batching plant and work beams made, cured and tested in accordance with IS:
1199 and IS: 516. Acceptance criteria for this shall be as per para 16.4.1.

4.7 All samples for tests shall be taken in the presence of the Engineer-in- charge and
the contractor or their authorized representatives.

5.0 SLUMP TEST

5.1 Slump tests shall be carried out as per IS: 1199 (latest revision). A slump test
shall be carried out as per clause 16.1 under quality control or more and
frequently, if directed by the Engineer-in-Charge. Any batch from which slump test
is being made shall not be transferred to the place of laying till the slump test has

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been completed and result approved. Not only the batch which gives a slump in
excess of that specified shall be rejected but the concrete already laid immediately
preceding the batch tested up to the nearest last transverse joint may be
rejected by the Engineer-in- Charge or his representative, if he is satisfied
that such preceding batches were sub-standard in this respect. The decision of
the Engineer- in-Charge in this respect shall be final and binding on the
contractor. Such rejected concrete shall be removed by the Contractor
immediately and replaced with proper concrete at his own cost and expense.

6.0 BATCHING AND MIXING OF CONCRETE

6.1 A system approach should be adopted for construction of pavement, and the
method statement for carrying out the work, detailing all the activities
including indication of time cycle, equipment, personnel etc. shall be got
approved from the Engineer-in-Charge before the commencement of work. The
above shall include the type, capacity and make of batching and mixing plant
beside the hauling arrangement and paving equipment. The capacity of paving
equipment, batching plant as well as all the ancillary equipment shall be adequate
for a paving requirement for day’s work.

6.2 Batching and mixing of the concrete shall be done at a central batching and mixing
plant of adequate capacity as per work program with automatic controls, located
at suitable place which takes into account sufficient space for stock piling of
cement, aggregate and stationary water tanks. This shall be however, situated
at an approved distance, duly considering the properties of the mix and transport
arrangements available with the contractor.

6.3 Proportioning of a material shall be done in the batching plant by weight,

each type of material being weighed separately. The cement from the bulk
stock may be weighed separately from the aggregates and water shall be
measured by volume. Wherever properly graded aggregate of uniform
quality cannot be maintained as envisaged in the mix design the grading of
aggregates shall be controlled by appropriate blending techniques. The capacity
of batching and mixing plant shall be at-least 25% higher than the proposed
capacity for the laying/ paving equipment.

6.4 The batching plant shall include preferably four bins, weighing hoppers, and
scales for the fine aggregate and for each size of coarse aggregate. If cement is
used in bulk (after opening bags on platform) a separate scale for cement
shall be included. The weighing hoppers shall be properly sealed and vented to
preclude dust during operation. Approved safety devices shall be provided and
maintained for the protection of all personnel engaged in plant operation,
inspection and testing. The batch plant shall be equipped with a suitable non
resettable batch counter which will correctly indicate the number of batches
proportioned.

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6.5 Bins preferably with four adequate separate compartments shall be provided in
the batching plant.

6.6 Batching plant shall be equipped to proportion aggregates and bulk cement by
means of automatic weighing devices using load cells. The weighing device shall
have an accuracy within + 1% in respect of quantity of cement and water
and + 2% in respect of aggregates and accuracy shall be checked at least once a
month.

6.7 Mixers shall be pan type, reversible type with single or twin shaft or any other
mixer capable of combing the aggregates, cement and water into a thoroughly
mixed and uniform mass within the specified mixing period and of discharging the
mix without segregation. Each stationary mixer shall be equipped with an
approved timing device which will automatically lock the discharge lever when
the drum has been charged and release it at the end of the mixing period.
The device shall be equipped with a bell or other suitable warning device adjusted
to give a clearly audible signal each time the lock is released. In case of failure of
the timing device the mixer may be used for the balance of the day while
it is being repaired provided that each batch is mixed for 90 seconds or as
per the manufacturer’s recommendation. The mixer shall be equipped with a
suitable non resettable batch counter which shall correctly indicate the number
of batches mixed.

6.8 The mixer shall be cleaned at suitable intervals. The pickup and throw over blades
in the drum or drums shall be repaired or replaced when they are worn down
20mm or more. The contractor shall have available at the job site a copy of the
manufacturers design, showing dimensions and arrangements of blades in
reference to original height and depth or provide permanent marks on blade to
show points of 20mm wear from new conditions. Drilled holes of 5mm diameter
near each end and at mid-point of each blade are recommended. Batching plant
shall be calibrated for the each ingredients upto its maximum quantity being
used in the mix at site in the beginning and thereafter at suitable interval
not exceeding one month.

6.9 Air-conditioned centralized computer control cabin shall be provided for automatic
operation of the equipment.

6.10 The design feature of the batching plant should be such that it can be shifted
quickly.

6.11 Concrete mixed as above is not to be modified by the addition of water or

otherwise in order to facilitate handling or for any other purpose.

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7.0 PAVING EQUIPMENT

7.1 The concrete shall be placed with Slip Form Paver/Fixed form paver (with
independent units to spread, consolidate from the mould, screed and float-finish,
texture and cure) or Manual method as per the item/as approved by Engineer-in-
Charge. If the concrete is to be laid by slip form paver, the paver shall be equipped
with electronic controls to control the line and grade from either one side or both
sides of the machine.

7.2 Vibrators shall operate at a frequency and spacing recommended by the

manufacturer. The variable vibration setting shall be provided in the machine.

7.3 The contractor shall provide adequate no. of concrete saws with
sufficient no. Of diamond edge saw blades. The saw machine shall be either
electric or petrol/ diesel driven type. A water tank with flexible hose and pump
shall be made available for this activity on priority basis. The contractor shall have
at least one standby saw in good working condition. The concreting work shall not
commence if the saws are not in working condition.

7.4 Guide wires for Slip form Paver

7.4.1 Guide wire shall be provided along both sides of the slab. Each guide wire shall
be at a constant height above and parallel to the required edge of the slab
as described in the contract/drawing within a vertical tolerance of + 2 mm.
Additionally, one of the wires shall be kept at a constant horizontal distance from
the required edge of the pavement as indicated in the contract /drawing with
in a lateral tolerance of +10mm.
7.4.2 The guide wires shall be supported on stakes 5-6 meters apart by connectors
capable of fine horizontal and vertical adjustment. The guide wire shall be
tensioned on the stakes so that a 500 grams weight shall produce a deflection or
not more than 20mm when suspended at the midpoint between any pair of stakes.
The ends of guide wire shall be anchored to fixing point or winch and not on the
stakes.

7.4.3 The stakes shall be positioned and the connectors maintained at their correct
height and alignment 12 hrs. on the day before concreting takes place until 12
hrs. after finishing of the concrete. The guide wires shall be checked and tensioned
on the connectors at any section at least 2 hrs. before concreting that section.

7.4.4 The contractor shall submit to the Engineer-In-Charge for his approval of line and
level, the stakes and connectors which are ready for use in the length of pavement
to be constructed next day. Such approval shall be obtained at least 12 hrs.
before commencement of paving operation. Any deficiencies noted by the
Engineer-in-Charge shall be rectified by the contractor who shall then
reapply for approval of the affected stakes. Work shall not proceed until the

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Engineer-in-Charge has given his approval. It shall be ensured the stakes and
guide wires are not affected by the construction equipment when concreting is
in progress.

7.6 Side Forms and Rails for Fixed form paver

7.6.1 All side forms shall be of mild steel channels of depth equal to the thickness
of pavement or slightly less to accommodate the surface irregularity of the
sub base. The forms can be placed in series of steel packing plates or shims to
take care of irregularity of sub base. They shall be sufficiently robust and rigid
to support the weight and pressure caused by a paving equipment.

7.6.2 Side forms for use with wheeled paving machines shall incorporate metal rails
firmly fixed at a constant height below the top of the forms. The forms and rail
shall be firmly secured in position by not less than 3 stakes/pins for every 3
meter length so as to prevent movement in any direction. Forms and rails shall
be straight within a tolerance of 3 mm in 3 meter and when in place shall not
settle in excess of 1.5 mm in 3 meter while paving is being done. Forms shall
be cleaned and oiled immediately before each use.

7.6.3 The forms shall be bedded on a continuous bed of low moisture content lean
cement mortar or concrete and set to the line and levels shown on the
drawings within tolerances of + 10 mm and + 2 mm respectively. The bedding
shall not extend under the slab and there shall be no vertical step between
adjacent forms of more than 2 mm. The forms shall be got inspected by the
Engineer-in-Charge for his approval 12 hrs. before construction of the slab and
shall not be removed until at least 12 hrs. Afterwards. No concreting shall
commence till form work has been approved by the Engineer-in-Charge.

7.6.4 At all times sufficient forms shall be used and set to the required alignment for
required length of pavement immediately in advance of the paving operations,
or the anticipated length of pavement to be laid within the next 24 hrs.

7.6.5 Forms shall be fixed in advance as per specifications. Before any paving is done
the site shall be shown to the Engineer-in-Charge in order to verify the
arrangement for paving as per the relevant clauses of this specification. The
mixing and placing of concrete shall progress only at such a rate as to permit
proper finishing, protecting and curing of the pavement.

7.6 Steel Forms for Manual Method

7.6.1 Manual method may be adopted where execution with slip form paver is not
feasible. All side forms shall be of mild steel. The steel forms shall be of mild
steel sturdy channels sections and their depth shall be equal to the thickness
of the pavement.

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7.5.2 The side forms shall have a length of at least 3.0 meters except on curves
of less than 45 meters radius where shorter length may be used. When set to
grade and stacked in place the maximum deviation of the top surface of any
section from a straight line shall not exceed 2 mm in the vertical plane and 5 mm
in the horizontal plane. The method of connection between sections shall be such
that the joint formed shall be free from difference in level, play or movement in
any direction. The use of bent, twisted or worn out forms will not be permitted.
At least three stake pickets for each 3.0 m of form and the bracing and support
must be ample to prevent springing of the forms under the pressure of concrete
or the weight or thrust of machinery operating on the forms.

7.5.3 The supply of forms shall be sufficient to permit their remaining in place for 12
hrs. after the concrete has been placed or longer, if in the opinion of the Engineer–
in-Charge, it is necessary.

7.5.4 The top line of the forms is not to vary from the correct level or alignment
and the levels and alignment of the forms are to be checked and corrected as
necessary immediately prior to the placing of concrete. The top edges and faces
of the forms are to be carefully cleaned and maintained in clean condition.

7.5.5 While removing the steel forms, care shall be taken to withdraw them gradually.
Any damages to the bull nosed edges shall be made good while the concrete
is still green, as directed by the Engineer–in- Charge.

7.5.6 Setting of forms shall be according to the slab plan subject to the approval
of the Engineer-in-Charge and concreting shall not commence until the setting
of forms is approved.

7.5.7 Forms shall be set at least 50 meters length in advance of the point where
the concrete is being laid and shall not be removed until at least 12 hrs. of the
placing of concrete or longer if in the opinion of Engineer- in-Charge, it is
necessary. After setting, the working faces shall be thoroughly oiled using
approved oil but before concrete is placed against them.

7.5.8 Sufficient rigidity shall be obtained to support the forms in such a position
during the entire operation of compaction and finishing that they will not at
any time deviate more than 3 mm from a straight edge 3 meters in length.
Forms which show a variation from the required rigidity or the alignment and levels
shown on the plans, shall be reset or removed, as directed. The length and
number of pins or stakes shall be such as to maintain the forms at the correct line
and grade. All forms shall be cleaned and oiled each time before they are used.

8.0 HAULING AND PLACING OF CONCRETE

8.1 Freshly mixed concrete from the central batching and mixing plant shall be

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transported to the paver site by means of tippers/transit mixers of sufficient

capacity and approved design in sufficient numbers to ensure a constant supply
of concrete. Cover shall be used for protection of concrete against the weather.
While loading the concrete, truck shall be moved back and forth under the
discharge chute to prevent segregation. The tipping trucks shall be capable of
maintaining the mixed concrete in a homogeneous state and discharging the same
without segregation and loss of cement slurry. The feeding to the paver is to be
regulated in such a way that paving is done in an uninterrupted manner with a
uniform speed throughout the day’s work. Tipping truck shall be washed at a
regular frequency as prescribed by the Engineer-in-Charge to ensure that no
leftover mix of previous loading remains stuck.

8.2 Concrete mixed in central mixing plant shall be transported to the site without
delay and the concrete which in the opinion of Engineer-in-Charge, has been
mixed too long before laying will be rejected and shall be removed from the
site. The total time taken from the addition of water to the mix until the
completion of surface finishing and texturing shall not exceed 120 minutes
when concrete temperature is less than 250C and 90 minutes when concrete
temperature is between 250C to 300C. Tippers/transit mixers delivering concrete
shall not run directly on plastic sheet nor shall they run on completed slabs until
after 28 days of placing of concrete.

8.3 In all cases the temperature of the concrete shall be measured at the point of
discharge from the delivery vehicle.

8.4 The addition of water to the surface of the concrete to facilitate the
finishing operations will not be permitted except with the approval of the Engineer-
in-Charge when it shall be applied as a mist by means of approved
equipment.

8.5 If considered necessary by the Engineer-in-Charge, the paving

equipment shall be provided with approved covers to protect the surface of the
slab under construction from direct sunlight and rain or hot wind.

8.6 As soon as the side forms are removed, edges of the slabs shall be
corrected wherever irregularities have occurred by using fine concrete composed
of 1:1:2, cement: sand: coarse aggregate (10 mm down) with water cement
ratio not more than 0.4 under the supervision of Engineer-in-Charge.
8.7 If the requirement for surface regularity fails to be achieved on two consecutive
working days then normal working shall cease until the cause of the excessive
irregularity has been identified and remedied.

8.8 Construction by Slip Form Paver: The slip form paving train shall consist of
power machines which spreads compacts and finishes the concrete in a continuous
operation.

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8.8.1 The slip form paving machine shall compact the concrete by internal vibration
and shape it between the side forms with either a conforming plate or by vibrating
and oscillating finishing beams. The concrete shall be deposited without
segregation in front of slip form paver across the whole width and to a height
which at all times in excess of the required surcharge. The deposited concrete
shall be struck off to the necessary average and differential surcharge by means
of the strike off plate or a screw auger device extending across the whole width
of the slab. The equipment for striking-off the concrete shall be capable of being
rapidly adjusted for changes of the average and differential surcharge necessitated
by change in slab thickness or cross fall.

8.8.2 The level of conforming plate and finishing beam shall be controlled automatically
for the guide wires installed by sensors attached at the four corners of the
slip form paving machine. The alignment of paver shall be controlled
automatically from the guide wire by at least one set of sensors attached to the
paver. The alignment and level of ancillary machines for finishing, texturing and
curing of the concrete shall be automatically controlled relative to the guide wire
or to the surface and edge of an adjoining hardened slab.

8.8.3 Slip form paving machines shall have vibrators of variable output with a maximum
energy output of not less than 2.5 KW per meter width of slab per 300 mm
depth of slab for a laying speed upto 1.5 m per minute or pro-rata for higher
speeds. The machine shall be of sufficient mass to provide adequate reaction
during spreading and paving operations on the traction units to maintain forward
movements during the placing of concrete in all situations.

8.8.4 If the edges of the slip formed slab slump to the extent that the surface of the top
edge of the slab does not comply with the requirements, then special measures
approved by the Engineer-in-Charge shall be taken to support the edges to the
required levels and work shall be stopped until such time as the contractor can
demonstrate his ability to slip form the edges to the required levels. The slumped
edge shall have to be corrected by adding fresh concrete after roughening the
surface.

8.8.5 Upon the instructions of the Engineer-in-Charge, contractor shall scrape the
concrete surface when in plastic state with a 3.0 m long tube float fixed with a
long and stable handle before texturing. Tube float shall be of an alloy steel
tube of 50-60 mm diameter with a long and stable handle. The length of
the tube float shall preferably be longer than half the length of slab i.e., half
the distance between two transverse contractions joints. This operation shall
be done to minimize surface irregularity caused due to varied causes like frequent
stoppage of work, surface deformation due to plastic flow etc. The tube float shall
be placed at the center of the slab parallel to longitudinal joint and pulled slowly
and uniformly towards the edges. After the use of the float tube, it shall be
frequently cleaned before further use. The slurry removed shall be discarded. This

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activity shall be advanced laterally by providing an overlap of half the length of

two float. The removal of the cement slurry from the surface shall be sufficient
enough such that the texture is formed on a firm surface and is more durable.
This operation however, shall be carried out after removing bleeding water.

8.8.6 In the case of construction by slip form paver, areas inaccessible to paving
equipment shall be constructed by manual/hand guided method. Areas in which
manual/hand guided methods of construction become indispensable shall be got
approved by the Engineer-in-Charge in writing in advance. Work shall be carried
out by skilled personnel as per methods approved by the Engineer-in-Charge. For
construction by hand guided method in the limited area, no cost adjustment will
be made.

8.10 Construction by Fixed Form Paver: The fixed form paving train shall consist
of separate powered machines which spread compact and finish the concrete in
a continuous operation. The paving train moves on the rails fixed on both sides
of the pavement and compacting/finishing is simultaneously carried with the
equipment fitted with paving train which moves on the rails.

8.10.1 The concrete shall be discharged without segregation into a hopper of the
spreader which is equipped with means for controlling its rate of deposition on
to the sub-base. The spreader shall be operated to strike off concrete upto a
level requiring a small amount of cutting down by the distributor of the spreader.
The distributor of spreader shall strike of the concrete to the surcharge adequate
to ensure that the vibratory compactor thoroughly compacts the layer. If
necessary poker vibrator shall be used adjacent to the side forms and edges of
the previously constructed slab.

8.10.2 The vibratory compactor shall be set to strike off the surface slightly high so
that it is cut down to the required level by the oscillating beam. The machine
shall be capable of being rapidly adjusted for changes in average and differential
surcharge necessitated by changes in slab thickness or cross fall. The final
finisher shall be capable to finish the surface to the required level and
smoothness as specified, care being taken to avoid bringing up of excessive
mortar to the surface by over working.

8.10.3 In the case of construction by fixed form paver, areas inaccessible to paving
equipment shall be constructed by manual/hand guided method. Areas in which
manual/hand guided methods of construction become indispensable shall be got
approved by the Engineer-in-Charge in writing in advance. Work shall be carried
out by skilled personnel as per methods approved by the Engineer-in-Charge.
For construction by hand guided method in the limited area, no cost adjustment
will be made.

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8.10 SURFACE TEXTURE

8.10.1 Surface of the pavement shall be finished for the newly constructed concrete
pavements such that texturing equipment shall not tear or unduly roughen the
concrete surface during the operation. The texture shall be uniform in appearance
and approximately 2.0mm in depth. Brush shall be applied when the water sheen
has practically disappeared and the surface of concrete shall be brush-textured in
a direction at right angles to the longitudinal axis of the carriageway to get
satisfactory texture.

8.10.2 The texture depth shall be determined by the Sand Patch Test as described
below. This test shall be performed at least once for each day’s paving and
wherever the Engineer-In-Charge consider it necessary at times after construction
as under:

Five individual measurement of the texture depth shall be taken at least

2m apart anywhere along a diagonal line across a lane completed between points
50m apart along the pavement. No measurement shall be taken within 300mm
of the longitudinal edges of a concrete slab constructed in one pass.

8.10.4 Measurement of Texture Depth – Sand Patch Method

The following apparatus shall be used:

v) A cylindrical container of 25 ml internal capacity.

ii) A flat wooden disc 64mm diameter with a hard rubber disc, 1.5mm
thick, stuck to one face, the reverse face being provided with
a handle.

iii) Dry natural sand with a rounded particle shape passing a

300micron IS sieve and retained on a 150 micron IS sieve.

Method: The surface to be measured shall be dried, any extraneous mortar and
loose material removed and the surface swept clean using a wire brush both at
right angles and parallel to the carriageway. The cylindrical container shall be
filled with the sand, tapping the base 3 times to the surface on ensure compaction,
and striking off the sand level with the top of cylinder. The sand shall be poured
into a heap on the surface to be treated. The sand shall be spread over to
surface, working the disc with its face kept flat in a circular motion so that the
sand is spread into a circular patch with the surface depressions filled with
sand to the level of peaks. The diameter of the patch shall be measured to the
nearest 5mm. The texture depth of concrete surface shall be calculated from
31000/(D x D) mm where D is the diameter of patch in mm.

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8.10.5 Texture depth shall not be less than a minimum required when measurement
are taken as given in table nor greater than a maximum average of 1.25 mm.
TABLE : TEXTURE DEPTH

S Time Test Number of Required Texture

No. measurements Depth (mm)

Specified
Tolerance
value

1. Between 24 Hrs. and 7 days after

the construction of the slab or An average of 5
1.00 ±0.25
until the slab is first used by Measurements
vehicles.

2. Not later than 6 weeks before the An average of 5

1.00 ±0.25
road is opened to public traffic. Measurements

8.10.6 After the application of the brushed texture, the surface of the slab shall have a
Uniform appearance.

8.10.7 Where the texture depth requirements are found to be deficient, the Contractor
shall make good the texture across the full lane width over length directed by the
Engineer-in-Charge, by texturing the hardened concrete surface in an approved
manner.

9.0 CONSTRUCTION BY MANUAL/HAND GUIDED METHOD:

The pavement shall be constructed using side forms. The acceptance criteria
regarding level, thickness, surface regularity, texture, finish strength
of concrete and all other quality control measures shall be the same as in
the case of machine laid down.

9.1 Placing of Concrete:

9.1.1 Concrete shall be deposited between the forms. Where a certain amount of
redistribution is necessary, it shall be done with shovels and not with rakes. The
concrete shall be compacted with the needle vibrator and vibrating screeds. Use
of vibrator near side forms is essential to eliminate honey combing. To effect
adequate compaction, the concrete shall be placed with appropriate surcharge
over the final slab thickness. The amount of surcharge will depend upon the
mode of placement of concrete and shall be determined by trial. In general, the
required surcharge is about 20% of the required slab thickness.

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9.1.2 The concrete is to be deposited and spread to such a depth that when compacted
and finished, the slab thickness indicated will be obtained at all points and the
surface will not at any point be below the level specified for the finished
surface.

9.2 Compaction of Concrete

9.2.1 Compaction shall be carried out by electrically operated needle and screed
vibrators as stipulated hereafter. Needle vibrators should be used all over
the area for obtaining initial compaction of concrete. These should be of
diameter not less than 4.5 cm and if the vibrators are pneumatic, the pressure
must not be below 4 kg/sq.cm. If electrically operated, they should have a
minimum frequency of 3500 impulses per minute. Minimum number of petrol
driven vibrators as specified by the Engineer-in-Charge with minimum frequency
of 3500 impulses per minute shall be provided at each work head as a standby
arrangement. The screed and internal vibrator shall conform to I.S.:2505 and
I.S.: 2506 respectively.

9.2.2 There should be at least three needle vibrators working in one bay. A vibrating
screed consisting of a steel or timber section weighing not less than 15 kg per
meter with a tamping edge of not less than 7 cm width and having a vibrator
mounted thereon shall follow needle vibrators to obtain full compaction. The
face of the wooden tamping edge of the screed shall be lined with M.S.
plate rigidly fixed by means of counter sunk screws. Where screed vibrators
are used for compaction, a standby unit shall always be maintained ready for
use, should the other one go out of order. Where electrically driven vibrators are
employed, a stand by pneumatic unit shall be kept ready for use in case of power
failure. At the discretion of the Engineer-in-Charge, for compaction at edges and
joints, vibrators may be supplemented by hand tamping and rodding for securing
satisfactory results. Under no circumstances, honey combing of concrete at joints
or elsewhere shall be permitted.

9.2.3 When using screed vibrator for compaction, it should not be dragged over
the concrete. During the initial passes, it shall be lifted to the adjacent forward
position in the steps. Subsequently, it shall be slowly slided over the surface
with its axis slightly tilted away from the direction of sliding and the
operation repeated until a close, dense surface is obtained.

9.2.4 Work men shall not be allowed to walk on freshly laid concrete. All
operations shall be carried out from suitable wooden bridges spanning the lane-
width.

9.2.5 IMPORTANT PRECAUTION: The vibration process shall be restricted just upto
the stage of appearance of water/ cement slurry on the surface. After
reaching this point vibration should be discontinued. It should be ensured that

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no over-vibration is resorted, as it leads to formation of thin cement slurry

layer over the top surface which tends to peel off with passage of time by
movement of traffic.

9.3 Finishing of Concrete

9.3.1 Immediately after compacting of concrete and the construction of joints but
before the concrete has hardened and while the concrete is still in a plastic state,
the pavement surface shall be inspected for irregularities with a profile
checking template and minor irregularities and score marks shall be eliminated
by removing surplus material or by adding and working in freshly mixed concrete
if necessary by means of long handled floats and scraping straight edges followed
by further compaction and finishing. The long handled floats may be used to
smoothen and fill in open textured area in the pavement surface, but the final
finishing is to be done with scraping straight edges.

9.3.2 The scraping straight edges are to be 3 meters long with flexible handles
long enough to reach the other side of the slab when operated from one side of
the pavement. They are to be placed parallel to the forms at the side of the
pavements and worked backwards and forwards uniformly across the width of the
slab. After this operation has been completed and the surface has been brought
to the required finish, the straight edge is to be moved forward but not more than
half its length and the process repeated.

9.3.3 The straight edge testing and refloating is to continue until the entire surface:

a) is free from observable departure from the straight edge.

b) conforms to the required levels and cross-section.
c) conforms to the specified surface finish when the concrete has
hardened.

9.3.4 The foregoing work is to be carried out while the concrete is still plastic and
workable and in such time sequence so as to ensure the removal of water and
laitance from the surface.

9.4 BELTING

Just b e f o r e t h e c o n c r e t e b e c o m e s n o n -plastic, the s u r f a c e

s h a l l b e belted with two ply canvas belt not less than 20 cm wide and
at least 1 meter longer than the width of the slab. Hand belts shall have
suitable handles to permit controlled uniform manipulation. The belt shall be
operated with short strokes transverse to the center line of pavement and
with a rapid advance parallel to the concrete line.

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9.5 BROOMING

9.5.1 After belting and as soon as surplus water, if any, has risen to the surface,
the pavement shall be given a broom finish with an approved steel or fiber
broom not less than 45 cm wide. The broom shall be pulled gently over
the surface of the pavement from edge to edge. Adjacent strokes shall be
slightly overlapped. Brooming shall be perpendicular to the centre line of the
pavement and so executed that the corrugations formed will be uniform in
character and width and not more than 2.0 mm deep.

9.5.2 Brooming shall be completed before the concrete reaches such a stage that the
surface is likely to be torn or unduly roughened by the operation. The
broomed surface shall be free from porous or rough spots, irregularities,
depressions and small pockets such as may be caused by accidental
disturbing of particle of coarse aggregates embodied near the surface.
The rate of the contractor for the item of quality controlled concrete pavement
includes the provision for belting and brooming operations and nothing
extra shall be paid on this account.

9.6 EDGING

After belting/ brooming has been completed but before the initial setting of
concrete, the edges of the slab shall be carefully finished with an edging
tool of 6 mm radius, and the pavement edges shall be left smooth and
true to line.

9.7 HONEY COMBING

As soon as the side forms are removed, any minor honey combed areas
shall be filled with mortar composed of one part of cement and two
parts of fine aggregate. Major honey combed areas or segregated
concrete or other defective work or areas damaged by removal of the
forms or concrete damaged by rain or due to any other reason
whatsoever shall be considered as defective work and shall be removed and
replaced by the contractor at his own expense. The total area of honey
combed surface not exceeding 2.5 sq.cm. each, shall not exceed 4% of the
area of the slab side. Engineer in charge’s decision as to whether the
concrete is defective or not shall be final and binding.

10.0 SURFACE ACCURACY

10.1 After the concrete has sufficiently hardened after about 12 hours and not
later than 24 hours, the surface shall be tested again for high spots. All high spots
shall be marked and those exceeding 3 mm shall be ground down
immediately as directed by the Engineer-in-Charge after obtaining his written

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permission. Care shall be taken to see that the grinding does not in any way
damage the concrete surface.

10.2 The final surface finish is to be such that when tested with a
profilograph/ roughness indicator/or a 3 meter long straight edge or an equivalent
mechanical unevenness indicator placed anywhere within the same or adjoining
slab in any direction on the surface, there shall be no variation greater than 3mm.

10.3 If the surface irregularities exceeding 3 mm still remains despite

grinding if permitted, as per para 10.1 the concrete shall be removed to its full
depth and replaced. The area of concrete to be removed shall be complete slab
between the nearest joints. Where the defective slab is less than 4.5 meter from
the construction joint, the whole area upto the construction joint shall be removed
to the full depth. The concrete so removed shall not be reused in the work.
Fresh concrete shall be laid in the manner already described in these
specifications and shall again be subjected to test for surface accuracy and
other quality control measures. Nothing extra shall be paid for all these
operations.

10.4 Every slab shall bear an impression not exceeding 3 mm in depth comprising
the number allotted to the slab and the date on which it is laid. This impression
shall be formed by the Contractor when the concrete is green so as to leave
permanent mark on setting.

11.0 CURING OF CONCRETE

Initial curing shall be done by application of curing compound or by

manual method as per clause 16.37.13.5 of CPWD specifications Vol-II, 2009.
However nothing extra shall be paid for curing by application of curing
compound.

11.1 Initial Curing by application of Curing Compound:

11.1.1 Immediately after the surface texturing, the surface and sides of the slab shall
be cured by the application of approved resin-based aluminized reflective
curing compound or white pigmented curing compound which hardens into an
impervious film or membrane with the help of a mechanical sprayer.

11.1.2 Curing compounds shall contain sufficient flake aluminium in finely divided
dispersion to produce a complete coverage of the sprayed surface with a
metallic finish. The compound shall become stable and impervious to evaporation
of water from the surface of the concrete within 60 minutes of application
and shall be of approved type. The curing compounds shall have a water
retention efficiency index not less than 90 percent in accordance with BS
Specifications No.7542 or as per ASTM C-309-81 Type 2.

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11.1.3 The curing compound shall not react chemically with the concrete and the film or
membrane shall not crack, peel or disintegrate within three weeks after
application. Immediately prior to use, the curing compound shall be
thoroughly agitated in its containers. The rate of spread shall be in accordance
with the manufacturer’s instructions checked during the construction of the trial
length and subsequently whenever required by the Engineer-in-Charge. The
mechanical sprayer shall incorporate an efficient mechanical device for
continuous agitation and mixing of the compound during spraying. Arrangements
should be made to spray the curing compound on the sides of the slab.
The curing compound shall be sprayed in two applications to ensure uniform
spread. In addition to spraying of the curing compound, the fresh
concrete surface shall be protected for at least 3 hours by covering the
finished concrete pavements with tents supported on mobile truss during
adverse weather conditions as directed by the Engineer-in-Charge.

11.2 FINAL CURING

Final curing shall be done either by spreading of wet hessian and moisturing it
regularly or by ponding method as given below. However, nothing extra
s h a l l be paid for curing by spreading wet hessian method. All joints
shall be filled in with temporary filler like sand etc. in order to prevent
the edges of joints from being damaged and entry o f clay m a t e r i a l s
i n t o t h e joints d u r i n g final curing.

11.2.1 Final curing by spreading of wet hessian method

After two or three hours after application of curing compound, the pavement
shall be covered including sides by moist hessian (minimum of two layers) and
the same shall then be kept damp for a minimum period of 14 days after
which time the hessian may be removed. During the curing period, the
hessian shall be kept continuously moist.
All damaged/torn hessian shall be removed and replaced by new
hessian on a regular basis.

11.2.2 Final curing by ponding method

After two to three hours after application of curing compound or upon

removal of the burlap as the case may be, the slab shall be thoroughly wetted
and cured by ponding as follows:

Exposed edges of the slab shall be banked with a substantial berm of

earth. Upon the slab shall then be laid a system of transverse and
longitudinal height of clay about 50 mm high immediately covered
with a blanket of sandy soil free from stones to prevent the drying up
and cracking of clay. The rest of slab within these boundaries shall

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then be covered with sufficient sandy soil so as to produce blanket of earth

not less than 40mm deep after wetting. The earth covering shall be
thoroughly wetted while it is being place on the surface and against the
sides of the slab and kept thoroughly saturated with water for 21
days and thoroughly wetted down during the morning of the
nd
22 day and shall thereafter remain in place until the concrete
has attained the required strength and permission is given by
the Engineer-in-Charge. Thereafter the covering shall be removed and
the pavement cleaned and swept. If the earth covering becomes
displaced during the curing period, it shall be replaced to the original
depth and restarted.

11.2.3 The contractor shall be liable at his cost to replace any concrete damaged
as a result of incomplete curing or cracked on a line other than that of a joint
as per procedure in IRC:SP-83.

11.2.4 The Contractor shall employ his own security personnel to prevent
workmen, cattle straying etc., on the pavement concrete.

11.2.5 Concrete shall not be subjected to any load or weight of any plant until at least
28 days after laying, except for cutting the joints as directed by the Engineer-in-
Charge.

12.0 CONTRACTION/DUMMY JOINTS

12.1 The spacing of transverse and longitudinal joints shall be 4.5 to 5 meter or
as shown in the drawing. It shall be 10 mm wide and shall extend vertically
from the surface of the slab to a depth equal to one-third depth of
slab. The joint shall be formed by cutting with a joint cutting machine. The
initial cut or slot of not less than 3mm wide is to be formed by sawing
the concrete with a joint cutting machine of approved design as soon
as the concrete hardens. Normally in summer when ambient
temperature is more than 30°C, initial cutting may be carried after 4-
8 hrs. of laying and in winter when ambient temperature is less
than 30°C, initial cut may be done at 8-12 hrs. of laying. Top 25mm of
this joint groove shall be subsequent widened to 10mm, after 14-16 days of
casting concrete pavements. The details of Contraction/dummy joint shall be
as given in Appendix –‘A’.

12.2 Before cutting the dummy joints, all necessary precautions shall be taken to ensure
that the joint alignment is marked straight and true as per the drawings. The joint
cutting machine will be handled only by an experienced person thoroughly familiar
with this type of work. The joint should be cut along this alignment only. Any error
in the joint cutting alignment shall be rectified by the Contractor at his own
expense as directed by the Engineer-in-Charge, preferably using epoxy

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concrete as approved.

12.3 The groove shall be inserted with 12mm dia closed-cell Polyethylene foam
back-up rod, 13mm below from the surface of the concrete and filling with
Polysulphide Sealant conforming to grade B.S.: 5212-1990 or IS:11433-1995.
Prior to filling with Polysulphide, the joints shall be cleaned by compressed
air up to full depth and primed properly with appropriate Polysulphide primer up
to back-up rod and masking tape shall be applied along the edges of joint to
prevent spillage of sealant on top surface to give neat finish to sealant. The
masking tape shall be removed after the sealant has been applied and tooled.

12.4 All joints shall be sealed as soon as practicable after 28 days of placing of slabs.
Joints shall be sealed flush with the adjacent pavement surface. The pavement
shall be opened to traffic only after joint sealing over the entire pavement has
been completed. To prevent tackiness or pick up under traffic, the exposed
surfaces of the sealing compound shall be dusted with hydrated lime, if
directed by Engineer-in-Charge, for which nothing extra shall be paid to the
Contractor.

12.5 Each lot sealant shall be supported with manufacturers test certificate. However
one sample per 1000 kg. of sealant received at site or part thereof shall be
collected by the Engineer-in-Charge or his authorized representative and sent
for testing to any Government/ AAI approved Laboratory.

The contractor shall note that as testing charges of sealant seem to be high,
they shall confirm the testing charges and quote their rates accordingly.
Nothing extra over and above the quoted rates is payable on this account and
no plea on what so ever ground will be entertained later on.

12.6 In case of sudden rain or storm, the work can be concluded at the dummy
joints but these will then be formed as construction joints.

12.7 Before sealing of joints, it may be ensured that the transverse joints on each side
of the longitudinal joint shall be in line with each other and of the same type and
width. Any concrete or other foreign matter must be removed from the groove
before sealing.

13.0 CONSTRUCTION JOINTS

13.1 Construction joints shall be provided as shown in the drawing and also at places
whenever day’s operations start and stops or where concreting is stopped due to
unforeseen circumstances. The joints shall be straight and vertical through the
full depth of the slab.

13.2 At all construction joints, bulk head shall be used to retain the concrete and care

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

shall be taken in striking off and finishing the surface to the top face of the
bulkhead. When work is resumed, the surface of concrete laid subsequently,
shall conform to the grade and cross section of previously laid pavement.
Where semi-mechanized method of construction is used, the concrete along the
face of all joints shall be compacted with an internal vibrator inserted in the
concrete and worked along the joint to ensure a concrete free from
honeycombing. In case of mechanized construction, working and vibration/RPM
of all the fixed vibrators shall be checked. There shall be two additional needle
vibrators to compact the concrete near bulk head.

13.3 The Sealing of joints shall be done in the same manner as for contraction
joints, by cutting a groove of 10mm wide and 25mm deep as shown in Appendix
‘A’.

14.0 EXPANSION JOINTS

14.1 Expansion joints are essential where cement concrete pavement

is designed to abut with structures like bridges, culverts, etc. and
at junction of building and pavement. Expansion joint shall also
be provided at the intersection of runway, taxiway and Apron.
The expansion joint shall be straight, extend through the full depth of the slab
and shall be of the shape and dimensions shown on the drawing. The slab
edges adjacent to the joint shall be formed truly vertical.

14.2 Where semi-mechanized method of construction is used, the concrete along the
face of all joints shall be compacted with an internal vibrator inserted in the
concrete and worked along the joint to ensure a concrete free from
honeycombing. In case of mechanized construction, working and vibration/RPM
of all the fixed vibrators shall be checked. There shall be two additional needle
vibrators to compact the concrete near bulk head.

14.3 Synthetic expansion joint filler board as per specification shall be used to fill the
gap between adjacent slabs at expansion joint. The joint groove shall be
filled with Polysulphide conforming to grade B.S.: 5212-1990 or IS: 11433-
1995. Prior to filling with Polysulphide, the joints shall be cleaned by
compressed air up to full depth and primed properly with appropriate
Polysulphide primer up to back-up rod and masking tape shall be applied along
the edges of joint to prevent spillage of sealant on top surface to give neat
finish to sealant. The masking tape shall be removed after the sealant has been
applied and tooled. The details of expansion joint shall be as given in Appendix –
‘A’.

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

15.0 APPLICATION OF POLYSULPHIDE JOINT SEALING COMPOUND

15.1 Materials

15.1.1 Sealant: It shall be cold Polysulphide sealant of approved make conforming

to BS: 5212-1990 or IS: 11433-1995.

15.1.2 Back-up Rod/Backer Rod: Type of material shall be Expanded closed

cell Polyethylene foam and shall conform to ASTMC-5249-95 or ASTMD
3575.

15.1.3 Primer: It shall be applied on the concrete faces of the joints. It shall be single
component primer suitable for use with Polysulphide joint sealant, as approved by
the Engineer-in-Charge.

15.1.4 Joint Filler Board: The joint filler shall be Synthetic joint filler board of approved
make. It shall be 25mm thick within a tolerance of +1.5mm and of a firm
compressible material and complying with the requirements of IS:1838 (Part
3):2011 with a compressibility more than 25%. It shall be provided to the
full width between the side forms. If two pieces are joined to make up full
width, the joint shall be taped such that no slurry escapes to the joint. The
physical requirement of filler shall be as per the table given below:

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

S.No Characteristics
1 Resistance to handling
2 Recovery
3 Compression
Method of
Requirement test, Ref.
to IS
Filler strips shall not be
deformed or broken by twisting, -
bending or other types of
ordinary handling when exposed
to atmospheric condition (see
note)
90% min. 10566
a) Load required to compress
the specimen to 50% of its
original thickness before the
test shall be (i) 7 kgf/cm2, min. -do-
(ii) 53 kgf/cm2, max.

4 Extrusion Amount of extrusion of the -do-

free edge shall not exceed
6mm
5 Water Absorption 1%, max. -do-

6 Density 100 + 10 kg/m3, min. -do-

7 Weathering a) shall show no sign of

disintegration,
delamination or separation
after the test -do-
b) shall satisfy the
requirement of recovery,

Note: Pieces of joint filler that have been damaged shall be rejected.

In order to ensure that sides of the PQC pavement in the portion of

above expansion joint filler board do not get dirty and this space does not
accumulate pieces of aggregates and other foreign materials, precaution is
required to be taken as indicated in note 1 given below.

Note:

1. Expansion joint filler board should be provided upto the top of finished
pavement surface. At the time of filling the joint with sealant material and back-
up rod/baker rod, the required depth of joint filler board from the top upto the
bottom of back-up rod/baker rod should be cut & removed. For easy removal of
top filler board and to avoid damage to the filler board, a pre-cut in the expansion

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

joint filler board shall be provided at a suitable depth so that back-up rod/baker
rod & sealant could be filled after removal of the top cut portion of the filler board.
Nothing extra shall be paid for the filler board from top upto the bottom of back-
up rod/baker rod.

2. As the period for the test will be around three weeks, advance planning is
required to avoid any delay on this account.

15.2 PROCEDURE

15.2.1 Preparation of Surface: All the joint surfaces to which the sealant is to be
applied should be clean, dry and free from any loose material, dirt, dust,
scale, protective lacquer, grease.

15.2.2 Expansion joint filler material must be checked to ensure that it is tightly
packed and no gaps or voids exist at the base of the joint slot.

15.2.3 Sealant should be prepared as per manufacturer’s specifications.

15.2.4 Before sealant is applied, primer shall be applied to secure better adhesion
between sealant and the concrete surface. The surface shall be allowed to dry for
at least 30 minutes but no longer than 3 hours before the sealant is applied.

15.2.5 To prevent accidental spillage of sealant on the top surface and to give a neat
finish, masking tape should be applied along the edge of joint before the sealant
material is filled.

15.2.6 Immediately after filling the joints, the sealant should be tooled either with a
stainless steel or wooden spatula of the size of the joint to give a smooth surface.
While tooling, the spatula should be wetted with a wetting agent like soap water.
Masking tape shall be removed immediately after the sealant has been tooled.
By tooling, the sealant is compressed with the result that air bubbles if any, are
broken up and the sealant becomes free of voids and there is a proper
adhesion of the sealant to the sides of the joints.

15.3 Sealant of approved make shall be filled only after complete curing of concrete
i.e., after 28 days. Sealant shall be applied slightly to a lower level than the slab
with a tolerance of 1+0.5mm as shown in Appendix –‘A’.

15.4 Sealant of approved make shall be filled up for a depth as specified in item. The
rate of application of sealant may be calculated on the basis of the following
formula:

Number of 1 Kilogram tins required = 0.0015 x L x W x D

where L = Length of joint in meters

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

W = Width of joint in mm.

D = Depth of joint in mm.
15.5 Manufacturer’s certificate shall be produced for establishing that the sealant is not
more than six months old or the shelf-life of the sealant. For storage, preparation
of sealant, health and safety precautions etc., manufacturer’s specifications shall
be applicable.

15.6 A typical sketch showing details of filling of joints is enclosed as

Appendix -‘A’.

16.0 Q U A L I T Y CONTROL

16.1 The following quality control tests shall be carried out at frequencies
specified against each, as per the table given below:

S.No Test Test Method Frequency Acceptance

Criteria
I Cement
Physical and IS:4031, Once for each As per
chemical tests IS:4032 source of supply relevant
and every 200 code as per
tonnes or part Para 1.1
thereof. Cement
remaining in
stores for more
than one and half
month from the
date of
manufacture must
be re-tested
before use and to
be rejected, if it
fails to conform to
any of the
requirements of
the specifications.
Each brand of
cement brought
to site shall be
tested as per
this frequency.
Besides, the
Contractor
also will

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

S.No Test Test Method Frequency Acceptance

Criteria
submit daily
test report on
cement
released by
the
manufacturer.
II Coarse aggregate
a) Flakiness IS:2386 (Part- Before approval Not more
Index I) of the quarry than 25%
and at every
subsequent
change in the
source of
supply and
one test for
every
2 0 0 0 cum
of
aggregate
b) Impact value
or IS:2386 (Part- Not more
Los Angeles IV) - do- than 30%
abrasion
value
c) Water IS:2386 (Part -do- Not more
Absorption III) than 3 %.
d) Deleterious IS:2386 (Part Before approval As per
materials II) of the quarry table -2 of
and at every IS: 383
subsequent
change in the
source of
supply.
e) Moisture IS:2386 (Part Regularly as This data
content III) required shall be used
subject to a for
minimum of correcting
one test per the water
day demand of
the mix on a
daily basis
f)Grading IS: 2386 (Part– One test per As per
I) day on each Table - 7

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

S.No Test Test Method Frequency Acceptance

Criteria
size of of IS: 383
aggregates
g) Soundness IS 2386 ( Part Before approval
(i) Loss with V) of the quarry
Sodium and at every Max. 12%
Sulphate for subsequent
5 cycles change in the
(ii) Loss with source of Max. 18%
Magnesiu supply
m Sulphate
with 5
cycles
(h) Presence of As per clause Before approval No presence
ferrous 1.3.1 of the quarry of ferrous
sulphide and and at every sulphide and
iron oxide subsequent iron oxide
change in the
source of
supply.
III Fine Aggregates
a) Silt Content CPWD One test Not more
Specificatio per 2 00 than 8%
n cum and
2009 Vol. I, part
Page thereof
78, Appendix –
C
b) Grading IS : 2386 (Part- -do- Fineness
I) modulus
between
2.5 to 3.9
c) Water IS : 2386 (Part- -do- Not more
Absorption III) than 3%
d) Deleterious IS: 2386 (Part- Before approval As per
materials II) of the quarry table 1 of
and at every IS 383
subsequent
change in the
source of
supply.

e)Moisture IS:2386 (Part- Regularly as This data

content III) required shall be used

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

S.No Test Test Method Frequency Acceptance

Criteria
subject to a for correcting
minimum of the water
two test per demand of
day. the mix on a
daily basis.
IV Combined Grading of Aggregates
a) Grading IS: 2386 (Part- 1 test per As per Para
I) 150 cum 1.5
a nd part
thereof
V Concrete
a) Slump test of IS : 1199 At least once As per Para
concrete in 50 batches 3.1
at each mixer
or more
frequently if
directed by the
EIC.
b) Flexural IS : 516 One test As per Para
strength consisting of six 16.4
beam
specimens and
6 cubes. Three
specimens shall
be tested after
7 days and
another three
shall be tested
after 28 days
for every
200 Cum of
Concrete &
part thereof
c) Surface As prescribed Regularly As per Para
accuracy 10
VI Polyethylene IS:2508 One test per As per
sheet Density lot IS:2508
Tensile strength
at break
Melt flow Index
VII GGBS IS:16714:2018 Once for each As per
Chemical and source of supply IS:16714:20
Physical 18

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

S.No Test Test Method Frequency Acceptance

Criteria
Properties and every 100
tonnes or part
thereof. Each
brand of GGBS
brought to site
shall be tested as
per this
frequency.
Besides, the
Contractor also
will submit daily
test report
released by the
manufacturer.

16.2 Equipment as per list at Appendix–‘B’ shall be provided by the

Contractor in the field testing laboratory. Nothing extra shall be paid to him on
this account. Records as required shall be maintained at site.

All test details in support of mix design shall be maintained as part of records
of the contract and shall be signed both by the contractor and the Engineer-
in-Charge or their authorized representatives. The contractor shall provide
all labour, materials and equipment required for all tests to be carried out, at
his own cost.

16.3 The Engineer-in-Charge reserves the right to test any concrete laid
regarding quality, soundness, compaction, thickness strength and finish of the
concrete at any time before the expiry of the “Defects Liability period”
notwithstanding that necessary tests had been carried out and found
satisfactory at the time of execution.

16.4 QUALITY CONTROL AND STANDARD OF ACCEPTANCE OF

STRENGTH OF CONCRETE

16.4.1 Samples of concrete shall be collected at the point of discharge on the pavement
and beams cast as controlled specimens and tested in accordance with IS:
516 and IS: 1199. The concrete will be said to comply with the specified
flexural strength, when the following conditions are met with.

(c) The mean strength determined from any group of four consecutive
samples (each sample containing 3 beam specimen i.e. 4x3 =12
beam specimens) at 28 days should exceed the specified characteristic
flexural strength by at least 0.3 MPa i.e., 4.4 MPa.

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

(d) The strength of any specimen is not less than the specified
characteristic flexural strength minus 0.1 MPa i.e., 4.0 MPa.

16.4.2 Should the concrete fail to pass the specification for strength as
described above, the contactor may, all at his own expense elect to cut cores
(diameter of the core not less than 150mm) as per the direction of Engineer-in-
Charge where the requirements are not met with. The points from where cores
are to be taken and the number of cores required shall be at the discretion
of the Engineer-in-Charge and shall be representative of the whole of concrete
concerned. In no case, however, shall fewer than 3 cores be tested.

16.4.3 Cores shall be prepared and tested as described in IS 516. Concrete in the
member represented by a core test shall be considered acceptable if the
average of the results of crushing strength tests of the cores shall not be
less than 0.8x0.85 times the corresponding Characteristic compressive strength
of cubes and no individual core has a strength less than 0.8x0.75 times the
corresponding Characteristic compressive strength of cubes where height to
diameter ratio of the core is 2. Where height to diameter ratio of
the core is not 2 necessary corrections shall be made in calculating
crushing strength of cubes as per clause 12.21.1 of IRC:15-2017.

Sample calculation for required core strength is placed below for core cut
with height to diameter ratio of core is 2:

Flexural strength fcr = K

Fcr = 4 . 1 MPa

4.1 = K

K - value as derived in clause 4.5

fck = 16.81/K2

Average core strength required = 0.8x0.85x fck MPa

Individual core strength required = 0.8x0.75x fck MPa

16.4.4 If however, the tests on cores also confirm that the concrete is not
satisfying the strength requirements, then the concrete corresponding to the
area from which the cores were cut should be replaced, i.e., over an
area extending between two transverse joints where the defects could
be isolated or over larger area as decided by the Engineer-in-Charge.

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

16.4.5 All defective and sub-standard work which includes concrete slab of
sub-standard strength as established in above para shall be liable to rejection
and shall be replaced by the contractor at his expense. Acceptance
criteria for cracked concrete slabs shall be as follows (ref. clause 12.33 of IRC-
15-2017):

i) Fine crazy cracks (plastic shrinkage cracks) with cumulative length of 3000
mm in a slab can be accepted after repair as per IRC:SP-83. Beyond
cumulative length of 3000 mm, it shall be rejected.
ii) Slabs with cracks running transversely or longitudinally penetrating to full
depth and length of the slab are to be rejected.
iii) Slabs with any type of cracks which are penetrating to more than half the
depth shall be rejected. (ref. clause 12.33 of IRC-15-2017).
iv) When due to operational or any other reason, such replacement does
not become possible (decision of Engineer-in-charge in this respect
being final and binding on the contractor), the cost of removal and
replacement of such rejected work shall be recovered from
the contractor whether such rejected work is subsequently replaced by
the Deptt. or not.

17.0 WEATHER LIMITATIONS

17.1 Concreting during rains: To prevent damage to freshly laid concrete during
monsoon, or sudden rains, the Contractor shall provide an adequate
supply of tarpaulins or other water-proof material. Any concrete
damaged by rain shall be removed and replaced by the Contractor at
his own cost as directed by the Engineer-in-Charge. If need be, necessary
provisions shall be made to support the water- proof material clear of
the newly-laid concrete surface to prevent smoothening or any damage due to
the contact with tarpaulin. The whole unit should be weighted down
appropriately to prevent from blown off by winds. The rate quoted shall include
all these.

17.2 Concreting in hot weather: No concreting shall be done when the concrete
temperature is above 30°C. Besides, in adverse conditions like high
temperature, low relative humidity, excessive wind velocity, imminence
of rains etc. if so desired by the Engineer-in-charge, tents on mobile trusses
may be provided over the freshly laid concrete for a minimum period of
3 hours as directed by the Engineer-in-charge. The temperature of the concrete
mix on reaching the paving site shall not be more than 30°C. To bring down
the temperature, if necessary, chilled water or ice flakes should be made use
of. No extra payment shall be made for this arrangement.

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

17.3 Concreting in cold weather: No concreting shall be done when the

concrete temperature is below 5°C.

18.0 MEASUREMENTS

18.1 For the purpose of ascertaining the quantity of concrete in the

pavement length, breadth and thickness shall be measured as detailed below:
a) Length
i) Between the end of a pavement to the center line
of the construction / expansion joints.
ii) Between the center lines of consecutive
construction/expansion joints.
b) Width
i) Between the edge of a pavement and the center line
of the construction joints.
ci) Between the center lines of construction joints and expansion joints.
cii) Between the center lines of construction joints and expansion joints.
ciii) Between the center lines of consecutive construction joints.

c) Thickness
Levels shall be taken before and after construction, at the grid of points
5 metre centre-to-centre longitudinally in straight reaches for each panel
and 2.5 metre centre-to-centre at curves. The shall also be taken
transversely, at 0.75 metre from either edge of the and the remaining
locations shall be at equi-distance but not more than 2 metre in the
balance portion of panel. The average thickness of the pavement course
in any panel shall be the arithmetic mean of the difference of levels
before and after construction at all the grid points falling in that panel,
provided that the thickness of finished work shall be limited to those
shown on the drawings or approved by the Engineer-In- Charge in
writing. As supplement to level measurements, the Engineer shall have
the option to take cores/ make holes to check the depth of construction.
The holes made and the portions cut for taking cores shall be made
good by the Contractor by laying fresh mix/material including
compacting as required at his-own cost immediately after the
measurements are recorded.

The finished concrete courses to be paid on volume basis by multiplying

length , breadth and thickness as measured above and its volume shall
be calculated in Cubic metres correct to two places of decimal.
Measurements of concrete slabs shall be recorded in aforesaid
manner jointly by the Engineer-in-Charge or his authorized
subordinate and the Contractor or his authorized agent.

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 AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

19.0 RATE

19.1 The rate of the item for concrete in pavement shall include the cost of all
materials and labour including charges for machinery tools & plants, making
profile including taking levels including all cartages and lift required in all
the operations described above complete in all respects for a successful
completion of the job. The rate also includes cost of mix design from outside
laboratory, trial mix, all costs of setting up of laboratory at site and carrying out
the quality control measures/tests enumerated above by the Contractor at
his own cost in the presence of Engineer-in-Charge or his authorized
representative, and submission of test results on completion of tests to the
Engineer-in-Charge thereof.

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AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

APPENDIX-A

EXPANSION JOINT

CONTRACTION /DUMMYJOINT

CONSTRUCTION JOINT

DETAILS OF FILLING OF JOINTS IN RIGID PAVEMENTS

Page - 733
AAI SPECIFICATIONS OF PQC FOR RIGID AIRFIELD PAVEMENTS (JULY 2020)

APPENDIX-B
List of minimum equipment to be provided in the field testing
laboratory by the contractor at his own cost.

1. Sieve analysis for combined grading of aggregates

Sets of I.S. Sieves of sizes 63mm, 45mm, 22.4mm, 11.2mm, 5.6mm,
2.8 mm, 1.4 mm, 710 micron, 355 micron and 180 micron.

2. Sieve analysis for coarse aggregates

Sets of I.S. Sieves of sizes 63mm, 40mm, 20mm, 12.5mm, 10mm,
4.75mm, 2.36mm.

3. Sieve analysis of fine aggregate

Sets of I.S. Sieves of sizes 10mm, 4.75mm, 600 micron, 300
micron and 150 micron
4. Silt content of sand
Graduated glass cylinders 500 C.C. capacity.

5. Bulkage of sand
a) Graduated glass cylinders 250 C.C. capacity
b) Graduated glass cylinders 500 C.C. capacity

6. Slump test
a) Slump cones
b) Slump rods 3/8" dia. 24" long bullet pointed.
c) Steel plates 24" x 24"
d) Steel scales

7. For making beam specimens for flexural strength

a) Beam moulds size 70x15x15cm (minimum 18 nos.)
b) Cube moulds size 15x15x15cm (minimum 18 nos.)
c) Tamping rods.
d) Table vibrator (size 1m x 1m)

8. Testing flexural strength of concrete:

100 tonne capacity equipment for compressive strength and 5-10
tonne equipment for flexural strength testing electrically operated.

9. Other miscellaneous items

a) Electronic weighing scale of different capacity
b) Glass measuring jar
c) Beakers
d) Towels, glass plates etc.
e) Apparatus for testing flakiness index, Impact value and Los Angeles
Abrasion value of coarse aggregates.

Page - 734
BLANK

Page - 735
 INDEX

1. INDEX ---------- 1-1

2. Section -1 ………… HIGH VOLTAGE PANEL ---------- 2-10
3. Section -2 ………… DISTRIBUTION TRANSFORMER ---------- 11-19
4. Section -3 ………… SURGE ARRESTORS ---------- 20-22
5. Section -4 ………… RISING MAIN & BUS DUCT ---------- 23-25
6. Section -5 ………… CABLES ---------- 26-28
7. Section -6 ………… DIESEL GENERATORS ---------- 29-43
8. Section -7 ………… L.T. PANELS ---------- 44-59
9. Section -8 ………… SURGE PROTECTION DEVICES ---------- 60-63
10. Section -9 ………… HYBRID APFC PANEL ---------- 64-68
11. Section -10………… INTERNAL & EXTERNAL ---------- 69-134
ELECTRIFICATION I/C LIGHTS
12. Section -11………… ADDRESSABLE FIRE DETECTION & ---------- 135-151
ALARM SYSTEM
13. Section -12………… FIRE FIGHTING SYSTEM ---------- 152-176
14. Section -13………… FIRE SUPPRESSION SYSTEM ---------- 177-179

15. Section -14………… VRV/ VRF BASED AC ---------- 180-208

16. Section -15………… IBMS ---------- 209-253
17. Section -16………… WATER SUPPLY ---------- 254-263
18. Section -17………… SEWAGE TREATMENT PLANT ---------- 264-280
19. Section -18………… SOLAR POWER PLANT ---------- 281-287
20. Section -19………… LIFT ---------- 288-316

PAGE - 736
SECTION-1 33 KV HIGH VOLTAGE PANEL
1.0 Scope: -
These specification covers Design, Manufacture, Assembly, Inspection, testing at
Manufacturer’s Works, Delivery to Site, Unloading, Handling, Installation and
Commissioning of the High voltage Switchgear, complete as to meeting the intents of
the Tender to make the system completely operational.

1.1 Codes & Standards: -

The HV Panel board shall be of indoor and expandable type, having the incoming and
outgoing switch gear as per IS 13118 of VCB, IEC 62271-100 for Breakers and IEC
62271-200 for Panels/IS 3427 of switch board. The degree of enclosure protection
shall be IP-4X.
HT panels with accessories shall be designed to conform to the requirements of the
following Standards with up to date amendments:

S.No. Applicable Standards /Mandatory Particulars

1. Type Metal Clad air insulated with VCB type indoor circuit
breaker
2. IEC:62271–1 High-voltage switchgear and control gear –Common
IS -13118 specifications.
3. IEC:62271–100 High-voltage switchgear and control gear –Alternating
current circuit-breakers.
4. IEC:62271–200 loss of service continuity category acc. to IEC 62271-
200: LSC 2B
5. IEC:62271–200 Internal Arc classification-IAC ALFR
6. IEC:6044-1 / Current Transformers
IS 2705
7. IEC:6044-2/ Voltage Transformers
IS: 3156
8. IEC:60529 Classification of degrees of protection provided
by enclosures (Protection against Accidental contact,
foreign bodies & water)
9. IEC:60038 Standard Voltages
10. IEC:60255 Measuring relays and protection equipment-Part24:
Common format for transient data exchange for power
systems.
11. ANSI IEEE Switch gear assemblies including metal enclosed
C37/20 bus.
The degree of enclosure protection shall be IP-4X.
1.2 Rating
All panels assembled to form a board shall be suitable for the nominal operation
voltage and rupturing capacity as specified. They should be rated as specified with a
minimum of 800 Amps. and suitable for operation on 33 KV, 3 phase 50 Hz system.
Type test certificate for the breaking capacity (From NABL Accreted laboratory) of the
panel shall be supplied. A circuit breaker for a given duty in service is best elected by
considering the individual rated values required by load conditions and fault

PAGE - 737
 condition. The internal arc capacity shall be equal to STC for duration of 1 Sec as for
latest IEC – 62271-200.

1.3 Types of Panel

The HV panel shall be metal clad, indoor, floor mounting, free standing type. It shall be
totally enclosed dust, damp and vermin proof with provision of future expansion.
The panel shall be suitable for following ratings: -

a. Rated System Voltage : 33KV/50Hz, 3Phase AC

b. Highest System Voltage : 36 KV
c. Rated breaking Capacity : 26.3KA for 3sec
d. Rated making capacity : 62.5 KA
e. Power Frequency withstand : 70 KV
f. Impulse with stand : 170 KVP
g. Self-contained short time current : Self-contained short time current 26.3
KA for 3 sec
h. Internal Arc : AFLR 26.3 KA for 1 Sec.

2.0 General Construction

Separately earthed compartment shall be provided for circuit breaker, bus bars, relay
& instruments, CT&PT and cable boxes, fully and effectively segregating these from
one another so that fault in any one compartment do not cause damage to
equipment(s) in other compartment(s). The housing shall be of bolted construction to
ensure compact and rigid structure, presenting a neat and pleasing appearance. The
sheet steel used should not be less than 2 mm thick. The panels shall be bolted together
to form a continuous flush front switch gear suitable for front operation of board and
for extension at both ends.
2.1 General Design Aspects
The HV panel board shall be designed such that the switchgear, instruments, relays,
Bus-bars, small wiring etc. are arranged and mounted with due consideration for the
followings: -
a) Facility for inspection, maintenance and repairs of testing terminals and terminal
boards for ease of external connection.
b) Minimum noises and vibrations.
Risk of accidental short circuits and open circuits.
Secured and vibration proof connections for power and control circuits
c) Risk of accidental contact and danger to personnel due to live connections.
d) Mounting at approachable height.

2.2 Circuit Breaker

2.2.1 General Arrangements
The circuit breaker panels shall be complete with the following: -
(a) Racking in / Racking out mechanism.
(b) Isolating plugs and sockets.
(c) Mechanical inter-locks and safety shutters.
(d) Mechanical ON/OFF indicator.

PAGE - 738
 (e) Minimum of 4 NO and 4 NC Auxiliary contacts directly operated by the circuit
breaker. Additional NO & NC contacts can be provided with auxiliary
contactors.
(f) Anti condensation space heaters suitable for operation on 240V, 1 Φ 50 Hz A.C.
for each panel.
(g) Suitable tripping arrangement.
(h) Mechanical counters to assess the total number of operations of the
breaker.
2.2.2 Type
The circuit breaker shall be horizontal isolation/ As per manufacture’s type tested
design.
2.2.3 Breaker Truck
The breaker carriage shall be fabricated from steel, providing a sturdy vehicle for the
circuit breaker and its operating and tripping mechanism. The carriage shall be
mounted on wheels, moving on guides, designed to align correctly and allow easy
movement of the circuit breaker and for removing the carriage for inspection and
maintenance purposes. Vacuum interrupters shall be hermetically sealed and shall be
designed for minimum contact erosion, fast recovery of di- electric strength,
maintenance free vacuum interrupter, suitable for auto-reclosing. The drive
mechanism shall preferably be provided with facility for pad locking at any position
namely, “SERVICE”, “TEST” AND “FULLY ISOLATED”. It should be possible for testing
the circuit breaker for its operation without energizing the power circuit in the
“Testing” position. The contacts shall be made only after the breaker is inserted into
service position. Interlocking should prevent contacts from being disconnected if
circuit breaker is tried to be moved from service position.
2.2.4 General Features
Single break contacts are provided in sealed vacuum interrupter.
2.2.5 Rating
The circuit breaker shall be continuously rated as specified with a minimum rated
current of 800 A with voltage rating and breaking capacity as specified.
2.2.6 Operating Mechanism
The operating mechanism shall be as specified;
Motor wound spring charged with both mechanical and electrical release for closing.
The operating mechanism shall be trip free. External auxiliary supply shall be made
available for charging motors & heaters operation.
2.2.7 External auxiliary supply shall be made available for charging motors & heaters
operation.

2.3 Bus Bar Section

2.3.1 General Requirement
The switch board shall be single bus bar pattern with air insulated encapsulated / full
voltage sleeve bus bars housed in a separate compartment, segregated from other
compartments.

PAGE - 739
2.3.2 Material
The bus bars shall be of high conductivity electrolytic copper rated as specified with a
minimum rated current of 800 Amps. The bus bars shall be sized for carrying the rated
and short circuit current without over-heating. Maximum bus bar temperature shall
be as per IEC 60694 & IEC 62271-1 clause 4.4.2
2.4 Current Transformer
2.4.1 General Requirements

Accommodation shall be provided in the circuit breaker panel to mount one set of
three numbers dual core dual ratio CTs for metering and protection purposes. Access
to the CTs for cleaning, testing or changing shall be front, back or top of the panel.

2.4.2 All current transformers shall have a 1-second short-time current rating of not less
than the maximum System fault level. Current transformers shall have an output rating
adequate to cater for the burden connected to them and shall function satisfactorily
under the maximum system fault condition.

2.4.3 Rating

Dual core & dual ratio CTs of suitable burden (but not less than 15 VA) shall be
preferred with 5 Amps secondary. Suitable burden calculation shall be submitted by
manufacturers.
Note: CT ratio shall be compatible with the loading pattern on HV side.
The CTs shall conform to relevant Indian Standards. The design and construction shall
be robust to withstand thermal and dynamic stresses during short circuits. Secondary
terminal of CTs shall be brought out suitably to a terminal block will be easily
accessible for testing and terminal connections. The protection CTs shall be of accuracy
class 5 P 10 of IS 2750- Part III- 1992.

The metering CTs shall conform to the metering ratio and accuracy class 0.5 of IS 2750-
1992 for incomer and class 1 for outgoing Panels.

2.5 Voltage Transformer

2.5.1 General Requirement
A voltage transformer of burden not less than 100 VA and of proper ratio as specified
shall be provided at the incoming panel. Suitable burden with backup calculation shall
submitted by manufacturer’s. The accuracy class for the VT shall be class 0.5 as per IS
3156 parts I to III for incomer and class 1 for outgoing.
2.6 Protection and Tripping Arrangement
2.6.1 Protection
The Relays shall be microprocessor based numerical relays with O/L, E/F and S/C
protection communicable type with RS 485 port. The Digital Numeric Relay shall be as
per IEC 61850. All Auxiliary relays, master trip relay, trip circuit supervision relay,
transformer protection relay etc. shall be of numerical & communicable type. Tripping
relay shall be used for tripping signal to the Shunt Trip Coil of Circuit Breaker operating
on 24V/30V D C supply / Power pack / 110 V VT supply.

PAGE - 740
 Note: - 24V/30V DC shall be provided through 2 No. SMF batteries of 12/15 volts of
minimum 26 AH capacity with a battery charger as per recommendation of the
manufacturer both for protection as well as indications.

2.6.2 Relays
Over current Relays shall have adjustable setting for current from 50% to 200% and
earth fault from 10% to 40% or 20% to 80%. These should be of manual reset type. All
relays shall have a LED indicator which will indicate operation for each function. It shall
be possible to reset it only by manual operation. The number and relays shall be as
required/specified. As per specification All Numerical relays shall have MIMIC
(Graphical) display and minimum following features: -
 Relay shall be native IEC 61850 compliant, Numerical & suitable for 1A and 5A
secondary CT current & 110 Volts secondary supply.
 Relay shall have negative sequence over current, O/C & E/F Protection.
 Relay shall have RS232/485 port/usb port and rear Redundant Ethernet port
remote communications. The communication shall be on IEC61850 protocol.
 Relay shall have minimum of 14 digital Inputs, minimum of 8 digital outputs,
minimum of 8 numbers programmable LED, all local hardwired shall be with
Numerical relay and the same be communicated to BMS via IEC 61850

2.6.3 Small Wiring

The small wiring shall be carried out with minimum 1.5sq. mm FRLS insulated copper
conductor cables. CT wiring shall be done with minimum 2.5sq mm wires with colour
code: RYB, Grey for auxiliary DC circuits and Black for auxiliary AC circuits. The wiring
shall be securely fixed and neatly arranged to enable easy tracing of wires.
Identification tags shall be fitted to all wire terminals to render identification easy
facilitate checking in accordance with IS 375. Necessary terminal block and cable
entries shall be provided for RTD relay wiring, power supply etc.
2.6.4 Arc Flash Protection
Panel shall be equipped with the following for Arc flash fault protection: Relay should
have integrated feature sensing any ARC produced in any of the 3 chambers i.e.
Breaker, Cable and Busbar apart from Protection features. In case integrated offer is
not available, separate module to be considered without compromising on the tripping
time. Necessary sensors to be supplied along with the relay and it should have
supervision of the sensors. Relay should operate due to ARC such that overall relay trip
time should not exceed 18-20 ms.

In case separate module is considered, then main protection relay and module
should be supplied from the same manufacturer. Panel shall be supplied with
numerical relay along with arc sensors & fibre cables to protect from arc flash fault at
Breaker, Cable and Busbar.
To avoid any nuisance tripping for ARC, relay should work on principle of detecting
Light and Current both to take decision. In no circumstance, only light detection
technique shall be considered.
The protection and tripping arrangement of incoming & outgoing circuit breaker shall
be as per actual requirement / design.
Additional min. protection, auxiliary trip and alarm relay for Oil Type transformer
protection.

PAGE - 741
  Buchholz relay Alarm & Trip
 Winding temperature relay Alarm & Trip
 Oil temperature relay Alarm & Trip
 Pressure relief valve relay Trip
 Oil surge Relay Alarm & Trip
 Magnetic Oil low level alarm
 Auxiliary trip and alarm relay for transformer protection such as Winding
temperature relay Alarm & Trip.

2.7 Metering Instrument, Panel Accessories (Digital)

2.7.1 Voltage Selection Scheme

 PT’s shall be provided on each the bus sections (incomers) with individual
metering on each incomer.
 VT Transfer Relay shall be incorporated to provide necessary potential for
metering. This will be necessary when energy metering is done on individual
feeders or where VT supply is used for trip circuits.
 Necessary arrangement for dual/Redundant power supply shall be incorporated
in panel using solid state/electronic devices.

2.7.2 Instrument Panels

The instrument panel shall form part of the housing. Relays, meters and instruments
shall be mounted as per general arrangement drawings to be submitted by the
tenderer. They shall be preferably of flush mounting type at a maximum height of 2000
mm.
2.7.3 Instrumentation
2.7.4.1 Voltmeters & Ammeters
 A voltmeter of class 0.5 accuracy as per IS-1248 shall be provided at each incomer
panel, with selector switch. The instrument shall be calibrated for the range
specified.
 Ammeter of specified range of class 0.5. accuracy as per IS-1248 shall be provided
at each incomer and outgoing panels along with necessary selector switches.

2.7.4.2 Digital Multifunction Meters

 Digital multifunction meters of class 0.5s, with LED display for measurement of-
 Max Demand Load, I;V;Hz,
 Active, Reactive, Apparent Power & Energy;
 Power factor.
 % unbalance of current & voltage; calculated neutral current;
 % TDH individual harmonics up to 15th level (complying with IEC61557-12) with
RS 485 port and protection MCBs, and required accessories to complete the
system.
 The rest all specification for MFM is same as described in LT panels.

2.7.4.3 The panel assembly shall also take care of the following requirements:

PAGE - 742
  Lamp indication shall be provided to indicate ON/OFF/TRIP (BY
red/green/Amber respectively) of switch gear.
 Panel illuminating lamp.
 Mechanical indication for spring charged status. If possible, an indicating lamp
could be provided.
 Lamp indicating tripping at fault status.
 Healthy trip supply status shall be indicated by clear lamp.
 Separate MCBs shall be provided for lamp, heaters, voltmeters and other
instrumentation etc. on each panel if specified.
 Anti- condensation space heater with MCB shall be provided, and shall be suitable
for operation on 240 V, 1 phase, 50 Hz A.C. for each panel is specified.
 Where there are more than one incomer and bus sections, these shall be castle
key interlocked as per interlocking scheme as specified.

2.8 Cable Boxes

Cable boxes shall be situated in a compartment at the rear/ side of the housing as
specified.
2.8.1 Cable Entry
Provision for bottom side entry shall be made as per requirement with sufficient head
room for cable termination. 3mm thick removable gland plate shall be provided for
cable termination.
2.8.2 Earthing
The earthing of the breaker body and moving portion shall be so arranged that the
earthing of the non-current carrying structure to the frame earth bar is completed well
before the main circuit breaker plugs enter the fixed house sockets.

The entire panel board shall have a common tinned copper earth bar of suitable section
with 2 earth terminals for effectively earthing metallic portion of the panels. The frame
earthing of panel shall be in accordance with IS: 3043 amended up to date.

2.8.3 Installation
The installation work shall cover assembly of panels lining up, grouting the unites etc.
In the case of multi panels switch boards after connecting up the bus bar all joint shall
be insulated with HV insulation tape or with approved insulation compounds. A
common earth bar shall be run preferably at the back of the switch board connecting
all the sections for connecting the earth system. All protection, indication & metering
connections and wirings shall be completed. Where trip supply battery is installed the
unit shall be commissioned, completing initial charging of the batteries. All relay
instruments and meters shall be mounted and connected with appropriate wiring.
Calibration checks of units as necessary and required by the licensee like CTs, VTs
Energy Meters etc. shall be completed before pre-commission checks are undertaken.

2.9 Type Test

The Manufacturer should submit the Type test report for MV Panel test conducted
earlier on similar equipment’s/Panels carried out from CPRI / Govt. accredited
Laboratory as per relevant IS/IEC- 62271- 200 and IEC-60694 Standard & Tender

PAGE - 743
 Specification . International Type test certificates are also acceptable from reputed lab
for which Indian NABL accredited lab certificates are not available.
The following type tests have been performed : -
 Test to verify the insulation level of the equipment’s
 Tests to prove the temperature rise of any part of the equipment’s and measure
of the resistance of the circuit.
 Tests to prove the capability of the main and earthing circuits to be subjected to the
rated peak and the rated short time withstand currents
 Test to prove the making and breaking capacity of the included switching device.
 Test to prove the satisfactory operation of the included switching devices and
removable parts.
 Test to verify the protection of persons against access to hazardous part and the
protection of the equipment’s against solid foreign objects.
 Tests to assess the effects of arcing due to an internal fault (for switchgear and
control gear classification IAC).
 Panel shall be tested for environmental aging to ensure extended life.

2.10 ROUTINE TESTS

Routine tests shall be carried out in accordance with a p p l i c a b l e IS / IEC 62271-
200 standards. These tests shall ensure the reliability of the unit.
Below listed test shall be performed as routine tests before the delivery of units;
(i) Withstand voltage at power frequency
(ii) Measurement of the resistance of the main circuit
(iii) Withstand voltage on the auxiliary circuits
(iv) Operation of functional locks, interlocks, signalling devices and auxiliary
devices
(v) Suitability and correct operation of protections, control instruments and
electrical connections of the circuit breaker operating mechanism
(vi) Verification of wiring
(vii) Visual inspection

Tests shall be performed in the presence of AAI’s representatives. The Contractor shall
give at least fifteen (15) days advance notice for witnessing the tests. Copies of certified
reports of all tests carried out at works shall be furnished. The equipment shall be
dispatched from works, only after receipt of AAI’s written approval of the test reports.
The Bidder shall indicate tests recommended to be carried out at site during
installation and commissioning to ensure satisfactory performance of all the
equipment supplied.

3.0 Testing and Commissioning

Procedure for testing and commissioning of relay shall be in general accordance with
good practice. Commissioning checks and tests shall include in addition to checking of
all small wiring connections, relays calibration and setting tests by secondary injection
method and primary injection method. Primary injection test will be preferred for

PAGE - 744
operation of relay through CTs. Before panel board is commissioned, provision of the
safety namely fire extinguishers, rubber mats and danger board shall be ensured. In
addition all routine megger tests shall be performed. Checks and test shall include
following.
(i) Operation Checks and lubrication of all moving parts.
(ii) Interlock function checks.
(iii) Continuity checks of wiring, fuses etc. as required.
(iv) Insulation tests.
(v) Trip test and protection gear tests.
(vi) The complete panel shall be tested with 5000V megger for insulation between
poles and poles to earth. Insulation test of secondary of CTs and VT to earth
shall be conducted using 500V megger.
(vii) Any other tests as may be required by the Licensee/ Inspector shall be
conducted.
(viii) Where specified, the entire switch board shall withstand high voltage test after
installation.

PAGE - 745
SECTION- 2 33/0.433 KV Distribution Transformer
(Oil Filled ONAN with ON Load Tap Changer )

1.0 General
The transformer shall be outdoor type, three phases, 50Hz, Oil cooled, copper wound,
core type, step down, delta/star, Dyn- 11, with on load tap changer.
The transformer shall be designed and manufactured as per IS 2026–1977 with up to
date amendments.

1.1 Codes & Standards

The transformers shall conform to the following Indian standard specifications with
up-to date amendments: Transformer losses should be as per latest ECBC & IS 1180.
S.No. Applicable Standards /Mandatory Particulars
1. Type Oil Transformer
2. IS 2026 part-I to V Power Transformers
3. IS 335 Transformer Oil
4. IS 10028 part 2 & 3 Installation & maintenance of Transformers
5. IS 2099 Bushings
6. IS 6600 Guide for loading of oil immersed transformers
7. IS 2070 Method of Impulse Voltage Testing
8. IS 3637 Gas operated Relays
9. IS 1180 Distribution Transformers

1.2 Power Supply parameters

The transformer shall be capable of continuous operation at specified rating under the
following condition:
a. Voltage variation -10% to + 10 % with steps 1.25 %
b. Frequency variation +/- 5%

1.3 Temperature Rise

The reference ambient temperatures assumed for the purpose of this specification are
as follows: -
(a) Maximum ambient air temperature 50° C.
(b) Maximum daily average ambient air temperature 40°C.
(c) Maximum yearly weighted average ambient temperature 32°C.
(d)Minimum yearly weighted average ambient temperature (-) 5° C.
The temperature rise at the above conditions and at the altitude not exceeding 1000
meters shall be as follows: -
By resistance method 55° C (maximum temperature being 95° C).
By thermometer 50° C.

2.0 Construction

PAGE - 746
 The standard constructional features of Manufacturer are acceptable
The transformer shall be free from annoying hum or vibration. The design shall be
such as not to cause any undesirable interference with radio or communication
circuits.

2.1 Transformer Oil

The Insulating oil used in Transformer shall comply with the requirement of IS 335
(Specification for insulating oil for transformers and switchgears).

If the transformer is filled up with oil and transported to site, then 10% oil shall be
supplied extra in non-returnable containers/drums suitable for outdoor storage. In
case, transformer is sent without oil, then full quantity of transformer oil along with
10% extra shall be supplied in non-returnable containers/drums suitable for outdoor
storage

2.2 Cooling
The transformer shall be oil immersed natural air-cooled type (ONAN)

2.3 On Load Tap changing Device

The tapping shall be arranged on the high voltage windings and the tap changer shall
be on-circuit type for voltage adjustments in steps of -10% to + 10 % with steps 1.25
% of rated voltage at constant kVA output.

2.4 Other Fittings & Accessories

The followings accessories and fittings shall be provided with the transformer.

1. Lifting Lugs / The arrangement of lifting the active part of the

Cover lifting eye transformer without disturbing the connections and
bolt also complete transformer lifting lugs shall be provided

2. Rollers 4 Nos. bi-directional rollers of suitable size

corresponding to weight of transformer, fitted on cross
channels, to facilitate the movement of transformer

3. Oil Conservator A conservator with welded end plates. Dimensions of

the conservator shall be such as to allow change in
volume due to change in temperature from 10 deg c to
95 deg c. It is to be bolted to the cover and can be
dismounted for purposes of transport. It has to be
provided with oil level gauge with marking for minimum
level and an oil-filling hole with a cap, which can be used
for filtering of oil. For draining purposes, a plug is to be
provided. A connection pipe between the conservator
and main tank is to be provided.

4. Air Release Valve An Air release valve on top of the tank cover to facilitate
the release of the entrapped air while filling of oil

5. Breather An indicating dehydrating silica gel breather of sufficient

PAGE - 747
 capacity along with breather pipe of suitable size

6. Drain Valve Oil drain valve of size as per IS with plug at the bottom
with Plug of the tank

7. Diagram and One diagram and rating plate indicating the details of
Rating Plate transformer connection, diagram vector group, tap
changing diagram etc
8. Thermometer Dial type thermometer (150 mm dia) and electrical
contacts for electrical alarm at high temperature

9. Explosion Vent Explosion vents or pressure relief device of sufficient

with diaphragm size for rapid release of any pressure that may be
generated within the tank and which might result in
damage to the equipment. The device shall operate at a
static pressure less than the hydraulic test pressure for
transformer tank.

10. Filter Valve Filter Valve in the tank.

11. Bucholtz Relay Oil & Gas actuated relay equipment shall conform to IS
3637 – 1966 (amended up to date) and shall be double
float type having contacts which close following oil surge
or under incipient fault condition. Bucholtz relay shall
have contacts for alarm/trip.

12. ON-circuit tap On- load tap changer to cater to voltage variation range
changer of -10% and + 10% in steps of 1.25%.
13. Oil Temperature Oil temperature indicator with alarm and trip contacts.
Indicator
14. Winding Winding temperature indicator with alarm and trip
temperature contacts.
indicator
15. Marshalling Suitable size marshalling box to terminate the control
Box cables of thermometer and Bucholtz relay.

16. Earthing Two separate earthing terminals consisting of bolts of

Terminals not less than 20 mm are to be provided at the sides of the
tank on both sides for body earthing
17. Other Standard As per IS
Accessories

2.5 Vector Group & Connections

Corresponding to the vector symbols Dyn-11.
The primary windings shall be connected in delta and the secondary windings in star
(Vector symbol Dyn-11) so as to produce a positive displacement of 30 degree from
primary to the secondary vectors of the same phase. The neutral of the secondary
windings shall be brought out to two separate insulated terminals.
2.6 Terminal Arrangements

PAGE - 748
 Secondary Side
The terminal arrangement at secondary side (0.433 kV side) shall be suitable for
terminating as per, 1.1kV Al Conductor, XLPE insulated, Armoured cable/BUS Duct
with sufficient space inside for termination and connections.

Two (2) nos. of neutral bushing shall be provided-one (1) for tapping neutral (4th wire)
and one (1) for neutral earthing.

2.7 Primary Side

The terminal arrangement on primary side (33 kV side) shall be suitable for
terminating 3 Core, Al Conductor, XLPE insulated, Armoured, 33 kV cable. The rating
of cable shall be as per design. The transformer shall be provided with weather proof
outdoor type cable box suitable for XLPE cable as mentioned. Outdoor heat shrinkable
termination kit shall be used for termination of HT Cable. Terminal box shall be
provided with removable gland plate.
In general, the arrangement shall be such as to permit removal of the transformer
without dismantling the bus duct/cable installation.

2.8 Painting
All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents as
required, to produce a smooth surface free of scales, grease and rust.

The steel surfaces after cleaning shall be given a coat of high-quality red oxide or
yellow chromate primer followed by final coats.

The internal surfaces in contact with insulating oil shall be painted with heat resistant
insulating varnish which shall not react with and not soluble in the insulating liquid
used.

The transformer shall be finished with two coats of synthetic enamel paint.

The paints shall be carefully selected to withstand tropical heat, rain etc. The paint
shall not scale off or crinkle or be removed by abrasion due to normal handling.

Where the painting is damaged during transit, installation etc., touch up painting shall
be done at site.

2.9 ON Circuit Tap Changing Mechanism /OLTC (On Load Tap Changer)
The OLTC shall follow following:
a) OLTC to be designed to complete successfully tap changes for the maximum
current to which transformer can be loaded i.e. 150% of the rated current.
Devices shall be incorporated to prevent tap change when the through current is
in excess of the safe current that the tap changer can handle. The OLTC gear shall
withstand through fault currents without injury.
b) When a tap change has been commenced it shall be completely independently of
the operation of the control relays and switches. Necessary safeguard shall be
provided to allow for failure of auxiliary power supply or any other contingency

PAGE - 749
 which may result in the tap changer movement not being completed once it is
commenced.
c) Oil in compartments which contain the making and breaking contacts of the OLTC
shall not mix with oil in other compartments of the OLTC or with transformer oil.
Gases released from these compartments shall be conveyed by a pipe to a
separate oil conservator or to a segregated compartment within the main
transformer conservator. An Oil surge relay shall be installed in the above pipe.
The conservator shall be provided with a prismatic oil level gauge.
d) Oil, in compartments of OLTC which do not contain the make and break contacts,
shall be maintained under conservator head by valve pipe connections. Any gas
leaving these compartments shall pass through the Buchholz relay before
entering the conservator.
e) Oil filled compartments shall be provided with filling plug, drain valve with plug,
air release vent, oil sampling device, inspection opening with gasketed and bolted
cover with lifting handles.
f) OLTC driving mechanism and its associated control equipment (local) shall be
mounted in an outdoor, weather-proof cabinet with IP 55 protection which shall
Include:-
 Driving motor (415V, 3-phase, 50 Hz. AC squirrel cage).
 Motor starting contactor with Motor Protection Circuit Breaker, isolating
switch and HRC fuses.
 Control switch: Raise/off/lower (spring return to normal type).
 Remote/local selector switch (maintained contact type).
 Mechanical tap position indicator showing rated tap voltage against each
position and resettable maximum and minimum indicators.
 Limit switches to prevent motor over-travel in either direction and final
mechanical stops.
 Brake or clutch/similar mechanism, to permit only one tap change at a time on
manual operation.
 Emergency manual operating device (hand crank or hand wheel).
 Operation counter.
 Electrically interlocked reversing contactors.
 240V, 50 Hz. AC space heater with 2A MCB.
 Interior lighting fixture with lamp door switch.
 Gasketed and hinged door with locking arrangement.
 Terminal blocks, internal wiring, earthing terminals and cable glands for
power and control cables.
 Necessary relays, contactors, current transformers etc.
g) Control requirements for OLTC shall be as per manufacturer.
h) Automatic Control of OLTC: Automatic OLTC control shall include the following
items:
 Voltage setting device.
 Voltage regulating devices.

PAGE - 750
  Timer 5-25 seconds for delaying the operation of the tap changer in the first
step for every tap change operation.
 Adjustable band for voltage variation.

2.10 OLTC/RTCC Panel:

The OLTC remote control equipment shall be suitable for 24V DC supply and shall be
housed in an indoor sheet cubicle to be located in a remote control room. The OLTC
control panel shall comprise of rigid welded structural frames made of structural steel
section or of pressed CRCA enclosures, doors and partitions shall be of cold rolled steel
of thickness 2 mm. Stiffeners shall be provided wherever necessary. All doors,
removable covers and plate shall be gasketted all around with neoprene gaskets. Panel
shall be dust, weather and vermin proof providing degree of protection of IP54.
Earthing bus shall be of 25 x 6 mm copper.
Control switch : Raise/Off/Lower
Auto/manual selector switch :
(Maintained contact type)
Tap position indicator :

2.10.1 Facia type alarm annunciator with “accept” and “lamp test” facilities.
a) A.C. supply failure
b) Drive motor auto tripped
c) Tap change delayed
2.10.2 Necessary auxiliary relays
2.10.3 Lamp indications for:
a) Tap change in progress
b) Lower limit reached
c) Upper Limit reached
d) Cable glands for power and control cables
e) 240 V rated panel space heater with ON-OFF switch
f) LED lighting fixture with lamp and door switch
g) Terminal blocks
h) Internal wiring
i) Earthing terminal
j) Supply ON Indication Lamp.
k) Labels for Accessories.
l) Automatic Voltage Regulating Relay.
m) Heater Switch (Rotary Type)
n) Control Supply Switch (Rotary Type)
o) Hooter
p) Time Delay Relay for ‘Tap Change Delayed’
q) H.V. Voltmeter (Digital Type)
r) H.V. Voltmeter Selector Switch (Rotary Type)
s) L.V. Voltmeter (Digital Type)
t) L.V. Voltmeter Selector Switch (Rotary Type)
u) PT for AVR.

PAGE - 751
 v) Tap changer Counter for registering No of times the Tap is changed for voltage
correction.

2.11 Valves
a) One (1) top filter valve with blanking plate.
b) One (1) bottom filter valve with blanking plate.

3.0 Installation
Following shall be the part of the installation works
 Transformer shall be installed in accordance with IS 10028-Code of Practice
for Installation & Maintenance of Transformer
 Verification for transit damages/ availability of all items including accessories,
operating handles, instruction manuals, drawings, test certificates etc and
taking necessary action where needed.
 Grouting/ securing to the floor/ base channels etc for stable installations.
 Touching up damaged painting portions.
 Making earth connection of the unit.
 Interconnection with OLTC, Marshalling box & RTCC Panel etc.
 scope of cable termination and bus duct connection is covered nothing extra
shall be paid.
 Provision of interlocks where needed.
 Obtaining requisite statutory approval, (CEA clearance) licenses etc. where
applicable.
 Satisfactory commissioning the equipment/system.

4.0 Testing
General
Tests shall be carried out on transformers in accordance with IEC Publication 76 / IS
2026, IEC as specified below.
Type & Special Test
The following shall be regarded as type tests.
 Temperature Rise Test. (IS 2026 Part-3).
NOTE – Maximum measured total loss (No load at rated excitation + load loss at
maximum current tap converted to 75 ºC reference temperature) at 100 percent
loading shall be supplied during temperature rise test.
 Lightning Impulse Test (IS 2026 Part-3).
 Vacuum test.
 Determination of sound levels (IS 2026: Part 10).
 Short-circuit withstand test (IS 2026: Part 5)
 BDV and Moisture content of fluid in the transformer IS 16099 and IEEE
C57.147
 Noise level measurement, in accordance with IEC Publication 551 using a precision
sound level meter conforming to IEC Publication 651. In addition the test shall be
repeated with narrow band filters for the harmonic frequencies from 100Hz. up
to 350 Hz.

PAGE - 752
 Following routine test shall be performed before dispatching Transformer from
Factory as per IS-2026-I in the presence of Engineer In charge or his authorized
representative
 Measurement of winding resistance
 Measurement of voltage ratio and check of phase displacement.
 Measurement of short-circuit impedance (principal tapping, when applicable) and
load loss at 50 percent and 100 percent load.
 Measurement of no-load loss and current.
 Measurement of insulation resistance.
 Induced over-voltage withstand test IS 2026 (Part 3).
 Separate-source voltage withstand test IS 2026 (Part 3)
 Dielectric Test
 Tests on on-load tap-changers, where appropriate
 Pressure test
 Oil leakage test

Following routine test shall be performed before Energizing the Transformer at

site as per IS-2026-I

 Operational checking of the protection system

 Insulation resistance (IR) measurement
 Measurement of capacitor bushings
 Measurement of voltage ratio (turns ratio)
 Measurement of vector group or polarity of the transformer
 Measuring of winding resistance
 Operational measurement on OLTC’S.

5.0 Specific Technical Requirement

 For all Indoor Transformers, the interconnecting cabling for various instruments
on the Transformer shall be routed on perforated MS cable tray with top cover till
the marshalling box. The PRV relay shall be provided with canopy to avoid any
ingress of water during rain.
 The finish shade for the transformer enclosure and its accessories shall be RAL
7032. The type of paint shall be synthetic enamel air-dried.
 Structural support for mounting lightning arrestor on the body above HT bushing
shall be provided.
 The transformer enclosure shall be provided with copper earth bus of size as per
applicable standards for neutral and body earthling by connecting to earth grid..
 The winding temperature and Oil temperature scanner shall be numeric type with
alarm and trip contacts. The scanner shall also provide rate of rise of temperature
feature with separate alarm and trip contacts. This shall also include hot spot
temperature and temperature trend displays. The scanner shall have RS 485
communication port.
 The HV and LV side cables shall not be directly terminated on the transformer. An
extension busbar with post insulator shall be provided for the purpose.
 RCBO of suitable rating shall be used in the control & aux. circuits. All control
scheme of Marshaling box shall be designed as fuse less system.

PAGE - 753
 20% spare terminal blocks shall be available in each termination location of TB's
for future use.

Test Certificates
Following test certificate shall be submitted by the agency: -
a. Test Certificate for the type tests
b. Test Certificate for the routine tests.
c. Test certificates for the site tests including di-electric strength of transformer
oil.
Drawings/Documents

The following drawings/documents (3 sets) shall be furnished along with the

transformer.
 Foundation details, if any.
 Installation, Operation & Maintenance manuals
 General layout including the dimensions
 Details of after-sales service
 Electrical drawings
 Others, if any, as per site requirements.

PAGE - 754
Section :-3 33 KV SURGE ARRESTORS
1.0 Introduction
This section covers the specification of Distribution class Surge Arrestor for 33 kV
indoor type VCB breaker panel, transformers etc.
1.1 Standards
The design, manufacture and performance of Surge Arrestor shall comply with IS:3070
Part-3 and other specific requirements stipulated in the specification. Unless otherwise
specified, the equipment, material land processes shall conform to the latest applicable
Indian/International Standards as listed hereunder:
IS:2071-1993(Part-1) Methods of High Voltage Testing
Requirements. General Definitions & Test
IS:2071-1974(part-2) Test Procedures
IS:2629-1985 Recommended Practice for hot dip galvanizing on Iron
& Steel
IS:2633-1986 Method for Testing uniformity of coating of zinc coated
Articles.
IS3070-1993 (Part–3) Specification for surge arrestor for alternating current
systems. Metal-Oxide lightening Arrestors without
gaps.
IS:4759-1996 Specification for hot dip zinc coating on
Structural Steel and Other allied products.
IS:5621-1980 Hollow Insulators for use in Electrical
Equipment.
IS:6209-1982 Methods of Partial discharge measurement.
IS:6745 Method for determination of mass of zinc coating on
zinc coated iron and steel articles.
ANSI/IEEE-C.62.11: Metaloxide, Surge Arrestor for AC Power(1982)
Circuits.
IEC–60099-4 Surge Arrestors
The equipment complying with any other internationally accepted standards shall also
be considered if it ensures performance equivalent to or superior to the Indian
Standards.
1.2 General requirement
 The metal oxide gaps less Surge Arrestor without any series or shunt gap shall be
suitable for protection of 33 kV Breaker & 33 kV side of transformer from voltage
surges resulting from natural disturbance like lightning as well as system
disturbances.
 The surge arrestor shall draw negligible current at operating voltage and at the
same time offer least resistance during the flow of surge current.

PAGE - 755
 The surge arrestor shall consist of non-linear metal oxide resistor elements placed
in series and housed in electrical grade porcelain housing/ silicon polymeric of
specified Creepage distance.
 The assembly shall be hermetically sealed with suitable rubber gaskets with
effective sealing system arrangement to preventing ress of moisture.
 The surge arrestor shall be provided with line and earth terminals of suitable size.
The ground side terminal of surge arrestor shall be connected with 25x6 mm
galvanized strip, one end connected to the surge arrestor and second end to a
separate ground electrode. The contractor shall also recommend the procedure
which shall be followed in providing the earthing/ system to the Surge Arrestor.
 The surge arrestor shall not operate under power frequency and temporary over
voltage conditions but under surge conditions, the surge arrestor shall change over
to the conducting mode.
 The surge arrestor shall be suitable for circuit breaker performing O-0.3min-CO-
3min-CO duty in the system.
 The reference current of the arrestor shall be high enough to eliminate the
influence of grading and stray capacitance on the measured reference voltage.
 The Surge Arrestor shall be thermally stable and the contractor shall furnish a copy
of thermal stability test with the bid.
 The arrestor shall be capable of handling terminal energy for high surges, external
pollution and transient over voltage and have low losses at operating voltages.
Arrestor housing
 The arrestor housing shall be made up of silicon polymeric housing and shall be
homogenous, free from laminations, cavities and other flaws of imperfections that
might affect the mechanical and dielectric quality. The housing shall be of uniform
Grey (for silicon polymeric) colour, free from blisters, burrs and other similar
defects.
 The housing shall be so coordinated that external flashover shall not occur due to
application of any impulse or switching surge voltage upto the maximum design
value for arrestor. The arrestors shall not fail due to contamination. Sealed
housings shall exhibit no measurable leakage.
Arrestor mounting
The arrestors shall be suitable for mounting on VCB breaker panel for transformer
and for incoming and outgoing lines.
Fittings & Accessories
The surge arrestor shall be complete with disconnect or and terminal connectors and
all other accessories.
 The terminals shall be non-magnetic, corrosion proof, robust and of adequate size
and shall be so located that incoming and outgoing connections are made with
minimum possible bends. The top metal cap and base of surge arrestor shall be
galvanized. The line terminal shall have a built in clamping device which can be
adjusted for both horizontal and vertical take-off.

PAGE - 756
2.0 Tests
Test on Surge Arrestors
The Surge Arrestors offered shall be type tested and shall be subjected to routine and
acceptance tests in accordance with IS : 3070 (Part-3)-1993. In addition, the
suitability of the surge arresters shall also be established for the followings
2.1 Acceptance tests:
Measurement of power frequency reference voltage of arrester units.
Lightning impulse residual voltage on arrester units (IECclause6.3.2)
Internal ionization or partial discharge test.
Special Acceptance tests:
Thermal stability test (IECclause7.2.2)

2.2 Routine tests:

Measurement of reference voltage
Residual voltage test of arrester unit
Internal ionization or partial discharge test.
Sealing test
Verticality check on completely assembled surge arresters as a sample test on each
lot if applicable.

PAGE - 757
Section :-4 RISING MAIN & BUS DUCT (Sandwich Type )
1.0 Scope
This section covers manufacture, supply, installation, testing and commissioning of
sandwich Rising Main/ insulated bus trunking for connection between the
Transformers to Main LT panel, DG Set to DG AMF Panel, DG AMF to Main LT panel, LT
panel to floor distribution panel & for Technical Block & ATC floor wise distribution .
1.1 Supply Voltage
For 3 phase, 4 wire, 50 cycles AC supply, operating voltage 415/ 440 volts.
1.2 Standard for Compliance
The equipment specified in the specification shall be designed, manufactured and tested
in accordance with latest relevant British standards or IEC codes. In the event of any
contradiction between this specification and IS/IEC codes then the stringent of the two
shall govern.
S.No. Applicable Standards /Mandatory Particulars
1. IEC 61439 (Part-1) Low-voltage switchgear and control gear assemblies
Part-1 General Rules
2. lEC 61439 (Part-6) Bus Trunking System
3. lEC 60529 Degree of protection provided by enclosures
4. IEC 60068-3-3 UBC/Indian Seismic Standard
5. EC 61439-6 Current density

1.3 Construction & Technical Parameters for Compliance

 The Bus Bar shall conform to IEC61439-6: 2012.
 Bus bars shall be in ‘Sandwich’ construction with Aluminium conductors
 Aluminium conductors will be individually insulated with 4 layers of insulating film.
 Busbar shall have minimum Class F insulation.
 Bus bar enclosure shall be made from 1.6 mm CRCA sheet steel/ extruded
Aluminium powder coated to shade RAL 7032 (or such other shade).
 Bus Bar conductors will be of 19501 grade and copper conductor of 99.5% purity
(or supreir)) and ETP grade with radialised edges.
 Enclosure will be tested for protection degree IP-54 for indoor & IP-65 for outdoor
use.
 Rated operation voltage of the busbar trunking up-to 690V., 3 – Phase, 4 or 5 Wire
with continual integral/internal earth busbar.
 Length of section will be limited to max 3 Mtrs.
 Bus bars of one section will be connected to Bus bars of adjacent section by uniblock
joint system removable as separate sub-assembly, so that it can be inserted or
removed without disturbing the adjacent sections.
 The whole busbar trunking system shall be capable of withstanding the rated short
circuit current (as per design requirement) of the electrical installation without
damaging the electrical, mechanical and thermal stress under fault condition at the
service voltage 50Hz.

PAGE - 758
  The minimum rated insulation voltage shall be 690V.
 Busbar system should be designed for an ambient temp. of 40 deg C. and temp. rise
restricted to 55 Deg. C max. above ambient on conductor Temperature rise of the
enclosure 40 Deg. C maximum. Temperature rise at terminals 70 Deg. C max.
 Maximum operating voltage = 1000 Volts (690 volts)
 Insulation voltage = 1000 Volts.
 Bus trunking will be suitably chosen to given permissible voltage drop (Limited to
4%).
 Rated impulse withstand voltage 12 KV at 1000 V (690 volts)

1.4 Expansion Joints & Thrust Pads

 Expansion joints shall be provided wherever necessary to take care of expansion &
contraction of the bus bars under normal operating conditions.
 Expansion joints shall be provided after length of 30 mtrs for aluminium conductor
bus trunking and after 40 mtrs for copper conductor bus trunking.
 The bus bars shall be provided with thrust pads so that the expansion of the
conductors is upwards only.
 The bus bar clamps and insulations shall be designed to withstand the forces due to
short circuit current. They shall also permit free vertical movement of the bus bar
during expansion and contraction.

1.5 Earth Strip

 Continual integral/internal earth busbar of copper are to be provided, one on each
side all along the Rising Mains/Bus duct of size dependent on short circuit withstand
for one second of Rising Mains specified as per derivation given below (IEC 60439/I).

1.6 Installation
 Normally manufacturer’s recommendations should be followed. For installation as
Rising Mains/ Vertical installation, at each floor, a set consisting of two Spring
Hangers will be provided for fixing it on channels grouted in wall. At the start of run,
Hangers without springs may be used for rigid support. In additional Horizontal
supports will be provided (2 Nos. per floor) to hold bus bars in position. Neutral cross
section will be same as Phase cross section.
 Necessary Vertical, Horizontal Bends, Tees, elbow, hangers (for support) will be
provided as required by design layout.
 Bus bars trunking will be rigidly fixed to the side on switchgear panel, busduct will
be provided with flange ends, adopter Box and copper flexibles (preferably multi
sheet types) to connect Bus bars of bus duct to busbars of switchgear panel or
transformer terminals or generator terminals.

Note- All the components like Adopter Boxes/end feed unit, flexible copper
connection/suitable material flexible connection. Vertical & Horizontal Bends, Tees,
elbow, hangers, Fire barriers (if required) shall be provided as per design requirement,
nothing extra shall be paid for this account.

PAGE - 759
2.0 Test

2.1 Type Tests: Copies of the following certificates should be submitted.

(i) Verification of Temperature Rise limits.
(ii) Verification of dielectric properties.
(iii) Verification of short circuit strength.
(iv) Verification of degree of protection.

2.2 Routine Tests

(i) Verification of insulation, resistance.
(ii) Inspection of assembly, interlocks, locks etc.
(iii) Check on wiring if provided.
(iv) Dielectric test.

PAGE - 760
Section -5 CABLES

1.0 HT CABLES

1.1 General
L.T. Cables shall be supplied, inspected, laid tested and commissioned in accordance
with drawings, specifications, relevant Indian Standards specifications and cable
manufacturer’s instructions. The cable shall be delivered at site in original drums with
manufacturer’s name clearly written on the drums. The recommendations of the cable
manufacturer with regard to jointing and sealing shall be strictly followed.
1.2 Construction
 H.T. Cables shall be of 33 kV grade 3 Core XLPE insulated Aluminium Conductor
armoured U.G Cables Un-earthed/Earthed as per design requirements with
electrolytic grade purity aluminium conductor, shall be manufactured & tested in
accordance with IS: 7098 (Part II).
 H.T. Cable shall be of earthed grade and shall be of stranded construction, comply to
IS 8130.
 The conductor screen & insulation screen shall both be of extruded semi conducting
compound and shall be applied along with XLPE insulation in a single operation of
triple extrusion process so as to obtain continuously smooth interphase.
 The metallic screen of each core shall consist of copper wires or tape. The method
of curing shall be dry curing. Metallic screen shall be suitable for carrying the fault
current of minimum 26.3 kA for 33 kV for one second.
 Outer sheath shall be of tough, PVC compound as per IS: 5831 and shall be extruded
over the armouring.
 Cables shall be tested for type test & routine test in accordance with IS: 7098 (Part
II).
1.3 Termination Joints
Terminal joints shall be carried out inside the cable end boxes fixed on the equipment.
Lugs shall be fitted by the means of bolts and nuts with the terminal studs. On the
glands, armour of the cable shall be fixed by means of clamps which shall be grounded.
Heat shrink/push on type cable termination kit shall be used for terminations.
1.4 Joints in Cables
The Contractor shall take care to see that the cables received at site are apportioned to
various locations in such a manner as to ensure maximum utilisation and avoiding of
cable joints. This apportioning shall be got approved from Engineer-in-Charge before
the cables are cut to lengths.
1.5 Inspection & Testing
 The HT cables shall be inspected in the OEM factory before dispatching.
 All LT Cables shall be inspected at site and checked for any damage during transit
 All the routine & acceptance as per IS: 7098 (Part II) shall be conducted in the
presence of AAI representative.

PAGE - 761
2.0 LT Cables

2.1 General

L.T. Cables shall be supplied, inspected, laid tested and commissioned in accordance
with drawings, specifications, relevant Indian Standards specifications and cable
manufacturer’s instructions. The cable shall be delivered at site in original drums with
manufacturer’s name clearly written on the drums. The recommendations of the cable
manufacturer with regard to jointing and sealing shall be strictly followed.
2.2 Construction

L.T. Cables shall be XLPE insulated and PVC sheathed aluminium conductor armoured
cables conforming to IS : 7098 (Part I). Cables shall be of 1100 volt and with ISI
certification mark. Conductor of power cables shall be made of electrical purity
aluminium conforming to IS : 8130-1984.
2.3 Joints in Cables
The Contractor shall take care to see that the cables received at site are apportioned to
various locations in such a manner as to ensure maximum utilisation and avoiding of
cable joints. This apportioning shall be got approved from Engineer-in-Charge before
the cables are cut to lengths.

2.4 Inspection & Testing

 The LT cables shall be inspected in the OEM factory before dispatching.

 All LT Cables shall be inspected at site and checked for any damage during transit
 All the routine & acceptance as per IS: 7098 (Part I) shall be conducted in the
presence of AAI representative.

3.0 Testing of Cables

Prior to installation burying of cables, following tests shall be carried out. Insulation
test between phases, phase & neutral, phase & earth for each length of cable.
 Before laying.
 After laying.
 After jointing.
On completion of cable laying work, the following tests shall be conducted in the
presence of the Engineer in Charge.

a. Insulation Resistance Test (Sectional and overall).

b. Continuity Resistance Test.
c. Earth Test.

Note -All tests shall be carried out in accordance with relevant Indian Standard code
of practice and Indian Electricity Rules. The Contractor shall provide necessary
instruments, Equipment’s and labour for conducting the above tests & shall bear all
expenses of conducting such tests.

PAGE - 762
4.0 HT & LT Cable laying
 Cables shall be laid directly in ground, pipes, HDPE pipe (through trenchless
mechanism) masonry ducts, on cable tray, etc. as as per the design & site
requirements.
 All the HT & LT cables shall be laid in accordance to CPWD specifications/ IS: 1255
amended upto date.
4.1 Route Markers
 Location
Route markers shall be provided along the runs of cables at locations approved by
the Engineer-in-charge and generally at intervals not exceeding 100m. Markers
shall also be provided to identify change in the direction of the cable route and at
locations of underground joints.
 CC Marker
Cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate of
20mm in size) shall be laid flat and centered over the cable. The concrete markers,
unless otherwise instructed by the Engineer-in-charge, shall project over the
surrounding surface so as to make the cable route easily identifiable.

5.0 Fire survival Cables (Armoured or Unarmoured )

 The MICA taped Fire survival cable shall be taped, insulated overall shielded LPCB
certified cable conforming to British Standard (BS: 7846) and shall pass the fire
tests as per BS6387 CWZ, BSEN 50200.
 The MICC cable shall be manufactured and tested to British Standard (BS EN
60702-1).
 The cable shall be conforming the following fire and safety test standard: BS 6387
C, W, Z which states the performance requirements for cables required for circuit
integrity under fire condition, BS EN 50200 PH 120 Enhance which demands for
continuous performance of 2 hrs. Fire resistance @850oC, BS 8434-2 test perform
on unprotected small cable for use in emergency circuit.
 The cable should withstand 950oC temperature for 3 hours conforming to BS 6387
C standard.
 The cable should withstand at 650oC temperature under fire with water condition
and conforms to BS 6387 W standard.
 The cable should withstand at 950oC temperature under fire condition with
mechanical shock and conforms to BS 6387 Z (highest) standard.
 The cable shall be LSZH (Low Smoke Zero Halogen) type, and approved by LPCB
board confirming BS EN 50267 British Standard.
 The cable shall be connected to the various devices with proper termination kits/
glands. Appropriate glands shall be provided where the cable enters the junction
box.
 Wherever required HPSR fire survival (for fire alarm and lower rating) as per
BS7629 shall comply; Insulated overall shielded, Halogen Free Sheathed, BASEC
and LPCB Certified for required sizes. Fire Test as per BS6387 CWZ, BSEN 50200
pH120.

PAGE - 763
SECTION-6 DIESEL GENERATORS

1.0 General

1.1 Scope

These specifications cover the general specifications pertaining to supplying,

assembling, erecting, testing and commissioning of Silent type with Acoustic enclosure
LT D.G. sets, AMF panel complete in all respects as indicated in these specifications.
The scope shall include supplying, assembling, associated equipment completes with
standard accessories etc. as required.
1.2 Approval /Conformity to Statutory Acts, Rules, Standards And Codes
 All components shall conform to relevant Indian Standard Specifications,
wherever existing, amended to date.
 All electrical works shall be carried out in accordance with the provisions of
Indian Electricity Act, 2003 and Indian Electricity Rules, 1956 as amended up to
date. They shall also conform to CPWD General Specifications for Electrical works,
Part-I (Internal), 2013 and Part-II (External), 1994 and Part IV (Sub-station),
2013, as amended up to date.
 Clearance/ Approval of the complete installation from CPCB/ State Pollution
Control Board, Central Electricity Authority (CEA)/ Local Bodies and other
licensing authorities, wherever required. Nothing extra shall be paid to the
contractor on this account.
 Applicable Standards are listed 1. below: -

S.No. Applicable Standards

1. IS 1601 Performance and testing of 1C engines for General
Purpose
2. BS-649 Performance and testing of diesel engines for General
Purpose
3. IS-4722 Rotating electrical machines
4. IS-4889 Method of determination of efficiency of Rotating
Electrical machinery.
5. IS-6491 Degree of protection provided by enclosures for
Rotating Electrical machinery
6. IS-4729 Measurement and evaluation of vibration of Rotating
Electrical machines.
7. IS-2705 Current transformers.
8. IS-1248 Electrical indicating instruments
9. AIEE-606 Recommended specification for speed governing of
internal (1959) combustion engine generator units
10. ISO-8528 Reciprocating IC engine driven AC Gensets Section (Part
II)
11. IS-10000 Method of tests for I.C engines

PAGE - 764
 12. CPWD Amended up to date
specifications
13. CPCB norms Amended up to date

1.3 Inspection and Testing of DG sets

1.3.1 Inspection at factory/ manufacturer premises
 Testing shall be carried out at factory/ manufacturer premises in presence of
representative of the Department.
 For testing, following procedure will be followed: All major items/ equipment’s
i.e. engine & alternator in assembled condition, associated electrical control
panels etc. shall be offered for inspection and testing at factory/ manufacturers
works. The successful tenderer shall give a notice of minimum two weeks for
carrying out such tests. The Engineer-in-charge/ or his authorized representative
shall witness such inspection & testing at mutually agreed date. The DG set will
be cleared for dispatch to site only when the testing is declared successful by
authorised representative/ Engineer-in-Charge
 The cost of the representative’s visit to the factory will be borne by the
Department.
 The department also reserves the right to inspect the fabrication job at factory
and the successful tenderer has to make arrangements for the same.
 DG set will be tested on load of unity power factor for the rated KW rating. During
testing, each of the D.G. sets covered under scope of work, shall be operated for a
period of 12 hours on the rated KW at DG set’s KW rating including one hour on
10% overload after continuous run of the 12 Hours.
 During testing all controls/ operations safeties will be checked and proper record
will be maintained. Any defect/abnormality noticed during testing shall be
rectified.
 The testing will be declared successful only when no abnormality/ failure is
noticed during the testing.
 The required load & fuel shall be borne by contractor ,nothing extra shall be paid
for testing the DG set.
 Copies of all documents of routine and type test certificates of the equipment,
carried out at the manufacturer’s premises shall be furnished to the Engineer-in-
charge and consignee.
1.3.2 Inspection at site
 After completion of the installation work in all respects, the contractor shall offer
the DG Sets for testing.
 Acceptance test on completion of the work shll be done at site
 The D.G. Set shall for 12 hours at rated KW load and thereafter at 10% overload
for one hour
 The required electrical load and all consumables including the fuel etc. shall be

PAGE - 765
 provided by the contractor and nothing extra shall be paid for this account.
 After this the DG Set will be made available for beneficial use. DG Set has operated
without any major break-down/ trouble, shall be taken over by the department
subject to guarantee clause of the contract.
 This date of taking over of the DG Set, after trouble free operation during the trial
run/ running-in period, shall be the date of acceptance/ taking over.

1.3.3 TYPE TEST and TEST CERTIFICATES

 Copies of manufacturer’s type test for the engine and the alternator shall be
enclosed along with the dispatch of the DG sets.

1.4 Statutory Clearance(S)

 Approval/ clearance of the complete installation shall be obtained by the
contractor from CPCB/ State pollution Control Boards/ Local Bodies/ Central
Electricity Authority (CEA)/ other licensing authorities wherever required.
 Nothing extra shall be paid for this account.

1.5 GUARANTEE
 All equipment’s shall be guaranteed, against unsatisfactory performance and/ or
break down due to defective design, workmanship or material, for a period of 12
months from the date of taking over the installation by the department.
 The equipment’s or components, or any part thereof, so found defective during
guarantee period shall be forthwith repaired or replaced free of cost, to the
satisfaction of the Engineer- in-Charge. In case it is felt by the department that
undue delay is being caused by the contractor in attending the defect/ fault
removed, the same will be got done by the department at the risk and cost of the
contractor. The decision of the Engineer- in-charge in this regard shall be final.

1.6 SHOP DRAWINGS FOR APPROVAL & COMPLETION DRAWINGS

The contractor shall prepare & submit three sets of following drawings and get them
approved from the Engineer-in-charge before the start of the work. The approval of
drawings however does not absolve the contractor not to supply the equipment’s/
materials as per agreement, if there is any contradiction between the approved
drawings and agreement.

 Lay out drawings of the equipment’s to be installed including control cables, fuel/
lube oil pipes and supports/ structure for exhaust piping, Chimney and bus ducts/
cable trays.
 Drawing including section, showing the details of erection of entire equipment’s.
 Electrical wiring diagrams from engine-alternator set to Electrical control/AMF
panel, Electrical control/AMF panel to Mainl LT Panel including the sizes and
capacities of the various electrical/ control cables and equipment.

PAGE - 766
  Dimensioned drawings of Acoustic enclosure/ Engine- Alternator set and
Electrical control panel.
 Drawings showing of support for pipes, chimney cable trays, ducts etc.
 Any other drawings relevant to the work.

1.7 Drawings/Documents to be furnished on completion of Installation-

Three sets of the following laminated drawings shall be submitted by the contractor
while handing over the installation to the Department. Out of these three, one set shall
be laminated on a hard base for display in the DG set room/ AMF panel to be installed.
In addition, drawings will be given on Hard drive /Pendrive:

 DG set installation drawings giving complete details of all the equipment’s,

including their foundations.
 Line diagram and layout of all electrical control/AMF panels giving switchgear
ratings and their disposition, cable feeder sizes and their layout.
 Control wiring drawings with all control components and sequence of operations
to explain the operation of control circuits in AMF panel/PCC.
 Manufacturer’s technical catalogues of all equipment’s and accessories.
 Operation and maintenance manual of all major equipment’s, detailing all
adjustments, operation and maintenance procedure.
1.8 After Sales Services
 The contractor shall ensure adequate and prompt after sales service free of cost
during guarantee period, and against payment after the guarantee period is over,
in the form of maintenance, spares and OEM personnel as and when required
during normal life span of the equipment’s and shall minimize the breakdown
period.
 In case of equipment supplied by other manufacturers the firm shall furnish a
guarantee from the manufacturer for the same before the DG Set installation is
taken over.

2.0 Technical Requirements

2.1 DG Sets with acoustic enclosure
 DG sets are required to be supplied with acoustic enclosure as per CPCB norms.
 Electrical Control/AMF panel has to be installed outside the acoustic enclosure,
location of room to house Electrical Control/AMF panel should be decided in
consultation with the Architect or Engineer-In-Charge so that,it shall be as near
to the acoustic enclosure as possible. Specially, in case of connection through bus
trunking, care should be taken for aesthetics.

2.2 Climatic Conditions & Rating

 The Capacity output of DG Set should be specified in terms of “Prime Power”
Rating as per IS 8528 under actual site conditions.
 The tenderer has to certify that the engine & alternator meets the capacity

PAGE - 767
 requirement after de-ration as per IS/ BIS.
 DG Set should be type tested for Noise and Emission norms/standards as per
CPCB.

2.3 Diesel Engine

2.3.1 Engine Rating:
 The engine shall be of standard design of the original manufacturers. It should be
4 stroke cycles, water/Radiator cooled, naturally aspirated /turbo charged (as
per manufacturer standard), developing suitable BHP for giving a power rating as
per ISO 8528- Part-1 in KVA at the load terminals of alternator at 1500 rpm at
actual site conditions.
 The engine shall be capable for delivering specified Prime Power rating at
variable loads for PF of 0.8 lag with 10% overload available in excess of specified
output for one hour in every 12 hours. The average load factor of the engine over
period of 24 hours shall be as per IS 8528 for prime power output.
 The engine shall conform to IS; 10000/ ISO 3046/ BS; 649 /BS 5514 amended up
to date.

Note-Necessary certificate indicating the compliance of the above capacity

requirement for the engine model so selected along with compliance of Noise and
Emission norms as per latest CPCB guidelines for DG set capacity, should be furnished
from the manufacturers along with the technical bid.
2.3.2 The engine shall be fitted with following accessories subject to the design of the
e manufacturer:
 Dynamically balanced Fly wheel
 Necessary flexible coupling and guard for alternator and engine
 Air cleaner (dry/ oil bath type) as per manufacturer standard,
 A electronic governor to maintain engine speed at all conditions of load.
 Daily fuel service tank of minimum capacity 990, fabricated from M.S. sheet with
inlet, outlet connections air vent tap, drain plug and level indicator (gauge) M.S.
fuel piping from tank to engine with valves, unions, reducers, flexible hose
connection and floor mounting pedestals, twin fuel filters and fuel injectors. The
location of the tank shall depend on standard manufacturers design.
 Dry exhaust manifold with suitable exhaust residential grade silencer to reduce
the noise level.
 Suitable self-starter for 12/24 V DC.
 Battery charging alternator unit and voltage regulator, suitable for starting
batteries, battery racks with interconnecting leads and terminals.
 Necessary gear driven oil pump for lubricating oil, priming of engine bearing as
well as fuel systems as per manufacturer recommendations.
 Naturally aspirated/ turbo charger (as per manufacturer standard)

PAGE - 768
  Lubrication oil cooler
 Lubrication oil filters with replaceable elements.
 Crank case heater as per manufacturer recommendations.
 Fuel injection: Engine should have suitable fuel injection system in order to
achieve low fuel consumption.
 Fuel control solenoid
 Fuel pump with engine speed adjustment.
 Engine Control Panel having digital display for following: -
(a) Start/stop key switch.
(b) Lube oil pressure indication
(c) Water temp. Indication
(d) RPM indication
(e) Engine Hours indications
(f) Battery charging indication
(g) Low lub. Oil Trip Indication
(h) High water temp. Indication
(i) Over speed indication.

 All moving parts of the engine shall be mechanically guarded in such a manner
that a human finger cannot touch any moving part.
2.3.3 Governor:
Electronic governor of class A1 as per ISO 3046/ BS5514 with actuator shall be
provided as per standard design of manufacturer. Governor shall be a self-contained
unit capable of monitoring speed
2.3.4 Frequency variation/regulation:
The engine speed shall be so maintained that frequency variation at constant load
including no load shall remain within a band of 1% of rated frequency

2.3.5 Fuel System:

 Fuel shall be fed through engine driven fuel pump. A replaceable element of fuel
filter shall be suitably located to permit easy servicing. The daily service tank shall
be complete with necessary supports, gauges, connecting pipe work etc. In case of
Top Mounted tanks, non-return valves are must in fuel supply and return line of
specified value. Pipe sealant should be used for sealing for all connections. No
Teflon tape to be used. If piping length is more than 10 meters, detail engineering
is required in consultation with OEM/ Manufacture.
 Fuel system shall be such used which comply to the latest environment flue gas
data limitations amended up-to date. NOX, CO, PM etc. has to be complied & shared
by the manufacturer with reports.
2.3.6 Lubricating oil system:
 It shall be so designed that when the engine starts after a long shut down
lubrication failure does not occur. Necessary priming pump for the lub. oil circuit
as per recommendation of manufacturer shall be installed, to keep bearings

PAGE - 769
 primed. This pump shall be fully automatically operative on AC/ DC supply
available with the set.
2.3.7 Air System:
It is preferable to provide vacuum indicator with all engines to indicate choked filter.
Maximum air intake restrictions with clean and choked filters should be within
prescribed limit as per OEM/ manufacturer recommendation for the particular model
of the engine. Gensets should be supplied with medium duty/ heavy duty air cleaners.
2.3.8 Cooling System
 Cooling System should be designed for ambient temperature of 40 Deg.C.
 Coolant should be used mixed with additive (in suitable proportion) as per
recommendation of OEM / Manufacturer.
 Radiator fan flow should be free from any obstruction.
 For radiator cooled DG Set, proper room ventilation should be planned at the time
of construction of DG room.
 Remote Radiator can be used in case of basement installation where fresh air may
not be available. The proper location of remote radiator is very essential for the
successful and efficient operation of remote radiator. In this the cooling media is
ambient air. So in order to obtain maximum efficiency from remote radiator, it is
necessary to get fresh air in its surrounding. The horizontal distance of remote
radiator from engine should not exceed 10 Meter.
2.3.9 Starting system:
 This shall comprise of necessary set of heavy-duty batteries 12V/ 24V DC (as per
manufacturer standard), and suitable starter motors, axial type gear to match with
the toothed ring on the fly wheel.
 A timer in the control panel to protect the starter motor from excessively long
cranking runs shall be suitably integrated with the engine protection system and
shall be included within the scope of the work.
 Battery capacity shall be suitable for meeting the needs of starting system (as
three attempt starting), as well as the requirements of control panel, indications
and auxiliaries such as priming pump as applicable etc.
 The scope shall cover all cabling, terminals, including initial charging etc. The
system shall be capable of starting the DG set within 15 sec., even in winter
condition with an ambient temperature down to 00C.
2.3.10 Battery Charger:
 The battery charger shall be suitable to charge required numbers of batteries at
12V/ 24 volts complete with, transformer, rectifier, charge rate selector switch,
indicating ammeter & voltmeter etc. Connections between the battery charger &
batteries shall be provided with suitable copper leads with lugs etc.
2.3.11 EXHAUST SYSTEM
 Engine exhaust system shall be fitted with hospital or most critical grade silencer
available as per manufacturer recommendation.

PAGE - 770
  The work include necessary piping, cladding of exhaust pipe work using 50mm
thick Loosely bound resin (LBR)mattress / mineral wool/ Rockwool, density not
less than 120kg/m3 and aluminium cladding ( 0.6mm thick) for the complete
portion.
 The exhaust pipe work includes necessary supports, foundation etc. to avoid any
load & stress on turbo charger / exhaust piping.
 The exhaust pipe shall be run along the existing wall of the building duly
clamped, supported on independent structure for which, the design and
Drawing for such structure shall be got approved from the Engineer in charge.
2.3.11.1 Exhaust stack height:
 Minimum exhaust stack height shall be calculated as per MOEF & CPCB
requirements of building height.
2.3.11.2 Exhaust system back pressure
 Number of bends should be kept minimum and smooth bends should be used to
minimize back pressure.
 Pipe sleeve of larger dia. should be used while passing the pipe through concrete
wall & gap should be filled with felt lining.
 Exhaust piping inside the Acoustic Enclosure/ Genset room should be lagged with
asbestos rope along with aluminium sheet cladding / insulated to avoid heat
input to the room.
 Exhaust flexible shall have it’s free length when it is installed.
 For 1000 kva engines, 2 flexible bellows can be used as per manufacturer
standards.
 The exhaust outlet should be in the direction of prevailing winds and should not
allow exhaust gases to enter air inlet/ windows etc.
 When tail end is horizontal, 45 Degree downward cut should be given at the end
of the pipe to avoid rain water entry into exhaust piping.
 When tail end is vertical, there should be rain trap to avoid rain water entry. If
rain cap is used, the distance between exhaust pipe and rain cap should be higher
than diameter of pipe. Horizontal run of exhaust piping should slope downwards
away from engine to the condensate trap. Silencer should be installed with drain
plug at bottom
2.3.12 Common bed plate:
Engine and alternator shall be directly coupled or coupled by means of flexoplate/
flexible coupling as per manufacturer standard design and both units shall be
mounted on a common bed plate together with all auxiliaries to ensure perfect
alignment of engine and alternator with minimum vibrations. The bed plate shall be
suitable for installation on suitable anti-vibration mounting system.

2.3.13 Optional items as under may be included as recommendation of

Manufacturer: -

PAGE - 771
2.3.13.1 Fuel System
 Fuel Water Separator
 Auxiliary Fuel Pump

2.3.13.2 Exhaust System

 Industrial Grade Muffler

2.3.13.3 Start System

 Battery Charger
- Automatic Float Equalizing
- Trickle
 Battery Warmer Plate

2.4 ALTERNATOR
2.4.1 General
The alternator shall be Self excited, screen protected drip proof , self-regulated, brush
less alternator, Horizontal foot mounted in Double bearing construction Synchronous
Alternator suitable for the following parameters:-

SN Technical Parameter for ALTERNATOR

1 Type Self-excited brushless synchronous
2 Output Suitable for 3 phase 415 Volt,50 Hz, 1500
rpm & 0.8 PF
3 Enclosure Type SPDP (Drip Proof Screen Protected)
4 Degree of protection IP 23
for Enclosure
5 Ambient 40deg C Maximum
Temperature
6 Insulation Class H
Temperature Rise Within class H limits at rated load Voltage
7
Frequency +/- 1%
8 Regulation
Voltage variation +/-5%
9
Overload 10% for one hour in every 12 hours of
10 duration/capacity continuous use
Excitation Separately excited
11
Type of AVR Electronic class A1
12
Type of Bearing Anti-friction bearings with Grease
13 lubrication
Standard IS-4722 & IEC: 34 as amended upto date
14

 The alternator shall be fitted with suitable Nos. Resistance Temperature Device
(RTD) Bearing Temperature Device (BTD) along with space heaters. The terminal
of space heaters will be wired to terminal box and the temperature scanner shall

PAGE - 772
 be provided in AMF/Control panel for scaling the winding and bearing
temperature.
 Excitation: The alternator shall be brushless type and shall be separately excited,
self-regulated having static excitation facility. The exciter unit be mounted on the
control panel or on the alternator assembly. The rectifier shall be suitable for
operation at high ambient temperature at site.
 Automatic Voltage Regulators (AVR): In order to maintain output terminal voltage
constant within the regulation limits i.e. +/- 1%, Automatic voltage regulator unit
shall be provided as per standard practice of manufacturer.
 Fault tripping: In the event of any fault e.g. over voltage/ high bearing
temperature/ high winding temperature or an external fault, the AVR shall remove
the excitation voltage to the alternator. An emergency trip shall also be provided.

2.4.2 Performance: Voltage dip shall not exceed 20% of the rated voltage for any step load
or transient load as per ISO: 8528 (Part-1). The winding shall not develop hot spots
exceeding safe limits due to imbalance of 20% between any two phases from no load
to full load. The generator shall preferably be capable of withstanding a current equal
to 1.5 times the rated current for a period of not more than 15 seconds as per IS
4722:1992.
The performance characteristics of the alternator shall be as below:
(a) Efficiency at full load 0.8 P.F. not less than 93.5%
(b) Total distortion factor Less than 3 %
(c) (i) 10% overload One hour in every 12 hrs of continuous use
(ii) 50% overload -15 seconds.
2.4.3 Terminal Boxes:
 The terminal box shall be suitable to Bus Duct .
 The terminal box shall be suitable to withstand the mechanical and thermal
stresses developed due to any short circuit at the terminals.
2.4.4 Earth Terminals:
2 Nos. earth terminals on opposite side with vibration proof connections, non-
ferrous hardware etc. with galvanized plate and passivated washer of minimum size
12mm dia. hole shall be provided.

2.4.5 Space Heaters:

Alternators shall be provided with suitable space heaters to maintain the winding
temperature automatically such that it does not absorb moisture during long idle
periods. The heater terminals shall be brought to a separate terminal box suitable
for 230 V AC supply and a permanent caution notice shall be displayed.

2.5 Engine mounted Instrument panel:

 Engine will be supplied with engine mounted microprocessor based fully
integrated generating set monitoring, metering and control system which should

PAGE - 773
 be equipped with digital electronic governor along with digital AVR to facilitate
discreet control of speed and voltage.
 It should be equipped with starting control including integrated fuel ramping to
limit the black smoke frequency overshoot with optimized cold weather starting.
 The indicating panel should have communication network facility to facilitate
remote hooking on a common network. Engine instrument panel should be
equipped with digital alarm and status mirage to monitor and display the following
parameters of engine and generator: -
(a) Engine Indicators
Digital Tachometer
Running hours counter
Starting attempts counter
Lube Oil pressure low (for idle and for rated speed)
Lube Oil temperature high
Turbocharger oil level low
Coolant temperature high
Coolant pressure high
Exhaust gas temperature high
Over speed
(b) Electrical Indicators
3 X current
3 X voltage
Frequency
Active power
Reactive power
Power factor
Frequency totalizer
Battery voltmeter
KWH Meter
(c) Signal Alarms
Cranking bar missing
Control panel fault
24 VDC fault
Failure to start
Fuel day tank level low
Cooling Tower fan fault
Water temperature low (inhibits rated speed)
Battery low voltage
(d) Control and selectors
Operating mode selector switch (stop, manual, auto, test)
Start/stop pushbuttons

PAGE - 774
 Manual control selector switch (idle, rated, synchro, loading)
Emergency stop pushbutton
Fault reset pushbutton

2.6 Electrical Wiring

Scope: This section covers technical and functional requirements of Electrical Wiring
System
2.6.1 Terminal blocks and wiring:
 Terminal blocks of robust type and generally not less than 15 Amps capacity,
250/500 V grade for DC upto 100V and 660/ 1100 volts grade for AC and rest of
the junction shall be employed in such a manner so that they are freely accessible
for maintenance.
 All control and small wiring from unit to unit inside the panel shall also be done
with not less than 2.5 sqmm copper conductor PVC insulated and 660/ 1100 volts
grade. Suitable colour coding can be adopted.
 Wiring system shall be neatly formed and run preferably, function wise and as far
as feasible segregated voltage wise. All ends shall be identified with ferrules at the
ends.
2.6.2 Labelling:
All internal components shall be provided with suitable identification labels suitably
engraved. Labels shall be fixed on buttons, indication lamps etc.
2.6.3 Painting:

The entire panel shall be given primer coat after proper treatment and powder
coating with 7 tanks process before assembly of various items.

2.6.4 AMF/CONTROL PANEL

 The AMF/control cubical shall be as per CPWD specification
 Control system equipment’s and components such as PLC, relays, contactors,
timers, etc. both for automatic operation on main failure and as well as for manual
operation.
 Equipment and components necessary for testing generating set’s healthiness with
test mode and with load on mains.
 Instruments and accessories such as voltmeter, power factor meter, KW meter,
KWH meter, Ammeter, Frequency meter etc..
 Indication lamps, fuses, terminal blocks, push buttons, control switches etc. as
required.
 Engine/ generating set shut down devices due to faults / abnormalities.
 Visual audio alarm indication and annunciation facility as specified.
 Battery charger.
 Excitation control and voltage regulating equipment. (Alternatively provided on

PAGE - 775
 the Alternator itself).
 Overhead bus trunking terminations all internal wiring, connections etc. as
required.
 Breakers/MCCB as per design/standard requirement.

3.0 SYSTEM OPERATION

3.1 Automatic Mode
 The AMF/control system shall monitor the main supply voltage & when the main
supply voltage drops below a certain preset value, the system shall sense these
conditions & shall give automatic start command to the control systems.
 After a time, delay of 1.5 seconds from the main supply failure the diesel engine
shall start.
 When the DG set attains its rated speed and voltage a closing signal shall be given
to the circuit breaker of the DG set.
 When the voltage in the mains gets restored, its quality is monitored for about one
minute and if proven satisfactory the main supply breaker shall close automatically
transfer the load from Diesel engine to the mains supply.
 The set shall stop after idle running of one minute after restoration of main supply.
 The diesel alternator set reverts to its standby conditions & it’s ready to start
should the mains supply fail again.

3.2 Manual mode:

 In a manual mode, it shall be feasible to start-up the generator set by the operator
on pressing the start push button.
 Three attempt starting facility shall be operative for the start-up function.
 Alternator circuit breakers close and trip operations shall also be through operator
only by pressing the appropriate button on the panel and closure shall be feasible
only after alternator has built up full voltage. If the load is already on ‘mains’,
pressure on ‘close’ button shall be ineffective.
 Engine shut down, otherwise due to faults, shall be manual by pressing a ‘stop’
button.
4.0 Foundation
 Foundation shall be as per manufacturers recommendations.
 Foundation level should be checked diagonally as well as across the length for even
flatness.
 The foundation should be within ± 0.5 Degree (angle) of any horizontal plane

5.0 Genset with acoustic enclosure:

5.1 Acoustic Enclosure
 Acoustic enclosure should be type tested at the climatic conditions specified
through one of the authorized laboratory.
 Acoustic enclosures are supplied with built in Anti Vibration Mountings (AVMs). As

PAGE - 776
 such Genset can be installed directly on the leveled surface.
 The acoustic enclosure placement should be such that there is no restriction in
front of air inlet and outlet from canopy.

5.2 Specifications for Acoustic Enclosure:

 The acoustic enclosure shall be designed and manufactured confirming to relevant
standards suitable for outdoor installation exposed to weather conditions, and to
limit overall noise level to 75 dB (A) at a distance of 1 mtr. from the enclosure as
per CPCB norms under free field conditions.
 The construction should be such that it prevents entry of rain water splashing into
the enclosure and allows free & quick flow of rain water to the ground in the event
of heavy rain. The detailed construction shall confirm to the details as under:
 The enclosure shall be fabricated out the CRCA sheet of thickness not less than
1.6mm on the outside cover with inside cover having not less than 0.6mm thick
perforated powder coated CRCA sheet.
 The hinged doors shall be made from not less than 16 SWG (1.6mm) thick CRCA
sheet and will be made air tight with neoprene rubber gasket and heavy-duty locks.
 All sheet metal parts should be processed through 7-tank process.
 The enclosure should be powder coated.
 The enclosure should accommodate the daily service fuel tank of the D.G. Set to
make the system compact. There should be provision of fuel gauge, which should
show the level of the fuel even when the DG Set is not running. The gauge should
be calibrated. The fuel tank should be filled from the outside as in automobiles and
should be with a lockable cap.
 The batteries should be accommodated in the enclosure in battery rack.
 The canopy should be provided with high enclosure temperature safety device.
 The acoustic lining should be made up of high-quality insulation material i.e.
Rockwool/ glass/ mineral wool/ PU foam of appropriate thickness & density for
sound absorption as per standard design of manufacturer’s to reduce the sound
level as per CPCB norms. The insulation material shall be covered with fine glass
fiber cloth and would be supported by perforated
 M. S. Sheet duly powder coated / GI sheet/ aluminum sheet.
 The enclosure shall be provided with suitable size & No. of hinged type doors along
the length of the enclosure on each side for easy access inside the acoustic
enclosure for inspection, operation and maintenance purpose. Sufficient space will
be provided inside the enclosure on all sides of the D.G. set for inspection, easy
maintenance & repairs.
 The canopy should be as compact as possible with good aesthetic look.
 The complete enclosure shall be of modular construction.
 The forced ventilation shall be as per manufacturer design using either engine

PAGE - 777
 radiator fan or additional blower fan(s). If the acoustic enclosure is to be provided
with forced ventilation then suitable size of axial flow fan (with motor and auto-
start arrangement) and suitable size axial flow exhaust fan to take the hot air from
the enclosure complete with necessary motors and auto start arrangement should
be provided. The forced ventilation arrangement should be provided with auto
stop arrangement to stop after 5 minutes of the stopping of D.G sets.
 The acoustic enclosure should be suitable for cable connection/connection
through bus-trunking. Such arrangements on acoustic enclosure should be water
proof &dust-proof conforming to IP-65 protection.
 The inside of enclosure should be provided with at least two nos. 28W- T5
fluorescent tube light luminaire controlled by a 5A switch for adequate lighting
during servicing etc. of the DG Set. The power supply to this luminaire should be
from the load side of the AMF Panel so that it can remain energized under all
conditions

PAGE - 778
SECTION -7 L.T. PANELS (Design Verified & Total Type Tested Assemblies TTA)

1.0 General
 This section covers the detailed requirements of medium voltage switchboard for
415 volts, 3 phase, 50 Hz, 4 wire system.
 LT PANELS shall be Totally Type Tested & Design Verified Assemblies (TTA) as per
IS/IEC-61439-1 & 2 and having Switchgear OEM verified design.
1.1 Applicable Codes & Standards

` IS/IEC 61439-1 & 2 Low Voltage switchgear Assemblies

2 IS 11353 1985 Guide for uniform system of marking identification of
Busbar and Terminals
3 IS13703 1992 Low voltage fuses
4 IS 2705 1992 Current transformers
5 IS 694 1990 PVC insulated cables for voltages including 1100 V with
Copper and Aluminium Conductor
6 IS 1248 1983 Direct Acting Electrical Indicating Analog
7 IS 5082 Electrolytic Aluminium Busbar, Trunking system, Rod
tubes & sections for Electrical Purposes.
8 IS 13779 1999 AC Electric Meters / Static Meters
9 IEC 62262 Degree of protection against mechanical impact shall be
IK10

1.2 SITE CONDITION & NETWORK PARAMETERS

1 Location Indore Airport

2 System requirements 415V, 3Ph+N+E, 50Hz

3 Maximum Ambient 50 Deg. C
Temperature
4 Design Ambient 45 Deg. C
Temperature
5 Relative Humidity Max 95%
6 Relative Humidity Min 10%
7 Control voltage 230 V
8 Temperature Rise As per IEC

PAGE - 779
 9 Neutral Earthing Solidly Earth
10 Pollution Class III
11 Sesismic Zone As per IEC/IS requires compliance for ZONE -IV
against 0.4g acceleration or higher
12 Internal arc tests IEC-61641
50 KA for 0.3 sec
13 Mechanical Impact IK- 10 as per IEC 62262
14 Form of separation 4b

2.0 Switch Boards

2.1 General
 The switchboards shall be completely Type Tested & Design verified Assemblies
as per IEC61439-1&2.
 Copies of Type Test certificate as along with Shop drawings of the type-tested
assemblies shall be (duly vetted & stamped by OEM) submitted to AAI for prior
Approval.
 All Switchboards shall have a short circuit level withstand as per short circuit fault
level of system.
 Agency has to submit the complete short circuit analysis of system & got approval
from AAI for short circuit rating of proposed panel as per system design
requirement.
 Panel shall tested for Internal arc 50 KA for 0.3 sec as per IEC-61641 for all three
chambers i.e. horizontal bus bar, vertical bus bar & cable chamber
 The enclosures shall be designed to take care of normal stress as well as abnormal
electro-mechanical stress due to short circuit conditions.
 All covers and doors provided shall offer adequate safety to operating persons and
provide ingress protection of IP 42 for Indoor & IP 54 for outdoor panels
 Ventilating openings and vent outlets, if provided, shall be arranged such that same
ingress protection of IP 42 is retained. Suitable pressure relief devices shall be
provided to minimize danger to operator during internal fault conditions.
 For operator safety IP2 X ( touch proof) protection to be available even after
opening the feeder compartment door. The compartmentalization to be achieved
by using metal separators, use of PVC sheet / Hylem sheets shall not be allowed.
 The switchboard shall be form 4B form of separation only metallic covers shall be
used, Hylem / PVC sheets shall not be allowed.

2.2 Switchboard Configuration

 The Switchboard shall be configured with Air Circuit Breakers, MCCB's, MPCB,
MCB’s and other equipment as per design requirement of the system.
 ACB shall be single tier only. ACB mounted in double tier is not acceptable due to
deration. (The incoming & outgoing Air Circuit Breakers shall be arranged in Single
tier formation)

PAGE - 780
  The MCCBs shall be arranged in multi-tier formation.
 The Switch boards shall have 25 % spares feeders with Breakers of each outgoing.

2.3 Constructional Features & Compartmentalization

 The Switchboards shall be metal clad totally enclosed, floor mounted free-standing
type of modular extensible design suitable for indoor mounting.
 All the doors and covers shall be fully gasket to prevent any ingress of dust.
 Gasket used for all doors shall be of double lip type.
 Switchboards construction shall be employ the principle of Compartmentalization
 For compartmentalized switchboards, separate totally enclosed compartments
shall be provided for horizontal busbars, vertical busbars, ACBs, MCCBs, and cable
alleys segregation
 Form of separation f4b for each circuit.
 Switchboard panels and cubicles shall be fabricated with CRCA Sheet Steel of
thickness not less than 2.0 mm and shall be Bolted and braced as necessary to
provide a rigid support for all components.
 The doors and covers shall be fabricated from CRCA sheet steel of thickness not
less than 1.6mm.
 Front access shall be available to all components in each cubicle which require
adjustment, maintenance or replacement.
 Switchboard shall be readily extensible on both sides by addition of vertical
sections after removal of the end covers.
 The switchboard shall have integral base frame or provide 100mm ISMC base
channel.
 Incomer and bus section panels or sections shall be separate and independent and
shall not be wired with sections required for feeder. The incomer panel shall be
suitable for receiving bus trunking or MV cable of size specified.
 Special care to be taken to ensure effective earthing of the frame and doors of the
switchboards.
 Earthed metal or insulated shutters shall be provided between drawout and fixed
portion of the switchgear such that no live parts are accessible with equipment
drawn out. Degree of protection within compartments shall be atleast IP 2X.
 Sheet steel hinged lockable doors for each separate compartment shall be provided
and duly interlocked with the breaker in "ON" and "OFF" position.
 For all Circuit Breakers separate and adequate compartments shall be provided for
accommodating instruments, indicating lamps, control contactors and control
MCB etc. These shall be accessible for testing and maintenance without any danger
of accidental contact with live parts of the circuit breaker, busbars and
connections.
 For Some MCCB feeders for critical loads like UPS it may be required to have
operation after opening the door, all other facilities like padlockable rotary handle
to be provided for such feeder. It shall be possible to do this change during
execution of order.

PAGE - 781
  Each switchgear cubicles shall be fitted with label in front and back identifying the
circuit, switchgear type, rating and duty. All operating device shall be located in
front of switchgear only.
 A suitable wire way with cover shall be provided to take interconnecting control
wiring between vertical sections.
 Cable compartments shall be of adequate size for easy termination of all incoming
and outgoing cables entering from bottom or top.
 Adequate and proper support shall be provided in cable compartments to support
and clamping the cable in the cable alley / cable chamber.
 Switchboard shall be provided with “Danger Notice Plate” conforming to relevant
Indian Standards.
 SLD of panel shall be provided in comer section of panel
 The LV panel manufacturer shall be ISO 9001 / 9002 certified.

2.4 Switchboard Dimensional Limitations

 The overall height of the switchboard shall be limited to 2400 mm or less as per
manufacturers standards for all the Busbar ratings and type of switchboards.
 The height of the operating handle, push buttons etc shall be restricted between
300 mm and 200 mm from finished floor level.
2.4.1 Switchboard Bus Bars
 Busbars shall be made of high conductivity, 99.9% purity, high strength Aluminium
of ETP grade Busbars shall be of rectangular cross sections, suitable for full load
current (As per design requirement) for phase bus bars and half/ full rated current
for neutral bus bar as per applicable standards
 The Busbar sizes shall be determined taking into consideration the continuous
rating without exceeding the final temperature as permitted by IEC 61439 when
carrying rated current; and must be suitable for a fault level kA as per design
requirement.
 Busbar shall be suitable to withstand the stresses of fault level as per system design
condition
 The bus bar system may comprise of a system of main horizontal bus bars and
auxiliary vertical bus bars run in bus bar alley on either side in which the circuit
could be arranged with front access for cable entrances.
 The bus bars shall be supported on non-breakable, non-hygroscopic epoxy resin
or glass fiber reinforced polymer insulated supports able to withstand operating
temperature of 110 deg C at regular intervals, to withstand the forces arising from
a fault level as stipulated in schedule of quantities. The material and the spacing
of the Busbar support should be same as per the type tested assembly.
 Auxiliary buses for control power supply, space heater power supply or any other
specified service shall be provided. These buses shall be insulated, adequately
supported and sized to suit specific requirement. The material for auxiliary supply
bus will be insulated electrolytic copper.
 The minimum clearances to be maintained for enclosed indoor air insulated bus
bars for medium voltage applications shall be as per IEC guidelines

PAGE - 782
  The busbar support to be supplied as per approved supplier of OEM or by as
recommended by OEM

2.4.2 Switchboard Interconnection

 All connection and tap offs shall be through adequately sized connectors
appropriate for fault level at location. This shall include tap off to feeders and
instrument/control transformers.
 All connections, tappings, clamping, shall be made in an approved manner as per
IEC/IS to ensure minimum contact resistance.
 All connections shall be firmly bolted and clamp with even tension.
 Before assembly joint surfaces shall be filed or finished to remove burrs, dents and
oxides and silvered to maintain good continuity at all joints. All screws, bolts,
washers shall be zinc plated. Suitable grade nuts and bolts shall be used for busbar
connections.

2.4.3 Drawout Features

 Air Circuit Breakers shall be fully electrically and mechanically drawout, unless
otherwise stated. These cubicles shall be such that drawout is possible without
disconnection of the wires and cables.
 The power and control circuits shall have self-aligning and self-isolating contacts.
 Mechanical latches shall be integrated in ACB at service, test and isolated position
to ensure that Breaker is firmly latched in respective position. It shall not be
possible to move the breaker from the position unless latch is manually operated.

2.4.4 Instrument Accommodation

 All voltmeter and ammeter and other instruments shall be flushed mounted Digital
type of size 96sq.mm.
 Instruments and indicating lamps shall not be mounted on the Circuit Breaker
Compartment door for which a separate and adequate compartment shall be
provided and the instrumentation shall be accessible for testing and maintenance
without danger of accidental contact with live parts of the Switchboard.
 For MCCBs, instruments and indicating lamps can be provided on the compartment
doors.
 The current transformers for metering and for protection shall be mounted on the
solid copper/aluminium busbars with proper supports.
 The incomers & Outgoing of switch boards shall have ON/OFF & Trip LED Type
indicator lamps suitable for operation on AC 230 volts supply. All lamps shall be
protected by MCBs.
 Multifunctional shall be provided in Incomer and outgoing feeders to meet GRIHA
-IV requirements for accuracy class i.e. 0.5 for incomer & 1 for outgoing.
 Meter shall have LED display and measure per phase and average of all the basic
electrical parameters like voltage, current, Power Factor, Hz, KW, KVA, KVAR,
%THD I & V.
 Meter shall able to capture and communicate individual harmonics up-to 15th
level to BMS/EMS/SCADA.

PAGE - 783
2.4.5 Wiring
 All wiring for relays and meters shall be with PVC insulated copper conductor FRLS
wires. The wiring shall be coded and labeled with approved ferrules for
identification.
 The minimum size of copper conductor control wires shall be 2.5 sq. mm. Runs of
wires shall be neatly bunched and suitably supported and clamped. Means shall be
provided for easy identification of wires. Identification ferrules shall used at both
end of wires. All control wires meant for external connections are to be brought
out on a terminal board. The cables and control wires shall be suitable for
withstanding 105 deg C.
 All terminal blocks and wires shall be tagged for identification in accordance with
IS 11353
 Clamp type control terminal blocks shall be provided for outgoing control cables.
Minimum 10% spare terminals shall be provided for future use. Control terminal
block shall be separated from power terminal blocks by means of an insulating
barrier.

2.4.6 Space Heaters

 Anti- condensation heaters shall be fitted in each cubicle together with an ON/OFF
isolating switch suitable for electrical operation at 230 volts A.C 50 Hz single phase
of sufficient capacity to raise the internal ambient.
 The electrical apparatus so protected shall be designed so that the maximum
permitted rise in temperature is not exceeded (as per IEC ) if the heaters are
energized while the switchboard is in operation. As a general rule, the heaters shall
be placed at the bottom of the cubicle.

2.4.7 Earthing
 Continuous earth bus sized for prospective fault current to be provided with
arrangement for connecting to station earth at two points.
 Hinged doors / frames to be connected to earth through adequately sized flexible
braids-02 Nos for each Hinged doors / frames.

2.4.8 Sheet Steel Treatment and Painting

 Sheet steel used in the fabrication of switchboards shall undergo a rigorous
cleaning and surface treatment seven tank process comprising of alkaline
degreasing, descaling in dilute sulphuric acid and a recognised phosphating
process after which a coat of primer paint with the final paint shall be applied over
the treated surface.
 Final paint coat of oven baked powder coating,
 The final paint thickness should be 60 to 80microns.

2.4.9 NABL/CPRI/ERDA TESTING

 Switchboard shall be tested for TTA assemblies as specified for all the type tests
for compliance to IEC61439-1 & 2 and internal arc tests from NABL/ERDA/CPRI.
 Copies of the type test certificates shall be submitted to AAI for approval.

PAGE - 784
2.4.10 Type Test FOR TTA PANEL
The following type tests certificates as specified in applicable IS/EC 61439-1 standards
to comply with requirements of TTA panel shall be provided:
1. Strength of material and parts. (IEC 61439 clause no. 10.2).
2. Degree of protection of enclosures (IEC 61439 clause no. 10.3)
3. Clearance and creep age distances (IEC 61439 clause no. 10.4).
4. Effective continuity between the exposed conductive parts of the assembly and the
protective circuit (IEC 61439 clause no. 10.5.2).
5. Effectiveness of assembly (protective circuit) for external faults (IEC 61439 clause
no. 10.5.3).
6. Incorporation of switching devices and components (IEC 61439 clause no. 10.6).
7. Internal electrical circuits and connections (IEC 61439 clause no. 10.7).
8. Terminals for external conductors (IEC 61439 clause no. 10.8).
9. Power frequency withstands voltage (IEC 61439 clause no. 10.9.2).
10. Impulses withstand voltage (IEC 61439 clause no. 10.9.3).
11. Temperature rise limits (IEC 61439 clause no. 10.10,9.2).
12. Short-circuit withstand strength (IEC 61439 clause no. 10.11).
13. Electromagnetic compatibility EMC (IEC 61439 clause no. 10.12).
14. Mechanical operations (IEC 61439 clause no. 10.13).

2.4.11 Routine test

The panel assembler shall perform the routine test and provide the test certificates as
defined in IEC standards. The routine test shall include but not limited to the following:
Verification shall comprise the following categories:
1- Construction (IEC 61439 clause no. 11.2 to 11.8):
a) degree of protection of enclosures;
b) clearances and creepage distances;
c) protection against electric shock and integrity of protective circuits;
d) incorporation of built-in components;
e) internal electrical circuits and connections;
f) terminals for external conductors;
g) mechanical operation.
h) Performance (IEC 61439 clause no. 11.9 to 11.10):
i) dielectric properties;
j) wiring, operational performance and function.
Note- Routine test certificates and test readings shall be submitted to the engineer in
charge for verification.

2.4.12 TESTING AT WORKS

 Copies of type test carried out at ACB/MCCB manufacturers works and routine
tests carried out at the switchboard fabricators shop shall be furnished along with
the delivery of the switchboards.

PAGE - 785
  AAI reserves the right to get the switchboard inspected by their representative at
fabricators works prior to dispatch to site to witness the following routine tests:-
a- Physical variation and dimensional check
b- Verification of bill of material
c- Functional check
d- HV test
e- IR test

2.4.13 INSTALLATION
 The foundations prepared as per the manufacturer’s drawings shall be levelled,
checked for accuracy and the Switchboard installed.
 All bus bar connections shall be checked with a feeler gauge after installation.
 The cable end boxes shall be sealed to prevent entry of moisture.
 The main earth bar shall be connected to the sub-station earths.
 Antistatic rubber matting of approved make conforming to IEC/BS relevant
standards, of minimum 1000 mm width 10 mm thickness shall be provided in front
of and along the full length of the Switchboard.
 The rubber mat shall withstand 15 KV for 1 minute and leakage current shall not
exceed 160 mA/sq. metre. After installation the Switchboard shall be tested as
required prior to commissioning.

2.4.14 TESTING AND COMMISSIONING AT SITE

 Commissioning checks and tests shall include all wiring checks and checking up of
connections. Relay adjustment/ setting shall be done before commissioning in
addition to routine Megger tests.
 Checks and tests shall include the following: -
i. Physical checking of the switchboards including checking alignment of panels,
interconnection of Bus bars, tightness of bolts/connections and evidence of
damage/cracks in any components.
ii. Checking free movement of ACBs/MCCBs.
iii. Checking of operation of breakers
iv. Checking of Interlocking function.
v. Continuity checks of wiring, fuses etc. as required.
vi. Insulation test: When measured with 500V Megger the insulation resistance
shall not be less than 100 mega ohms.
vii.Trip tests and protection gear test.

Note – Main LT panel shall be Equipped with surge protection device Type-1 as
per IEC 62305-4/ NBC 2016.
3.0 Switchgear
3.1 LT Air Circuit Breakers
3.1.1 General
 The circuit breakers shall be of the air break type, robust and compact design
suitable for indoor mounting and shall comply with the requirement IEC 60947-
Part 1 & 2.

PAGE - 786
  The breaker shall comply with the isolation function requirement of IEC 60 947-
2/IS 13947-2.
 The breaker shall provide IP 2X protection between the front panel and internal
power circuits to avoid any accidental contact with the live main current carrying
path with the front cover open.
 Protective devices, metering, CTs, PTs, push buttons and indicating lamps shall be
provided as per design requirements.
 ACB shall be type tested & certified for compliance to standards from–CPRI, ERDA/
NABL accredited lab/ any international lab.
 The circuit breaker shall be suitable for415 V + 10%, 50Hz supply system.
Manufacturer should submit Combined sequence test certificate
 The Circuit Breaker shall be flush front, modular construction, horizontal draw-out
pattern, four pole as required ( For APFC Three Pole ACB accepted) and fully
interlocked. Each Circuit Breaker shall be housed in a separate compartment
enclosed on all sides. In case of 4 pole breaker neutral shall be fully rated with
adjustable settings from 50% to 100% of In.
 The Circuit Breaker cradle shall be designed and constructed to permit smooth
withdrawal and insertion. The movement shall be free of jerks, easy to operate.
Mechanical Latch to be provided to identify the Isolated, test & service position of
breaker to prevent over racking.
 Self-aligning cluster type isolating contacts shall be provided for the Circuit
Breaker, with automatically operated shutters to screen live cluster contacts when
the Breaker is withdrawn from the cubicle. Sliding connections including those for
the auxiliary contacts and control wiring shall also be of the self-aligning type. The
fixed portion of the sliding connections shall have easy access for maintenance
purposes.
 The circuit breakers shall be for continuous rating and service short Circuit
Breaking capacity (Ics) shall be as per design requirement.
 ACB shall have the breaking performance Ics = Icu = Icw (1sec) as per design
requirements.
 The ACB shall have double insulation (Class-II) with moving and fixed contacts
totally enclosed for enhanced safety and in accessibility to live parts.
 The circuit breakers shall be for continuous rating at 40 deg C ambient
temperature.
 The Rated insulation voltage shall be 1000 volts AC & Rated impulse withstand
Voltage shall be 12kV for main circuit.
 ACB shall confirm compliance to ROHS/IEEE guidelines.
 The ACB shall be provided with a door interlock i.e. door should not be open when
circuit breaker is closed and breaker should not be closed when door is open.

3.1.2 Operating Mechanism

 The Circuit Breaker shall be trip free with independent manual spring operated or
motor wound spring operated mechanism as specified and with mechanical
ON/OFF indication. The operating mechanism shall be such that the circuit breaker

PAGE - 787
 is at all times free to open immediately the trip coil is energised. The breaker shall
be provided with in built anti pumping mechanism.
 The operating handle and mechanical trip push button shall be at the front of and
integral with the Circuit Breaker.
 There shall be mechanical indicator on the front panel for ‘Ready to close’ situation
for the breaker by checking all interlocking.
 The Circuit Breaker,s cradle shall be so designed and constructed as to permit
smooth withdrawal and insertion of the breaker into it. The movements shall be
free from jerks, easy to operate and shall be on steel balls/rollers and not on flat
surfaces.
 There shall be 3 distinct and separate position of the circuit breaker on the cradle.
Racking interlock in Connected / Test / Disconnected Position.

Service Position : Main Isolating contacts and control contacts of the breaker are
engaged.
Test Position : Main Isolating contacts are isolated but control contacts are still
engaged.
Isolated Position : Both main isolating and control contacts are isolated.

3.1.3 Circuit Breaker Interlocking

 Sequence type strain free interlocks shall be provided to ensure the following:
 It shall not be possible for the Breaker to be withdrawn from the cubicle when in
the "ON" position. To achieve this, suitable mechanism shall be provided to lock
the Breaker in the tripped position before the Breaker is isolated.
 It shall not be possible for the Breaker to be switched "ON" until it is either in the
fully inserted position or, for testing purposes, it is in the fully isolated position.
 It shall not be possible for the Circuit Breaker to be plugged in unless it is in the
OFF position.
 A safety latch shall be provided to ensure that the movement of the Breaker, as it
is withdrawn, is checked before it is completely out of the cubicle, thus preventing
its accidental fall due to its weight.
 Mechanical and electrical anti pumping devices shall be incorporated in the ACB's
as required.
 Mechanical ‘ON’ pushbutton shall have suitable locking arrangements for carrying
out maintenance of downstream load.

3.1.4 Circuit Breaker Auxiliary Contacts & Electrical Auxiliaries

 The Circuit Breaker shall have minimum 4 NO/NC auxiliary contacts rated at 10
amps 415 volts 50 Hz.
 The auxiliary contacts in the trip circuits close before the main contacts when the
Circuit Breaker is plugged in and vice versa when the Circuit Breaker is Drawn Out
of the cubicle.
 The auxiliary contacts blocks shall be so located as to be accessible from the front.

PAGE - 788
  All electrical auxiliaries, including the spring charging gear motor shall be
installable on site without requiring adjustment or any tools other than a screw
driver.
 The auxiliaries shall be placed in a compartment which under normal operating
conditions, shall not contain any conducting parts capable of entering into
electrical contact with the circuit breaker poles. It shall be possible to connect all
auxiliary wiring from the front of the circuit breaker.

3.1.5 Circuit breaker Releases

 The ACB shall be equipped with an integral self-powered microprocessor based
LSING protection release, which works on true R.M.S values for ensuring accurate
protection.
 Microprocessor-based release shall offer accurate and versatile protection with
complete flexibility in the following four zones:
a- Long-time protection with an adjustable current setting and time delay;
b- Short-time protection with an adjustable pick-up and time delay;
c- Instantaneous protection with an adjustable pick-up and an OFF Position.
d- Ground/Earth-fault protection with an adjustable pick-up and time delay shall
be provided.
e- The release shall have Real-time on-line display of measurements, Current:
phase / neutral / earth, average, max, % loading, Voltage: Phase, Line and with
communication port facility etc.
 ACB On, off, trip & ready to close status should be able to communicate on
MODBUS-TCPIP/PROFINET protocol.
 The protection release shall have following features and settings:
a- True RMS Sensing- The release shall sense true RMS value of current to
avoid nuisance tripping during starting, effect of harmonics shall also taken
into account.
b- Thermal Memory : The release incorporate thermal memory feature to
achieve faster tripping in case of repetitive overloads.
c- Defined time-current characteristics: A variety of pick-up and time delay
settings shall be available to define the current thresholds and the delays to be
set independently for different protection zones thereby achieving a close-to-
ideal protection curve
d- Trip Indication Trip indicators shall be provided to display the exact nature
of fault (i.e. O/L, S/C, and E/F) that caused tripping of circuit breakers. The
circuit breaker will have to be necessarily with mechanical re-closing lockout.
e- Self-powered -The release should provide local LED indication/ indication on
display for identification of type of fault, without requiring using external
power supply. The release shall draw its power from the main breaker CTs and
shall require no external power supply for its operation. Indication of O.L, S.C,
E.F trips shall be available with the help of battery to give indication when CB
is off.

 Zone Selective Interlocking The release shall be suitable for communication

between breakers to enable zone selective interlocking. This feature shall be
provided for both short circuit and ground fault protection This feature enables
faster clearance of fault conditions, thereby reducing the thermal and dynamic

PAGE - 789
 stresses produced during fault conditions and thus minimises the damage to the
system. Accessories required to enable this feature to be supplied by ACB
manufacturer. It should be possible to carry out testing of release without tripping
the breaker. To implement ZSI manufacturer should supply all related equipment
like power supply, wiring etc
 The release shall meet the EMI / EMC requirements.
 Derating factor- In panel there shall not be any derating up to 50 degree
Centigrade. ACB Manufactures shall provide the derating table/chart and ambient
temperature
 The frame of CB shall be Postively earthed when CB is ready into cradle. Release
shall have current, Voltage & trip history on display
 The setting range of release shall be as follows :
Type of Setting Range of Release
Protection Pick-Up Current Time Delay
Long Time 0.4 to 1.0 times In 0.5 to 30 sec
Short Time 2 to 10 times In 20 ms to 400 m
Instantaneous 2 to 15 times In Not applicable
Ground Fault 0.1 to 1 time In 100 ms to 400 ms

 All incomer ACBs shall have following additional protections other than mentioned
above.
a- Under and over frequency.
b- Phase sequence reversal.
c- Restricted Earth Fault protection (For Transformers) with
electromechanical relay for Main LT Panel.

Note: In case any relay is required for additional protection as per IEC/IS shall be
provided to ensure full protection to the system. Nothing extra shall be paid for this
account.
3.1.6 Moulded Case Circuit Breakers

3.2.1 General
 The circuit breakers shall comply with the requirement of IEC 60 947 Part-1 & 2 /
IS 13947-2 : 1993. MCCBs shall be suitable for nominal voltage of 3 phase 440 Volts
AC 50 HZ supply.
 The circuit breaker shall comply with the isolation function requirement of IEC 60
947-2/ IS 13947-2 section 7.1.2 to be marked as suitable for isolation /
disconnection to facilitate safety of operating personnel while the breaker is in use.
 Type Test certificate as per IEC IEC 60 947 Part-1 & 2 shall be submitted for
approval.
 The MCCBs shall have a rated service breaking capacity (Ics) equal to the ultimate
breaking capacity (Icu) at 415V and as per system fault levels. The MCCBs shall be
made of halogen free high strength heat resisting and flame retardant thermo
setting insulating material.

PAGE - 790
  Suitable arc extinguishing devices shall be provided for each contact.
 The operating handle of the MCCBs shall be quick make / break, trip free type.
 The operating handle and mechanical trip push button shall be at the front of and
integral with the circuit breaker
 MCCBs shall be capable of limiting the fault currents. The maximum thermal I² t
shall be indicated by the manufacturer.
 The electrical endurance of MCCBs shall be more or equal to that specified by IEC
60 947-2 standard.
 Manufacturer shall furnish discrimination curve/chart for coordination between
upstream and downstream devices. The MCCB’s shall be from one manufacturer.
 MCCB up-to 250 A shall be Thermal magnetic release based (Adjustable thermal
and Fixed Magnetic and shall have individual fault difference for both Thermal and
Magnetic fault differentiation).
 Thermal magnetic release based MCCBs (Upto 250A) shall be provided with inbuilt
O/L & S/C protection & E/F Module with CBCT or Earth Fault Relay (ELR 30-
3000mA) with required CTs. (E/F protection shall be provided as per design
requirements)
 MCCB above 250 A shall be Microprocessor based, having in-built protection for:

O/L protection with fault LED indication

S/C protection with fault LED indication

E/F protection with fault LED indication

 MCCB shall have Individual fault LED indication for each type of fault
 Microprocessor trip units shall comply IEC 60947-2 standard (measurement of
rms current values, electromagnetic compatibility, etc.).
 MCCB shall comply to ROHS norms. Terminals shall be such designed to withstand
higher thermodynamic stress cross bolted/circular as per OEM standards. It shall
be invariably be used with spreader terminals. MCCB shall have min. 8000
electrical operations upto 250A and shall be available in frame sizes of 160A &
250A up-to 250A.
 All MCCBs shall have the facility of accommodating Aux Contact (For On,Off
Indication), Trip Alarm Contact (For Trip Indication) or Shunt / UV Release as
required per site condition.
 All MCCBs shall have Phase Barriers & Extended Rotary Operating Handles. The
Rotary operating mechanism shall be of robust design and should be with door
interlock & padlock facility.

3.2.2 Circuit Breaker Interlocking

MCCBs shall be provided with following interlocking devices.

 Handle interlock to prevent unnecessary manipulations of the breaker.

 Door interlock to prevent door being opened when the breaker is in ON position
 Daintier locking device to open the door even if the breaker is in ON position.

PAGE - 791
3.3 Motor Protection Circuit Breaker (MPCB)
 Motor circuit breakers shall conform to the general recommendations of standard
IEC 947 -1,2 and 4 (VDE 660, 0113 NF EN 60 947-1-2-4, BS 4752) and to standards
UL 508 and CSA C22-2 N°14.
 The devices shall be in utilization category A, conforming to IEC 947-2 and AC3
conforming to IEC 947-4.
 MPCB shall have a rated operational and insulation voltage of 690V AC (50 Hz) and
MPCB shall be suitable for isolation conforming to standard IEC 60947-2 and shall
have a rated impulse withstand voltage (Uimp) of 6 kV.
 The motor circuit breakers shall be designed to be mounted vertically or
horizontally without derating.
 Power supply shall be from the top or from the bottom. In order to ensure
maximum safety, the contacts shall be isolated from other functions such as the
operating mechanism, casing, releases, auxiliaries, etc, by high performance
thermoplastic chambers.
 The operating mechanism of the motor circuit breakers must have snap action
opening and closing with free tripping of the control devices. All the poles shall
close, open, and trip simultaneously. The motor circuit breakers shall accept a
padlocking device in the “isolated” position.
 The motor circuit breakers shall be equipped with a “PUSH TO TRIP” device on the
front enabling the correct operation of the mechanism and poles opening to be
checked. The auxiliary contacts shall be front or side mounting, and both
arrangements shall be possible. The front-mounting attachments shall not change
the breaker surface area. Depending on its mounting direction the single pole
contact block could be NO or NC.All the electrical auxiliaries and accessories shall
be equipped with terminal blocks and shall be plug-in type.The motor circuit
breakers shall have a combination with the downstream contactor enabling the
provision of a perfectly co-ordinated motor-starter. This combination shall enable
type 1 or type 2 co-ordination of the protective devices conforming to IEC 60947-
4-1. Type 2 co-ordination shall be guaranteed by tables tested and certified by an
official laboratory.
 The motor circuit breakers, depending on the type, could be equipped with a door-
mounted operator which shall allow the device setting. The motor circuit breakers
shall be equipped with releases comprising a thermal element assuring overload
protection and a magnetic element for short-circuit protection. In order to ensure
safety and avoid unwanted tripping, the magnetic trip threshold (fixed) shall be
factory set to an average value of 12 Ir.
 All the elements of the motor circuit breakers shall be designated to enable
operation at an ambient temperature of 60°C without derating. The thermal trips
shall be adjustable on the front by a rotary selector. The adjustment of the
protection shall be simultaneous for all poles. Phase unbalance and phase loss
detection shall be available. Miniature Circuit Breakers

3.4 Miniature Circuit Breaker

 Miniature Circuit Breaker shall comply with IS-8828-1996/IEC898-1995.

PAGE - 792
  Miniature circuit breakers shall be quick make and break type for 240/415 VAC 50
Hz application with magnetic thermal release for over current and short circuit
protection.
 The breaking capacity shall not be less than 10 KA at 415 VAC. MCBs shall be DIN
mounted.
 The MCB shall be Current Limiting type (Class-3).
 MCBs shall be classified (B,C,D ref IS standard) as per their Tripping Characteristic
curves defined by the manufacturer.
 The MCB shall have the minimum power loss (Watts) per pole defined as per the
IS/IEC and the manufacturer shall publish the values.
 MCB shall ensure complete electrical isolation & downstream circuit or equipment
when the MCB is switched OFF.
 The housing shall be heat resistant and having high impact strength. The terminals
shall be protected against finger contact to IP20 Degree of protection.
 All DP, TP, TPN and 4 Pole miniature circuit breakers shall have a common trip bar
independent to the external operating handle.

3.5 ENERGY MONITORING SOLUTION (Multi-Function Meters) for LT & HT Panels

3.5.1 GERENAL
 MFM shall be Digital Multi-function meter of Class 0.5S Accuracy conforming to IS
13779/ IS14697/ IEC 62052 / IEC 62053 standards.
 Sampling plan shall be as per IS: 14697.
 MFM shall have communication facility to BMS/EMS/SCADA system via Modbus
communication
 MFM shall be able to communicate over RS 485 Port with Modbus RTU /Profinet
communication.
3.5.2 Technical Requirement.

Sl. Technical Requirement

No.
1 Model Panel Flush mountable Digital Multifunction Meter
2 Measuring 3 phase 3 wire & 3 phase 4 wire compatible with field
method configurable
3 True RMS Up to 15th harmonic on single or three phase AC System
measurement (3P, 3P + N), 64 samples per cycle with THD voltage and
current per Phase & Neutral
4 Measurement Class 0.5S
Accuracy
5 Application For measuring the instantaneous values of voltage,
current, power factor, frequency, power (active &
Reactive) and recording of Energy (real & reactive) etc
6 Voltage input  63.5(110 V) -240V(415V) AC RMS +/- 10% from
panel PT secondary to measure HV system voltages
(3.3kV, 6.6 kV, 11kV & 33kV).

PAGE - 793
  440 V direct measurements with in-built field
programmable feature for LT systems (3Ф 3 wire &
3Ф 4 wire).
7 Current input 5A AC RMS +/- 10% from panel CT Secondary (Field
programmable, primary current range 1-9999 Amps)
shall work in 10A continuously
8 Power Factor 0.3 Lag – Unity – 0.3 Lead
range
9 Display 1. Line and Phase voltages
parameters 2. Line currents and Avg. Current
3. KVA, KW and KVAR
4. Power factor & Frequency
5. KWh.
6-Maximum Demand
7. Total Active, Reactive and Apparent Power,
8. THD for Voltage, Current and Power.
These parameters are to be displayed in full-scale
reading with auto ranging.
10 Display Auto & Manual - all parameters V, A, W, VA, VAR, Hz, and
PF are to be shown continuously by auto & manual
scrolling one by one with LED / LCD Display
11 Auxiliary Power 80 – 300 V, 50 Hz, AC & 24 - 110 VDC
Supply
12 Display selection By set of membrane keys with status LED /LCD
13 Energy reset Through keyboard & password protection
facility
14 Programming Through front panel keys
15 Programmable PT ratio (HT supply), CT ratio, device address, Baud rate,
Parameters Connection Type (Measuring method).
16 Communication
details
 Computer  Modbus RTU – suitable for BMS /EMS/SCADA
Protocol
 Serial Port  RS 485

 Baud rate  1200-38400 (Default- 9600)

range
17 IP rating IP 54 from front end of panel and IP 20 at Terminals
18 Applicable IS13779 / IS 14697 / IEC 62052-11 / IEC 62053-22
Standards
19 Dimension Bezel - 96mm X 96mm; Cutout- 92mm X 92 mm
20 Test Reports Routine Tests and Type Test reports as per IS 14697
amended up-to date shall be submitted for approval.

PAGE - 794
SECTION-8 SURGE PROTECTION DEVICES (SPD’S)

1.0 SYSTEM
Surge Protection Devices (SPD’S) shall be provided at main LT Panel incoming feeders
(Stage I / Class B) & Distribution Boards (Stage II / Class C) for the protection of
Building electrical and Electronics system from the effect of Lightning discharges, line
induced transient surge voltage or switching surges as per the design condition
1.1 CODES & STANDARDS
The following standards in addition to local relevant codes & publications as referred
in the various parts of this Specification shall apply.
 IEC-61643-1 edition 1.1:2000, IEC-61643-12:2002
 IEC 60364 – 5 – 5 53
 IEC 62305 – All parts.
1. General Principle
2. Risk assessment
3. Physical Damage
4. Electrical and Electronic system within the structure

2.0 PRODUCT SPECIFICATIONS

2.1 Surge Protector at Stage I / Class B (LT Panel Protector)
 The Surge Protection Device (SPD) manufacturer shall offer a complete line of
Surge Protection Devices to support the requirements for Main LT Panel Incoming
feeders. The surge protector at this stage shall be provided to protect the down-
stream electrical and electronics against any lightning discharges surges that may
enter into the system through Mains panel.
 The Protection unit shall be based on single arc spark gap technology and shall be
able to withstand 10/350 microsecond surge currents associated with external
lightning discharges.

2.1.1 Protection Network Configuration:

 The work required under this section consists of furnishing, installing and
connecting SPD device as per design requirements. The SPD device shall be
installed in a NETWORK configuration, consisting of one set of SPD panel device at
the service entrance of switchboard.
 All SPD devices in this network configuration shall be of same manufacturer.
 All SPD device shall be modular, mountable on 35 mm DIN rail and be field
replaceable without interruption of electrical distribution circuit Unit status
indicator shall be provided to indicate the status of complete Protection unit.
 Protection shall be manufactured for the specific type and voltage of the electrical
Service and shall provide clamping for both normal (L-N) and common (N-G) mode
operation.
 Protection shall be manufactured to withstand a maximum continuous operating
voltage of not less than 115% of normal RMS Line voltage of 240 V.

PAGE - 795
  The Protection shall be provided with safety MCB’s to be connected in series
between Line/s to neutral & neutral to earth as per the TNS configuration of wiring.
It shall be testable on line for routine maintenance, module failure and in order to
prevent catastrophic failure modes.
 Protection shall be a fail-safe type device, shall have a follow through current
quenching capacity upto 25 KA r.m.s., shall have repeated surge capability state,
shall be self-restoring and be fully automatic in all mode of operation.
Protection shall comply with IEC 61643 and shall be approved for the location in
which they are listed.
 Protection shall have an operating temperature ranges from -20oC to 60oC.

2.1.2 Protection Criteria

 The maximum continuous operating voltage (Rated Voltage) for SPD devices
connected to phase-neutral shall not be less than the values shown in table:
Maximum Continuous Operating
Nominal Voltage Rating per phase
Voltage

(Vrms) (Vrms)
240 320
 Listing
 The surge protective device and associated hardware must comply with IEC
61643-11.
 The Protection voltage of the complete rail mount surge protective device shall
be type test to the figures as indicated in table below, which must not exceed
the values shown:
Service Voltage / per phase Protection Voltage @ In (Nominal discharge
current) / Protection Level
240 V < 2.5 k V (between Line to Neutral)
1.5 kV (between Neutral to Earth)
 Surge protective device application at Low Voltage AC main LT Panel incoming
feeder surge impulse current withstanding capacity as shown in table below:
Application Panel Location Max. Single Withstand Surge Current
(of 10/350 μs Impulse)
Service Entrance (Main LT 25 KA, 10/350μs (between Line to Neutral
Panel) 100 KA, 10/350 (between neutral to Earth)

 Compliance to this specification must be provided in the form of a certificate

from an independent testing laboratory.
 Response time of stage-I class –B arrester should not be < 100 ns.
 Follow current extinguishing capability Ifi >=7KA
 TOV voltage Ut (L-N / N-G) (5s / 200ms) = 400/1200 V
 Max. back up fuse gG/gL of 125A should available.
 Visual indicator shall be available.

PAGE - 796
2.1.3 Surge protector at Stage II / Class C (Final Distribution Board Protector)
 The surge Protection manufacturer shall offer a complete line of surge Protection
product to support the requirements for the Distribution Board. The surge
protector at this stage shall be provided to protect the downstream electrical and
electronics against any induced switching surges that may be passed on to the
downstream electrical & electronic system.
 The Protection unit shall be based on Single High Capacity Metal Oxide Varistors
(MOV), capable of handling 8/20 μs surges and shall be able to give an indication in
the event module failure and be pluggable to facilitate the in-service replacement
without distributing the lines. One extra set of replacement module shall be
furnished to the job site.

2.1.3.1 Protection Network Configuration.

 The work required under this section consists of furnishing, installing and
connecting SPD device as specified/as per design requirement. The SPD device
shall be installed in a NETWORK configuration, consist of one set of SPD panel
device at the service entrance of switchboard.
 All SPD device in this network configuration shall be of same manufacturer.
 All SPD device shall be modular, mountable on 35 mm DIN rail and be field
replaceable without interruption of electrical distribution circuit Unit status
indicator shall be provided to indicate the status of complete Protection
 Unit status indicator shall be provided to indicate the status of complete Protection
unit on the product as well as provision for remote indication must be provided.
 Protection shall be manufactured for the specific type and voltage of the electrical
Service and shall provide clamping for both normal (L-N) and common (N-G) mode
operation.
 Protection shall be manufactured to withstand a maximum continuous operating
voltage of not less than 115% of normal RMS Line voltage of 240 VAC.
 The Protection shall be provided with internal safety fusing if required, to be
connected in parallel between Line/s to neutral & neutral to earth as per the TNS
configuration of wiring. It shall be testable on line for routine maintenance,
module failure and in order to prevent catastrophic failure modes.
 Protection shall be a fail-safe type device, shall have no follow through current
shall have repeated surge capability, shall be solid state, shall be self-restoring and
be fully automatic in all mode of operation. It shall have thermal disconnection and
indication against overloading of the device.
 Protection shall comply with IEC 61643 standards.
 Protection shall have an operating temperature ranges from -20oC to + 60oC.

2.1.3.2 Protection Criteria

 The maximum continuous operating voltage (Rated voltage) for SPD devices
connected to phase-neutral shall not be less than the values as shown in table
below:
Nominal Voltage Rating per phase Maximum Continuous Operating Voltage
(Vrms) (Vrms)
120 150
240 320

PAGE - 797
 350 440
480 600

 Listing
 The surge protective device and associated hardware must comply with IEC
61643-11.
 The Protection voltage of the complete rail mount surge protective device shall be
type test to the figures as indicated in table below, which must not exceed the
values shown:
Service Voltage / per phase Protection Voltage @ In (Nominal
discharge current) / Protection Level
240 V 1500 V

 Nominal Withstand Surge Current.

Surge Protective device (including all fusing and over current protection) for
application at sub-Distribution Panels shall have a Nominal surge current withstand
capacity as shown in table below. The failure or operation of any fuse / over – current
device during the test is not permissible.
Application Panel Location Max. Single Withstand Surge Current of 8/20
µs Impulse
Sub-Distribution Panel 10KA for 8 / 20 μs (between Line to Neutral)
Final Distribution Board 25 KA for 10/350 μs (between Neutral to
Earth)

 Compliance to this specification must be provided in the form of a certificate

from an independent testing laboratory.
 Response time of Class C arrestor should not be <25 ns.
 The unit shall be pluggable

PAGE - 798
SECTION-9 HYBRID APFC PANEL (AUTOMATIC POWER FACTOR CORRECTION
PANEL)
1.0 General Technical Requirements-
 This section covers the detailed requirements of Integrated hybrid APFC panel for
415 volts, 3 phase, 50 Hz, 4 wire system, with minimum of Super Heavy-Duty type
capacitors, microprocessor-based controller and Copper wound detuned filter.
 Single hybrid panel consisting of APFC with step configuration and Stati-VAR
Generator with combination of one or more modules which provides the smooth
stepless effect of reactive power requirement in capacitive as well as inductive
mode.
 Panel shall be capable to maintain the PF 0.999.
 Panel should be capable of Fast Transient Free Dynamic response in Real Time
through contactor Switching.
 Modular Active Harmonic Filtration Units for Harmonic elimination with
centralized display unit.
 Both Real Time PF section and Active Harmonic Filter section should work in
perfect synchronization in Hybrid combination.
 Both Real Time PF Section and Active Harmonic Filter should be controlled
through single centralized Touch Screen Controller.
 The Total Harmonic Distortion Voltage (THD V) shall be within the limits as
specified in IEEE Std 519-2014 (Standards on IEEE recommended practices and
requirements for Harmonic Control in Electric Power System)
 Panel shall have _-
- Fault level as per design requirements.
- Maximum voltage variation + 10%
- Maximum frequency variation + 5%
- Combined voltage & frequency variation: 10%

1.1 Codes & Standards

S.N. Applicable Standards /Mandatory Particulars
1. Type Integrated Hybrid Panel
Hybrid Integrated Solutions
IS 16636: 2017- Automatic power factor correction panels for voltage
2 amended up-to date up to and including 1000 Volt
IEC 61921 Power Capacitors- Low voltage power factor
correction banks
IEC 519 Harmonic filtering Through Active Devices (IGBT)
CAPACITORS
3 IEC 60831: Part 1 & 2 Shunt power capacitors of the self-healing type for a.c.
systems having rated voltage up to and including 1kV
IEC 61439-1: Low voltage switchgear and control gear assemblies.
SWITCHGEARS (ACB MCCB & Contactors)
4 IEC 60947 Low Voltage Switchgear & Control gear
 Part -1  General Rules
 Part-2  Air circuit Breakers & Molded Case Circuit
Breakers

PAGE - 799
  Part-3  Switches, disconnectors, switch-disconnectors
and fuse-combination units
 Part-4  Power Contactors

DETUNING REACTORS
IEC 60076-6: Power transformers – Part 6: Reactors
5 IS: 5553 (Part 5) Reactors: Part 5 Tuning reactors
amended up-to date
Power Factor Controller
IEC 61000-4-2 Electrostatic discharge Test
Edition 1.2 2001-04
IEC 61000-4-5 High energy surge test
6 Edition 1.1, 2001-04
IEC 61000-4-6 Conducted radio frequency susceptibility test
Edition 2.1, 2004-11
IEC 61000-4-8 Power frequency magnetic field immunity test
Edition 1.1, 2001-3
IEC 61000-4-11 Voltage dips and interruption
Second Edition 1.1,
2004-03
CISPR 11, Fifth Conducted emission test
edition, 2005-04
IEC 61000-6-4 Electromagnetic compatibility
IEC 61000-4-2 Electrostatic discharge Test
Edition 1.2 2001-04
CISPR 22, Class A Radiated emission test
edition 4.1, 2004-06
IEC 62052-11,2003 Accuracy measurement
& IEC 62053-21, 2003
ENCLOUSRE
7 IEC 62208 Empty enclosures for low-voltage switchgear and
control gear assemblies – General requirements.
IEC 60529:2001 Degree of protection provided by enclosures.
8 Active Harmonic filter
EN 50178: General and Safety requirements.

IEC 61000-6-2: Generic standards — Immunity for industrial

environments
IEC 61000-6-4: Generic standards — Emission standard for industrial
environments.
EN 60529: Degrees of protection provided by enclosures (IP Code)

1.2 DESIGN AND CONSTRUTION PARAMTERS

 All the components like Capacitor (Stepped section), AMC Controller, circuit
breaker, busbars, anti-condensation heater, and other ancillaries necessary for
power factor correction shall be housed in an enclosure.
 Degree of protection for enclosure is IP 42.

PAGE - 800
  The enclosure shall be force ventilated/self-contained, metal-enclosed type, floor
mounted, flush fronted and suitable for front and rear access.
 All materials used in the construction and for the primary insulation shall be non-
hygroscopic and have fire retardant properties.
 To ensure safety, reliability and accountability of component coordination, all the
major components such as Active Filters, Capacitor units, De tuning reactors, PF
controllers, Circuit breakers, Contactors and the Enclosure system called for in this
specification should preferably be from a single manufacturer.
 Busbars shall be made of high conductivity aluminium conductors in accordance
with IS and of adequate rectangular cross-section to carry continuously the
specified current without overheating and shall be rigidly mounted on non-
hygroscopic insulators so as to withstand any mechanical force to which they may
be subjected under maximum fault condition.
 Each phase busbar shall be able to withstand at least applied AC test voltage of
2.5kV to ground, for a period of 60 seconds.
 Panel shall be fabricated from CRCA sheet of 2mm thickness for load bearing
members not less than 1.6 mm thick for other non-load bearing members .
 Thickness of gland plate shall be 3mm.
 Panel shall be finished with powder coating in the approved colour shade/s to
match the colour of the other panels. The thickness of powder coating should be
minimum 60-80 microns.
 Earthing for every step of in APFC section and every module in Active filter should
be provided.
 Following minimum protections shall be provided in panel:
i. Over voltage (AC) protection
ii. Over voltage (DC) protection
iii. Phase sequence protection
iv. Over current protection
v. Over temperature protection
vi. Protection circuits for the inverter stack and its components.

1.3 System Components

1.3.1 Capacitors
 Manufacturing & testing of Capacitors shall be incompliance with IEC 60831-1 & 2
 The rated voltage for capacitors shall be 525 Volt 3 phase system.
 The capacitors shall be self-healing type.
 The dielectric film used in the capacitor shall be of the self-healing type utilizing
metalized polypropylene.
 Each capacitor unit shall be fitted with discharge resistors across the capacitor
terminals such as to discharge to 50 V within one minute, after the Capacitor is de-
energized.
 Each stage of the capacitor bank shall also have a suitably rated MCCBs with an
electronic over-current relay for overload protection.
 The electronic over-current relay shall be adjusted to trip if the RMS current of the
stage exceeds the overload setting.
 The Capacitor bank shall be of certified design confirming to IEC 61921 & IEC 61439-
1&2.

PAGE - 801
1.3.2 Detuning/Series Reactors
 Detuning reactors shall be in compliance to temperature class H according to IEC
60076 and IS 5553 and operating ambient up to 55 C.
 14% de-tuned type series reactors (135 Hz) for each capacitor stage.
 The detuning reactor shall be supplied with a normally closed thermostat contact
to be connected in series with the power factor regulator step switching relay,
When the reactor iron core has overheated, the thermostat contact will open and
thus cut off that particular step to prevent thermal runaway of the reactors.
 The detuning reactor should have been Type tested according to IEC 60076-6 &
IS 5553.

1.3.3 Capacitor Switching Module

 Switching ON/OFF of capacitor banks shall be done through electromagnetic
contactors.
 Capacitor switching Contactors with appropriate KVAR ratings and utilization
category shall be selected for reactive capacitor switching.
 The contactors should conform to IEC 60947-4-1.
 The Contactors should have been Type tested to IEC 60947.

1.3.4 ADVANCED MULTILEVEL CONTROLLER (HYBRID CONTROLLER) /power Factor

Controller
 The power factor controller shall be microprocessor based.
 Its controls shall be dependent on the reactive power and insensitive to EMI/ EMC
concerns.
 The integrated controller shall ensure that the reactive current requirement of the
base load shall be drawn through the capacitors and the additional requirement
shall be automatically catered through active filter ensuring stepless
compensation of reactive current.
 Controller should be capable of switching Banks in Real Time through static
outputs.
 Controller should have programmable option for taking inputs from 5A or 1A CT’s.
and shall have LCD Display
 The automatic power factor controller shall be manufactured in full compliance
with and tested to the requirements of IEC 61326-1.

1.3.5 ACTIVE HARMONIC FILTER (AHF)

 AHF shall be Modular IGBT based Active Harmonic Filter.
 AHF shall be capable of Dynamic VAR compensation and load balancing in all the 3
phases.
 The AHF shall not only provide harmonic mitigation, but also, power factor
correction and load balancing.
 The AHF system should be able to eliminate harmonic current of 2nd to 51th order
(selectable) and correct load imbalance (compensate Negative and Zero sequence).
 AHF shall provide field selection as-
a- Harmonic filter
b- Reactive current correction
c- Supply current balancing

PAGE - 802
 d- Any combination of the above three modes.
 The response time for AHF shall be at least 25μs and the correction time shall be
less than 10 ms.
 AHF shall have digital Display /LED Backlit Display with door mounted touch
screen unit.
 The AHF shall continuously display the voltage, current, THD-I, THD-V and
harmonic current injected for each phase.
 AHF Display unit shall also have feature to display Waveform for all above
parameter
 The AHF Display shall have event log facility with date, time and event description
for each module to know the status of its operation.
 The Active Harmonic Filter shall have following protection
a- Undervoltage and Overvoltage protection.
b- Integrated overload protection.
c- Internal short circuit protection.
d- Overheating protection.
e- Inverter bridge protection.
f- Grid Resonance detection and protection.
g- Fan fault alarm.
h- Overheating protection.

 The AHF shall be CE marked in accordance with EEC directives 73/23 “low voltage”
and 93/68 “electromagnetic compatibility.”
 The AHF and all associated equipment and components shall be designed and
manufactured in accordance with the following applicable standards:
- EN 50178: General and Safety requirements.
- IEC 61000-6-2: Generic standards — Immunity for industrial environments.
- IEC 61000-6-4: Generic standards — Emission standard for industrial
environments
- EN 60529: Degrees of protection provided by enclosures (IP Code)

1.3.6 DRAWING, INSPECTION & TESTING: -

 Routine testing at OEM works shall be done as per IS/IEC
 GA drawing along with SLD of panel showing all Electrical equipment’s shall be
submitted to AAI for approval.
 Composition of Active and passive components.
 Protection and control schematics of the Hybrid Compensation System.
 Foundation plan, including foundation loading.
 Original catalogues for various proposed components.
 Type test certificates of the Active Harmonic Filter, Capacitor bank, Detune/ Series
Reactor, Switchgear shall be submitted as described above in relevant paras.
 Installation and maintenance manual.

PAGE - 803
SECTION-10 - INTERNAL & EXTERNAL ELECTRICAL INSTALLATION I/C LIGHTING

1.0 GENERAL
This section deals with the requirements of Internal Electrical Installations,
Lightning Protection System, LT Cables, MV Panels, Cable tray, Earthing etc.
The electrical Installation work shall be carried out in accordance with Indian
Standard Code of Practice. It shall also be in conformity with the current Indian
Electricity rules and regulations and requirements of the Electricity Supply
Authority and Fire regulations, so
far as these become applicable to the installation. Electrical work in general shall
be carried out as per following CPWD Specifications amended upto date.
General Specifications for Electrical Works:
- Part - I : Internal (2013)
- Part - II : External (1994).
Wherever these specifications call for a higher standard of material and or
workmanship than those required by any of the above-mentioned regulations
and specifications then the specifications here under shall take precedence over
the said regulations and standards.
The details of scope of work sub-head wise are given in the subsequent paras.
The quantities worked out in schedule of quantities are based on particular
equipment considered at design stage. The contractor is required to recheck the
quantities based on the approved design to achieve required parameters.

1.1 SCOPE OF WORK

This section covers general requirements of Electrical installations & allied
works.

2.0 GENERAL INSTRUCTIONS

2.1 The Contractor shall include whole of the new material in accordance with the
Particular Specifications for supply & fixing accessories for the complete
installation. This shall also include any materials, appliances, equipment not
specifically mentioned herein or noted on the drawings as being furnished or
installed but which are necessary and customary to make the installation complete
in all respects. In general, the work to be performed under this contract shall
comprise supply and installation of the following as per schedule of quantities.
 All conduit work shall include for junction boxes, outlet boxes, swapping and
drawing fish wires etc. as required and as directed.
 Light control switches, plug sockets, cover plates, metal boxes etc. shall include
under the wiring accessories. Back boxes required for the control switches shall also
form part of the scope of work.
 LT Cables for power to equipment and main panel boards sub-main panel boards
and final distribution boards.
 Main panel boards and final distribution boards.

PAGE - 804
  Cables laying in existing trench / duct / ground / surface / on existing cable trays,
all fixing accessories complete supplying and fixing of cable trays, excavation of
trench & back filling (in case of cable laying in ground) etc.
 Earthing system.
 Lighting Fixtures.
 Lightning Protection System.
 Any other items, which is required for successful commissioning of system.

2.2 The Scope of work covered in this tender. The contractor has to coordinate with the
other agencies for proper co-ordination and execution of the work at site.

3.0 QUALITY OF WORK

The work shall be carried out to the satisfaction of the Engineer In-charge. The
supply, Installation, testing and commissioning shall comply with the latest
requirements of Bureau of Indian Standards and code of practice as amended upto
date. All equipments and materials being supplied shall meet the requirements of IS,
Indian Electricity Rules, Local Electrical Inspectorate and other governmental
statutory bodies.

4.0 FEES, PERMITS AND TESTS

The Contractor shall obtain and pay for any and all fees and permits required for the
installation of work. Fee paid / deposited with statutory Authorities will be
reimbursed on production of documentary evidence. On completion of the work the
contractor shall obtain and deliver to the owner certificates of final inspection and
approval by the local electricity authority, as required.

5.0 DRAWINGS & SPECIFICATIONS

5.1 Specifications
The specifications shall be considered as part of contract. Any changes found
essential to coordinate the installation of other services Installations and to
comply with the Local Regulations shall be made without any cost to the AAI. The
drawings are for the guidance of the contractor; exact locations, distances and
levels shall be governed by the site conditions.
5.2 Shop drawings
On the basis of GFC drawings issued by the department, the Contractor shall
prepare and submit shop drawings with proper visible scale min. on A2 Size to
the Engineer In-charge for approval. The detailed shop drawing shall include all
Schematics, Load distribution and balancing, Cable routing and Schedule, all
lighting, UPS, Signages, Network / Telephone and Power Circuit layout,
Distribution Board / Panels, Switch boards, Special Junction Boxes, Raceway
layout, Earthing and any other item etc. provided by the contractor.
5.3 Completion drawings
On the completion of the work and before issuance of certificate of virtual
completion, the Contractor shall submit a soft copy of as built drawings in a soft
media after incorporating changes done during execution. These drawings should
necessarily show the following details:

PAGE - 805
  Complete conduiting and wiring diagram including control circuits as
installed from starting point i.e. power supply panel / telephone / network
panel to last receiving end i.e. power / light / telephone/ network point and
schematic drawings showing all connections, Junction box, DBs, Raceway,
Electrical switch gears, accessories etc. in the complete electrical system.
 Location of all earthing stations, routes and size of all earthing conductors,
manholes i/c lightning Arrestor system etc.
 Layout and particulars of all cables.
 Instruction, maintenance and operation manuals, if any for the equipment.

6.0 MATERIALS AND EQUIPMENT

All materials and equipments shall be of the one of the approved make listed in
Appendix enclosed with this document and design. Unless otherwise called for
only the best quality materials and equipments shall be used. The materials and
equipments shall conform to relevant IS as listed under the sub-head
'Regulations and Standards'. The contractor shall be responsible for the safe
custody of all materials. The materials shall be insured against theft or damage
in handling or storage etc. All changes and substitutions shall be requested in
writing and approvals obtained in writing from the Engineer In-charge shall be
maintained.

7.0 TOOLS AND TACKLES

The contractor shall provide and install all necessary hoists, ladders, scaffolding,
tools, tackles, plants, transport for labour and materials and plant necessary for
the proper execution and completion of the work to the satisfaction of the
Engineer In-charge.

8.0 SAFETY PROCEDURES

The policy is to clearly define responsibilities and then to obtain the commitment
of all contractors to maintain a high safety standard compatible with the policy.
Safe methods of working shall be the main consideration in all operations.
Contractors shall provide the Engineer In-charge with details of their methods
statement of work, highlighting the safety aspects and they shall update this
information as necessary. It is the responsibility of all persons employed on this
project to act responsibly to prevent accidents to themselves and others. The
contract shall be governed by the Latest National Safety Rules and Regulations as
stipulated from time to time and the contractor shall provide as mentioned
herein, wherever required for the safety of working manpower: -
 Providing safe plant, tools, equipment etc. wherever required and working
conditions
 Ensure and establish safe working procedures.
 Provide suitable protective equipment, clothing, gloves, ear muffs, goggles,
safety belts, Helmets, Aluminium ladders, Steel scaffolding etc.
 Provide adequate job training.
 Provide fire extinguishers and First aid box with adequate medical supplies.
 SOP with emergency contact details etc. for clarity towards action to be taken by
various persons, in case of accident / mis-happening.
 Report accidents and dangerous occurrences if any, to the Engineer In-charge
with copies of relevant documents.
 Ensure that hazardous materials, if necessary on site, will be stored and used in

PAGE - 806
 the safe manner.
 The Contractor shall co-operate with AAI in creating and maintaining a high
standard of safety, health and welfare.

9.0 COMPLETION
On completion of the Electrical Installation, the Contractor shall furnish a
certificate signed by the licensed supervisor and Contractor’s Engineer, under
whose direct supervision the installation was carried out as per form of
completion certificate.

10.0 TESTING
a. On the completion of the work, the entire installation shall be subject to the
following tests in the presence of the Engineer Incharge.:
 Wiring continuity test
 Insulation resistance test
 Earth continuity test
 Earth resistively test
 Test as per IS: 732-1989
 Any other Tests as per relevant CPWD / IS specifications as required.

b. Besides the above and any other tests specified by the Local Statutory
Authority / Supply Company (DISCOM) shall also be carried out. Approved
testing laboratories shall calibrate all testing instruments and the
Contractor shall produce the test certificates thus obtained on demand to
Engineer-in- charge for his inspection and record.

11.0 DEMONSTRATION TO AAI

On completion of the Installation, devices subject to manual operation shall be
operated at least in presence of Engineer In-Charge or his representative to
demonstrate the satisfactory operation of the complete system.

12.0 MANUFACTURER’S INSTRUCTION

Where manufacturers have furnished specific instructions relating to the
material used in the job and points that are not specifically mentioned in this
document, manufacturer’s instruction shall be followed.

13.0 POINT & SUBMAINS WIRING etc.

13.1 SCOPE
This section covers the general technical requirements and measurement of the
various components in Internal Electrical Installation Works.
13.2 TERMINOLOGY
The definition of terms shall be in accordance with IS 732: 1989 (Indian Standard
Code of Practice for Electrical Wiring) and CPWD Specifications of Internal EI –
2013 with up to-date amendments.
13.3 POINT WIRING
13.3.1 Definition:
A point (other than socket outlet point) shall include all works necessary in
complete wiring to the following outlets from the controlling switch. The scope

PAGE - 807
 of wiring for a point shall, however, includes the wiring work necessary in
tapping from another point in the same distribution circuit: -

a) Ceiling rose or connector (in the case of points for ceiling / exhaust fan points,
pre-wired light fittings and call bells)
b) Ceiling rose (in case of pendants except stiff pendants)
c) Back plate (in the case of stiff pendants)
d) Lamp holder (in the case of gooseneck type wall brackets, batten holders and
fittings which are not pre-wired.

13.3.2 In the case of call bell points, the words “from the controlling switch or MCB” shall
be read as “from the ceiling rose meant for connection to bell push”.

13.3.3 SCOPE
i) Following shall be deemed to be included in point wiring -
a) Conduit, accessories for the conduit and wiring cables between the switch box
and point outlet, loop protective earthing of each fan / light fixture i/c loose
wire in switch board & points for connection.
b) All fixing accessories such as clips, nails, screws, Phil plug, rawl plug etc. as
required.
c) Metal switch boxes for control switches, regulators, sockets etc. recessed or
surface type and phenolic laminated sheet covers in case of piano type
switches and outer & inner cover plates in case of modular type switches.
d) Outlet boxes, junction boxes, pull-through boxes etc. but excluding metal boxes
if any, provided with switchboards for loose wires/ conduit terminations.
e) Control switch or MCB as specified.
f) Ceiling rose or connector as required/ flexible conduit for connecting the wires
to fitting.
g) Connections to ceiling rose, connector, lamp holder, switch etc.
h) Interconnection wiring between points on the same circuit, in the same switch
box or from another.
i) Bushed conduit or porcelain tubing where wiring cables pass through wall i/c
repairing cost etc.
(Note: In areas where false ceiling is provided, termination of wires should be at
the fittings. Flexible conduits from ceiling junction box to the fittings shall be
provided duly coupled at both ends. This shall be included within the scope of
point wiring.)
ii) Following shall be deemed to be included in group control (Looped) point
wiring:
Wiring for group controlled (looped) light point/fan point/exhaust fan point/
call bell point (without independent switch etc.) will include all work necessary
from 1st switch-controlled point to subsequent looped points which shall include
wires / cable, earth wire/ cable as per SOQ as required.
All fixing accessories such as conduit, clips, nails, screws, Phil plug, rawl plug,

PAGE - 808
 loose wire for connection etc. as required.
Junction boxes pull-through boxes etc. Connector as required.
Bushed conduit or porcelain tubing where wiring cables pass through wall i/c
repairing cost etc.

13.4 MEASUREMENT
13.4.1 POINT WIRING (OTHER THAN SOCKET OUTLET POINT)
(i) Unless and otherwise specified, there shall be no linear measurement point
wiring for light points, fan points, exhaust fan points and call bell points.
These shall be measured on unit basis by counting, as per following: -
(a) Residential Buildings

(ii) Group ‘A’, for point wiring for type I, type II and type III residential quarters
and hostels.
(iii) Group ‘B’, for point wiring for type IV and above type of residential quarters
and barracks.
(a) Non-residential Buildings
Group ‘C’ for all types of non-residential buildings such as offices, hospitals,
laboratories, educational institutions, libraries etc.
(b) For any other Type of Building
The group under which the points shall be decided by the TS Authority.

13.4.2 POINT WIRING FOR SOCKET OUTLET POINTS

i) The light plug (6 Amp) point and power (16 Amp) point wiring i/c conduit,
loose wire for connection shall be measured on linear basis, from the
respective tapping point of live cable, namely, switchbox, another socket
outlet point, or the Sub distribution board as the case may be, upto the
socket outlet.
ii) The metal box with covers, switch/ MCB, socket outlet shall be measured
and paid as separate item.
Note: There shall normally be no “on the board” light plug point.
iii) The power point may be 16/6 Amp 6 pin socket outlet, where so specified
in the Tender documents. (2 pin or 5 pin socket outlet shall not be
permitted).

13.4.3 GROUP CONTROL POINT WIRING

i) In the case of points with more than one point controlled by same switch,
such points shall be measured in part i.e. from switch to the first point outlet
as one point and subsequent looping points i.e. from first point to another
point in the same group will be measured as a subsequent/loop point
without independent switch.
ii) No recovery shall be made for non-provision of more than one switch in such
cases.

PAGE - 809
13.4.4 MCB CONTROL GROUP POINT WIRING
i) In the case of points with more than one point controlled by one MCB, such
points shall be measured in part i.e. from MCB to the first point outlet as one
point and subsequent looping points i.e. from first point to another point in
the same group will be measured as a subsequent/loop point without
independent MCB
ii) Providing MCB is not covered in this scope and will be measured separately
and shall be separately paid for.

13.4.5 TWIN CONTROL LIGHT POINTS WIRING

i) A light point controlled by two numbers of two way switches shall be
measured as two points from the fitting to the switches on either side.
ii) No recovery shall be made for non-provision of more than one ceiling rose
or connector in such cases.

14.0 CIRCUIT AND SUBMAIN WIRING

14.1 Circuit Wiring
Circuit wiring shall mean the wiring from the distribution board to the first tapping
point inside the switchbox, from where point wiring starts.
14.2 Submain Wiring
Submain wiring shall mean the wiring from one Main/Distribution switchboard to
another switch board.
14.3 Measurement of circuit and submain wiring
i) Circuit and submain shall be measured on linear basis along the run of the wiring.
The measurement shall include all lengths from end to end of conduit exclusive of
interconnections inside the switchboard etc. The increase on account of diversion
or slackness shall not be included in the measurement
ii) The length of circuit wiring with three wires (including protective loop earthing)
shall be measured from the distribution board to the first nearest switch box from
which point wiring starts. Looping of switch box will also be counted towards
circuit wiring, measured along the length of conduit / channel.
iii) When wires of different circuit are grouped in as single conduit the same shall be
measured on linear basis depending on the actual numbers and sizes of wires run.
iv) Conduit carrying sub main wiring will not carry circuit / point wiring. Similarly,
conduit carrying circuit wiring will not carry submain/point wiring. Conduit
carrying point wiring will not carry circuit/submain wiring.

15.0 OTHER WIRING WORKS

Except as specified above for point wiring, circuit wiring and submain wiring, other
types of wiring shall be measured separately on linear basis along with the run of
wiring depending on the actual number and sizes of wires run.

PAGE - 810
16.0 SYSTEM OF DISTRIBUTION AND WIRING
(i) Each main distribution board and branch distribution board shall be controlled
or provided with miniature circuit breaker (MCB) of specified rating on the
phase or live conductor or combined phase and neutral control gear for
incoming and outgoing as indicated in the SOQ. The system design and location
of boards will be properly worked out.
(ii) DBs shall be separate for light, UPS and power.
(iii) Essential / non-essential / UPS distribution each will have a completely
independent and separate distribution system starting from the main,
switchboard upto final wiring for each system. As for example, conduit carrying
non-essential wiring shall not have essential or UPS wiring. Wiring for essential
and UPS supply will have their own conduit system. No mixing of wiring is
allowed.
(iv) Generally, no switchboard will have more than one source of incoming supply.
Distribution of submain and circuits- As per final approved single line diagram.
16.1 Balancing of Circuits
The balancing of circuits in three wire or poly phase installations shall be done.
16.2 Wiring System
i) Unless and otherwise specified in the tender documents, wiring shall be
done only by the “Looping System”. Phase of live conductors shall be looped
at the switch boxes and neutral conductors at the point outlets.
ii) Power wiring shall be kept separate & distinct from light wiring, from the
level of circuits, i.e., beyond the branch distribution board. Conduit for light/
power wiring shall be separate.
iii) The wiring throughout the installation shall be such that there is no break
in the neutral wire except in the form of linked switchgear.
iv) All distribution boards should have 20 %( decimal point shall be rounded
to next whole digit) of spare outgoing ways / shall be provided suitable
capacity spare MCBs.
v) Ferrules of suitable size indicating circuit & DB numbers are to be provided at
both the ends.
vi) Light, fans and call bells shall be wired in the ‘lighting’ circuits. 15A / 16A
socket outlets and other power outlets shall be wired in the ‘power’ circuits.
5A / 6A socket outlets shall also be wired in the ‘power’ circuit both in
residential as well as non-residential buildings.
vii) Colour Coding
Following colour coding shall be followed in wiring:
Phase : Red / Yellow / Blue. (Three phase wiring)
Live : Red (Single phase wiring)
Neutral : Black
Earth : Green.
viii) Termination of Circuit into Switchboard Circuit will consist of phase / neutral /
earth wire. Circuit will terminate in a switch board (first tapping point, where
from point wiring starts) in following manner:

PAGE - 811
 Phase wire terminated in phase connector. Neutral wire terminated in neutral
connector. Earth wire terminated in earth connector.

The switchboard will have phase, neutral and earth terminal connector blocks
to receive phase / neutral / earth wire.

16.3 Run of Wiring

The type of wiring shall be as specified in SOQ. Surface wiring shall run, as far as
possible, along the walls and ceiling so as to be easily accessible for inspection.
In no case, the open wiring shall be run above the false ceiling Wiring will be
done in recessed conduit / surface conduit only. In all types of wiring, due
consideration shall be given for neatness, good appearance and safety.

Generally, conduits for wiring will not be taken in floor slabs. When it is
unavoidable special precaution to be taken to provide floor channels with
provision for safety and maintenance. Alternatively, false flooring can be
provided.

16.4 Passing through walls or floors

When wiring cables are to pass through a wall, these shall be taken through a
protection (Steel / PVC) pipe or porcelain tube of suitable size such that they pass
through in a straight line without twist or cross in them. The ends of metallic pipe
shall be neatly bushed with porcelain, PVC or other approved material.
Where a wall pipe passes outside a building so as to be exposed to weather, the
outer end shall be bell mouthed and turned downwards and properly bushed
on the open end.
All floor openings for carrying any wiring shall be suitably sealed after installation.
16.5 Joints in Wiring
i) No bare conductor in phase and / or neutral or twisted joints in phase,
neutral, and/or protective conductors in wiring shall be permitted.
ii) There shall be no joints in the through runs of cables. If the length of final circuit
or submain is more than the length of a standard coil, thus necessitating a
through joint, such joints shall be made by means of approved mechanical
connectors in suitable junction boxes.
iii) Termination of multi-stranded conductors shall be done using suitable
crimping type thimbles.

17.0 INTERCHANGEABILITY
Similar parts of all switches, lamp holders, distribution boards, switchgears, ceiling
roses, brackets, fans and all other fittings of the same type shall be interchangeable
in each installation.

18.0 WIRING CABLES

i) Copper conductor cable only will be used for submain/circuit/point wiring.

PAGE - 812
 ii) Minimum size of wiring:
Point wiring : 1.5 sq.mm
Circuit Wiring : 2.5 sq.mm
Power wiring : 4.0 sq.mm Power circuit rated
more than 1 kW : size as per calculation.
iii) Insulation : Copper conductor cable shall be PVC insulated,
FR-LSH type conforming to BIS specification.
iv) Multistranded cables : allowed to be used.

19.0 FLEXIBLE CABLES

i) Conductor of flexible cables shall be of copper. The minimum cross sectional
area of conductor for flexible cable shall be as per design
ii) Only 3 core flexible cables shall be used for connecting single-phase appliances.
iii) Unless flexible cables are mechanically protected by armour, or tough rubber,
or PVC sheath, these shall not be used in workshops and other places where
they are liable to mechanical damage.
iv) Flexible cable connection to bell push from ceiling rose shall be taken through
steel conduit / metallic casing and capping.

20.0 WIRING ACCESSORIES

20.1 (a) Control Switches for Points
i) Control switch (single pole switch) carrying not more than 16 A shall be
modular type. The switch shall be ‘ON’ when the knob is down.
ii) (a) In type I, II & III quarters, Barracks & school buildings (except principal’s &
staff rooms) etc. Piano type switches shall be provided (unless specifically
asked for by the user department / Architect.)
(b) Modular type switches to be provided for remaining types of buildings
i.e. in all types of remaining non-residential buildings & residential buildings of
type IV & above & Transit hostel or as may be decided by the Architect/ user
department. (Note: Provision is meant for new constructions and in existing
buildings during rewiring if the building work renovation is also in progress in
the area. Otherwise existing type of piano switches will be continued.)
iii) It is recommended to provide double pole MCB in proper enclosure as power
outlet for window type AC, geysers, etc.
iv) Control switch shall be placed only in the live conductor of the circuit. No single
pole switch or fuse shall be inserted in the protective (earth) conductor, or
earthed neutral conductor of the circuit.
(b) Switch Box
(i) Switch box shall be hot dip galvanized, factory fabricated, suitable in size for
surface/ recess mounting and suitable in size for accommodating the
required number of switches and accessories (where required to be used for
applications other then modular switches / sockets).

PAGE - 813
 (ii) Switch box also can be of non-metallic material. The technical sanctioning
authority will approve specified makes of reputed quality and specifications.
(c) Switch Box Covers (for application other than modular type)
Phenolic laminated sheets of approved shade shall be used for switch box
covers. These shall be of 3 mm thick synthetic phenolic resin bonded
laminated sheet as base material and conforming to grade P- I of IS 2036:
1974.
(d) Switch box covers (for modular type)
Modular Switches/socket/ wiring devices plates shall be the same product
as of switches/sockets/wiring devices. This shall be of best quality molded
plastic grid mounting type device plates/frames and shall match with the
type of switches/ sockets & boxes.
Note: Specification for switch boxes is covered in the chapters on the various
types of wiring.

20.2 Socket Outlets

Combined switch cum socket shall not be permitted.

20.3 Switch box covers

Modular type switches / sockets suitable outer and inner cover plates as specified
shall be provided over the standard box as recommended by the manufacturers
of modular type switch / sockets and no separate sheet cover is required to be
provided.

20.4 Ceiling Rose

i) A ceiling rose shall not be used on circuit the voltage of which normally exceeds
250 Volts.
ii) Only one flexible cord shall be connected to ceiling rose. Specially designed
ceiling roses shall be used for multiple pendants.
iii) A ceiling rose shall not embody fuse terminal as an integral part of it.

20.5 Lamp Holders

i) The standard constructional feature of manufacturers (ISI approved) of lamp
holders is acceptable. Where the lamp holders are part of light fixtures the
holders shall be suitable for the type of lamps used.

21.0 FITTINGS
The type of fittings shall be as specified in SOQ of tender documents.
i) The contractors shall supply the specified model and make of the fittings as
per Approved Make List of tender. The standard constructional features of
specified make and model as given in the tender document are acceptable.

PAGE - 814
 ii) Where conductors are required to be drawn through tube or channel leading
to the fitting, the tube or channel must be free from sharp angles or projection
edge, and of such size as will enable them to be wired with the conductors
used for the final circuit without removing the braiding or sheathing. As far
as possible all such tubes or channels should be of sufficient size to permit
looping back.
iii) Fittings shall be installed such that the lamp is at a height specified in
approved drawings or as directed by the Engineer-In-Charge.

22.0 ATTACHMENT OF FITTINGS AND ACCESSORIES

22.1 Conduiting Wiring System
i) All accessories like switches, socket outlets, call bell push and regulators shall be
fixed in flush pattern inside the switch boxes. Accessories like ceiling roses,
brackets, batten holders; stiff pendants etc. shall be fixed on metal outlet boxes.
ii) Brass screws/Aluminium Alloy screws shall be used to fix the accessories to their
bases.
iii) The switch box shall normally be mounted with their bottom 1.25 m from floor
level, unless otherwise directed by the Engineer-In-Charge.
22.2 Fixing on Walls and Ceiling
i) PVC sleeves / dash fasteners should normally be used for fixing to walls or
ceiling. Wooden plugs are not allowed.
ii) Plugging of walls or ceiling is to be done in a better way for neatness. In all such
cases, an approved type of asbestos or fiber fixing plug (rawl or Phil plug) with
correct size of tools shall be used and done in a workmanlike manner.
iii) Looping of fittings etc. shall be done using connectors of suitable rating.

22.3 FANS, REGULATORS AND CLAMPS

22.3.1 Ceiling Fans
i) Ceiling fans including their suspension shall conform to relevant Indian
Standards.
ii) Any additional hardware items required for installation of ceiling fans including
fan hooks/ clamps shall be provided as required.
iii) All ceiling fans shall be wired to ceiling roses or to special connector boxes, and
suspended from hooks or shackles, with insulators between hooks and
suspension rods. There shall be no joint in the suspension rod.
iv) Recessed type fan clamp inside a metallic box shall be used. The metallic box shall
suitably be covered with 3mm thick phenolic laminated sheet.
v) Canopies on top of suspension rod shall effectively hide the suspension.
vi) The leading in wire shall be of copper and nominal cross sectional area not less
than 1.5 Sq.mm. and shall be protected from abrasion.

PAGE - 815
 vii) Capacity of ceiling fan to meet the requirement of room with the longer
dimension ‘D’ meters should be about 55 D cum / min. The height of fan blades
above the floors should be (3H + W)/4, where H is the height of room & W is the
height of the work plane. The minimum distance between fan blades and ceiling
should be about 0.3 mtrs.
viii) In the case of measurement of extra down rod for ceiling fan including wiring, the
same shall be measured in units of 10 cm. Any length less than 5cm shall be
ignored.
ix) The wiring of extra down rod shall be paid as supplying and drawing cable in
existing conduit.
x) Energy efficient fans with BEE 5-star rating shall be used.
22.3.2 Exhaust Fans
i) The contractors shall supply Exhaust Fan of model and make as per Approved
Make List of tender. The standard constructional features of specified make and
model as given in the tender document are acceptable.
ii) Exhaust fans shall be erected at the places indicated by the Engineer-In-Charge,
additional hardware items required for installation of exhaust fans including
clamps etc. shall be provided as required.
For fixing an exhaust fan, as per requirement of site, a circular opening shall be
provided in the wall to suit the size of the frame, which shall be fixed by means
of rag bolts embedded in the wall. The hole shall be neatly plastered to the
original finish of the wall. The exhaust fan shall be connected to the exhaust fan
point, which shall be wired as near to the opening as possible, by means of a
flexible cord, care being taken to see that the blades rotate in the proper
direction.
iii) Louvers shall be erected with exhaust fan at the existing opening with the
required hardware clamps etc. as required.
iv) Exhaust fans for installation in corrosive atmosphere, shall be painted with
special PVC paint or chlorinated rubber paint.
v) Junction box
Thickness of junction box shall not be less than 1.2 mm (18 gauge) for boxes upto
a size of 20 cm x 30 cm, and above this size 1.6 mm (16 gauge). The metallic
boxes shall be duly painted with anticorrosive paint before erection. JB shall
have Z- bend design for superior mechanical strength. The gasketing will be PU
foam.
23.0 MARKING OF SWITCH BOARDS
i) Marking of each Main Board
Each main board/sub main board shall be marked indicating rating of each
incoming / outgoing switch and the details of load/area it feeds. Detail /size
of incoming and outgoing cable shall also be marked indicating from where
the incoming cable has originated.
ii) Marking of Distribution Board

PAGE - 816
 Each Distribution Board shall be marked indicating detail of incoming switch
(Size of cable and from where it is fed) and marking of each outgoing MCB
indicating the area it feeds. Suitable marking sticker will be suitably fixed to
indicate such details.
iii) Marking of Power / Light DBs
Power/light DBs shall be marked ‘P’ and ‘L’ respectively.

iv) Marking for Non-essential / Essential / UPS / Switch Boards

Each switchboard shall be marked essential / non-essential / UPS to indicate
the nature of such switchboards.
v) Marking of Main Earthing Terminal
Main earthling terminals in main / sub main switchboard shall be
permanently marked, as “Safety Earth – Don’t Remove”.

24.0 TESTING OF INSTALLATION

All the completed installations shall be tested as per specification for “Testing of
Installation”.
24.1 Drawings
(i) The work shall be carried out in accordance with the approved drawings and
also in accordance with modification thereto from time to time as approved by
the Engineer-In- Charge.
(ii) All wiring diagrams shall be deemed to be ‘Drawings’ within the meaning of the
term as used in the Conditions of Contract. They shall indicate the main
switchboard, the distribution boards (with circuit numbers controlled by them),
the runs of various mains and submains and the position of all points with their
controls.
(iii) All circuits shall be indicated and numbered in the wiring diagram and all points
shall be given the same number as the, circuit to which they are electrically
connected.
25.0 COMMISSIONING ON COMPLETION
Before the workman leaves the work finally, he must make sure that the
installation is commissioned, after due testing.

25.1 Conformity to IE act, IE rule & standard

Conformity to IE Act, IE Rule & standard. All Electrical works shall be
commitment in Accordance with the provisions of Indian Electricity Act 2003
and Electricity Rules 1956 amended upto date.

26.0 METALLIC CONDUIT & OTHER ACCESSORIES

26.1 SCOPE
This section covers the detailed requirements for wiring work in metallic
conduits both surface and recessed types of works.

PAGE - 817
26.2 APPLICATIONS
I) Recessed conduit generally suitable for all applications. Surface conduit work
may be adopted in place like workshops, plant rooms, pump rooms, wiring
above false ceiling/below false flooring and locations where recessed work
may not be possible.
II) Flexible conduits shall only be used only at terminations, wherever specified.
26.3 MATERIALS
26.3.1 Conduits:
i) All rigid conduit pipes shall be of steel and be ISI marked. The wall thickness
shall be 1.6mm (16 SWG) for conduits upto 32mm dia. and 2mm (14 SWG) for
conduits above 32mm dia and as per IS. These shall be solid drawn or reamed
by welding, and finished with galvanized or stove enameled surface.
ii) The maximum number of PVC insulated cables conforming to IS: 694-1990 that
can be drawn in one conduit is given size wise in Table I., and the number of
cables per conduit shall not be exceeded. Conduit sizes shall be selected
accordingly in each run.
iii) No steel conduits less than 20mm in diameter shall be used.
26.3.2 Conduits Accessories:
i) The conduit wiring system shall be complete in all respects, including their
accessories.
ii) All conduit accessories shall be of threaded type, and under no circumstances
pin grip type or clamp grip accessories shall be used.
iii) Bends, couplers etc. shall be solid type in recessed type of works and may be
solid or inspection type as required, in surface type of works.
iv) a) Saddles for surface conduit work on wall shall not be less than 0.55mm (24
gauge) for conduits upto 25mm dia and not less than 0.9mm (20 gauge) for
larger diameter. The corresponding widths shall be 19mm and 25mm.
b) The minimum width and the thickness of girder clips used for fixing
conduits to steel joints, and clamps shall be as per Table-II.
26.3.3 Outlets:
i) a) Outlet boxes for light / power sockets shall be of standard size of
manufacturer to accommodate required number of modular switches, socket
outlet.
b) Where a large number of control switches and/ or fan regulators are
required to be installed at one place, these shall be installed in more than one
outlet box adjacent to each other for ease of maintenance.
ii) An earth terminal with stud and 2Nos. metal washers and terminal block shall
be provided in each DB / MS box for termination of protective conductor and
for connection to socket outlet / metallic body of fan regulator etc.
26.4 INSTALLATION
26.4.1 Common aspects for recessed and surface conduit works.
i) Conduit Joints

PAGE - 818
 a) The conduit work in each circuit or section shall be completed before the
cables are drawn in.
b) Conduit pipes shall be joined by means of screwed couplers and screwed
accessories only. Threads on conduit pipes in all cases shall be between
13mm to 19mm long, sufficient to accommodate pipes to full threaded
portion of couplers or accessories.
c) Cut ends of conduit pipes shall have neither sharp edges, nor any burrs left
to avoid damage to the insulation of the conductors while pulling them
through such pipes.
d) The Engineer-In-Charge, with a view to ensuring that the above provision has
been carried out, may require that the separate lengths of conduit etc. after
they have been prepared shall be submitted for inspection before being
fixed.
e) No bare threaded portion of conduit pipe shall be allowed, unless such bare
threaded portion is treated with anticorrosive preservative or covered with
approved plastic compound.

ii) Bends in Conduit

a) All necessary bends in the system, including diversion, shall be done either
by neatly bending the pipes without cracking with bending radius of not less
than 7.5 cm., or alternatively, by inserting suitable solid or inspection type
normal bends, elbows or similar fittings, or by fixing cast iron inspection
boxes, whichever is most suitable.
b) No length of conduit shall have more than the equivalent of four quarter
bends from outlet to outlet.
c) Conduit fittings shall be avoided as far as possible on conduit system
exposed to weather. Where necessary, solid type fittings shall be used.
iii) Outlets
a) All outlets such as switches, wall sockets etc. may be either flush mounting
type, or of surface mounting type.
iv) Painting after erection
After installation, all accessible surfaces of conduit pipes, fittings, switch and
regulator boxes etc. shall be painted in compliance with the clauses under the
painting specification in clause 26.5.
26.4.2 Additional requirements for surface conduit works
i) Painting before erection
The outer surface of conduit including all bends, unions, tees, junction boxes, etc.
forming part of the conduit system, shall be adequately protected against rust,
by painting with 2 coats of red oxide paint applied before they are fixed.

ii) Fixing Conduit On Surface

Conduit pipes shall be fixed by saddles, secured to suitable approved plugs with
screws in an approved manner at an interval of not more than one meter, but
on either side of the couplers or bends or similar fittings, saddles shall be fixed

PAGE - 819
 at a distance of 30 cm from the centre of such fittings.
Where conduit pipes are to be laid along the trusses, steel joists etc. the same
shall be secured by means of saddles or girder clips or clamps as required by the
Engineer-In-Charge.
In long distance straight run of conduit, inspected type couplers at reasonable
intervals shall be provided, or running threads with couplers and jam nuts shall
be provided.
iii) Fixing Outlet Boxes
Only a portion of the switch box shall be sunk in the wall, the other portion being
projected out for suitable entry of conduit pipes into the box.

26.4.3 Additional requirements for recessed conduit works

i) Making Chase
a) The chase in the wall shall be neatly made and of ample dimensions to permit
the conduit to be fixed in the desired manner.
b) In the case of building under construction, the conduits shall be buried in the
wall before plastering, and shall be finished neatly after erection of conduit.
c) In chase of exposed brick/ rubber masonry work, special care shall be taken
to fix the conduit and accessories in position along with the building work.
ii) Fixing Conduits in Chase
a) The conduit pipe shall be fixed by means of staples, J-hooks, or by means of
saddles, not more than 60 cm apart, or by any other approved means of
fixing.
b) All threaded joints of conduit pipes shall be treated with some approved
preservative compound to secure protection against trust.
iii) Fixing Conduits in RCC work
a) The conduit pipes shall be laid in position and fixed to the steel
reinforcement bars by steel binding wires before the concreting is done.
The conduit pipes shall be fixed / (tied at uniform intervals) firmly to the
steel reinforcement bars to avoid their dislocation during pouring of
cement concrete and subsequent tamping of the same.
b) Fixing of standard bends or elbows shall be avoided as far as practicable,
and all curves shall be maintained by bending the conduit pipe itself with
all long radius, which all permit easy drawing in of conductors.
iv) Fixing Inspection Boxes
Suitable inspection boxes to the minimum requirement shall be provided to
permit inspection and to facilitate replacement of wires, if necessary. The
distance between inspection / junction boxes shall not exceed 12.5 mts in
straight run. Inspection box shall have Z- bend design for superior mechanical
strength and thickness of the same shall not be less than 1.6 mm. These boxes
shall be duly painted with anticorrosive paint before erection. The gasketing

PAGE - 820
 will be PU foam.
Location of inspection/ junction boxes in RCC work should be identified by
suitable means to avoid unnecessary chipping of the RCC slab subsequently to
locate these boxes.
These shall be mounted flush with the wall or ceiling concrete. Minimum
65mm depth junction boxes shall be used in roof slabs and the depth of the
boxes in other places shall be as per IS: 2667-1977.
Suitable phenolic laminated sheet cover shall be provided on the inspection box.
Suitable ventilating holes shall be provided in the inspection box covers.
v) Fixing Switch Boxes and Accessories
Switch boxes shall be mounted flush with the wall. All outlets such as switches,
socket outlets etc. shall be flush mounting type, unless otherwise specified.
vi) Fish wire
To facilitate subsequent drawing of wires in the conduit, GI fish wire of 1.6mm
/ 1.2mm (16 / 18 SWG) shall be provided along with the laying of the recessed
conduit.
vii) Bunching of Cables
a) Cables carrying direct current may, if desired, be bunched whatever their
polarity, but cables carrying alternating current, if installed in metal conduit
shall always be bunched so that the outgoing and return cables are drawn
into the same conduit.
b) Where the distribution is for single phase loads only, conductors for these
phases shall be drawn in one conduit.
c) In case of three phase loads, separate conduits shall be run from the
distribution boards to the load points or outlets as the case may be.

26.4.4 Earthing Requirements

i) The entire system of metallic conduit work, including the outlet boxes and
other metallic accessories, shall be mechanically and electrically continuous
by proper screwed joints, or by double check nuts at termination. The
conduit shall be continuous when passing through wall or floors.
ii) Protective (loop earthing) conductor (s) shall be laid inside the conduit
between the metallic switch boxes and the distribution boards/
switchboards and terminated into proper earth lugs / terminals. Only PVC
insulated copper conductor cable of specified size, green-yellow in color
shall be allowed Such conductor will not run external to the conduit.
iii) The protective conductors shall be terminated properly using earth studs,
earth terminal block etc. as the case may be.
iv) Gas or water pipe shall not be used as protective conductor (earth medium).

PAGE - 821
 TABLE – I
Maximum number of PVC insulated 650/1100 V grade aluminum/copper
conductor cable conforming to IS: 694 - 1990
Nominal Cross- 20mm 25mm 32mm 38mm 51mm 64mm
Sectional area of
Conductor in sq.mm
S B S B S B S B S B S B
1 2 3 4 5 6 7 8 9 10 1 12 13
1
1.5 5 4 1 8 1 1 - - - - - -
0 0 8 2
2.5 5 3 8 6 1 1 - - - - - -
0 2 0
4 3 2 6 5 10 8 - - - - - -
6 2 - 5 4 8 7 - - - - - -
10 2 - 4 3 6 5 8 6 - - - -
16 - - 2 2 3 3 6 5 10 7 12 8
25 - - - - 3 2 5 3 8 6 9 7
35 - - - - - - 3 2 6 5 8 6
50 - - - - - - - - 5 3 6 5
70 - - - - - - - - 4 3 5 4
NOTE :
1. The above table shows the maximum capacity of conduits for a simultaneous
drawing in of cables.
2. The columns headed 'S' apply to runs of conduits which have distance not
exceeding 4.25 m between draw in boxes and which do not deflect from the
straight by an angle of more than 15 degrees. The columns headed 'B' apply to
runs of conduit which deflect from the straight by an angle of more than 15
degrees.
3. Conduit sizes are the nominal external diameters.

TABLE - II
Girder clips or clamp

Size of Conduit Width Thickness

i) 20 mm - - - - 19 mm 0.9mm (20 SWG)
ii) 25 mm - - - - 19 mm 0.9mm (20 SWG)
iii) 32 mm & - - - - 25 mm 1.2mm (18 SWG)
above

PAGE - 822
 26.5 PAINTING
26.5.1 Scope
This section covers the requirements of painting work in internal electrical
installations, carried out manually by brush. This does not cover spray painting
work of factory made items.
26.5.2 Painting Work in General
26.5.2.1 Paints
Paints, oils, varnishes etc. of approved make, in original tin to the satisfaction
of the Engineer-In-Charge shall only be use.
26.5.2.2 Preparation of the Surface
The surface shall be thoroughly cleaned and made free from dust or foreign
matter before painting is started. The proposed surface may be inspected by
the Engineer-In-Charge before the paint is applied.
26.5.2.3 Application
i) Paint shall be applied with brush. The paint shall be spread as smooth and
even as possible. Particular care shall be paid to rivets, nuts, bolts and over-
lapping. Before drawing out in small containers, it shall be continuously
stirred with a smooth stick, while painting work is taken up.
ii) Primary coat of anti-corrosive paint shall be given in the case of steel work,
after preparation the surface. In all cases of painting work, finishing shall be
with 2 coats of paint in approved shade.
iii) Each coat shall be allowed to dry out sufficiently before a subsequent coat is
applied.
26.5.2.4 Precautions
All furniture, fixture, glazing, floors etc. shall be protected by suitable covering.
Al stains, smears splashing, dropping etc. shall be removed. While painting etc.
it shall be ensured that the painting of wall and ceiling etc. is not spoiled in any
way.

27.0 NON-METALLIC CONDUIT WIRING SYSTEM

27.1 Scope
This chapter covers the detailed requirements for wiring work in non-metallic
conduits. This chapter covers both surface and recessed types of wiring work.

27.2 Application
27.2.1 Recessed conduit work is generally suitable for all applications. Surface conduit
work may be adopted in places like workshops etc. and where recessed work may
not be possible to be done. The type of work shall be as specified in individual
works.
27.2.2 Flexible non-metallic conduits shall be used only at terminations, wherever
specified.

PAGE - 823
 27.2.3 Special Precautions

(i) If the pipes are liable to mechanical damages, they should be adequately protected.
(ii) Non-metallic conduit shall not be used for the following applications: -
(a) In concealed/inaccessible places of combustible construction where ambient
temperature exceeds 60 degrees C.
(b) In places where ambient temperature is less than 5 degrees C.
(c) For suspension of fluorescent fittings and other fixtures.
(d) In areas exposed to sunlight.

27.3 Materials
27.3.1 Conduits
27.3.1.1 All non-metallic conduit pipes and accessories shall be of suitable material
complying with IS 2509: 1973 and IS 3419: 1989 for rigid conduits and IS 9537
(Part 5): 2000 for flexible conduits. The interior of the conduits shall be free from
obstructions. The rigid conduit pipes shall be ISI marked.
27.3.1.2 The conduits shall be circular in cross-section. The conduits shall be designated by
their nominal outside diameter. The dimensional details of rigid non-metallic
conduits are given in Table III.
27.3.1.3 No non-metallic conduit less than 20 mm in diameter shall be used.
27.3.1.4 Wiring Capacity
The maximum number of PVC insulated aluminium /copper conductor cables of
650/1100 V grade conforming to IS 694: 1990 that can be drawn in one conduit of
various sizes is given in Table I. Conduit sizes shall be selected accordingly.

27.3.2 Conduit Accessories

27.3.2.1 The conduit wiring system shall be complete in all respect including accessories.
27.3.2.2 Rigid conduit accessories shall be normally of grip type.
27.3.2.3 Flexible conduit accessories shall be of threaded type.
27.3.2.4 Bends, couplers etc. shall be solid type in recessed type of works, and may be solid
or inspection type as required, in surface type of works.
27.3.2.5 Saddles for fixing conduits shall be heavy gauge non-metallic type with base.
27.3.2.6 The minimum width and the thickness of the ordinary clips or girder clips shall
be as per Table IV.
27.3.2.7 For all sizes of conduit, the size of clamping rod shall be 4.5 mm (7 SWG) diameter.
27.3.3 Outlets
27.3.3.1 The switch box shall be made of either rigid PVC molding, or mild steel, or cast iron
on all sides except at the front. The regulator boxes shall however be made only of
mild steel or cast iron.
27.3.3.2 PVC boxes shall comply with the requirements laid down in IS 14772: 2000. These
boxes shall be free from burrs, fins and internal roughness.
The thickness of the walls and base of PVC boxes shall not be less than 2 mm. The
clear depth of PVC boxes shall not be less than 60 m.

PAGE - 824
27.3.3.3 The specifications for metallic boxes shall be as per requirements of clause 20.1(b)
27.3.3.4 3 mm thick phenolic laminated sheet covers for all types of boxes shall be as per
requirements of clause 20.1 (c).
27.4 Installation

27.4.1 Common Aspects for Both Recessed and Surface Conduit Works
27.4.1.1 The erection of conduits of each circuit shall be completed before the cables are
drawn in.
27.4.1.2 Conduit Joints
27.4.1.2.1 All joints shall be sealed/cemented with cement. Damaged conduit pipes/fittings
shall not be used in the work. Cut ends of conduit pipes shall have neither sharp
edges nor any burrs left to avoid damage to the insulation of conductors while
pulling them through such pipes.
27.4.1.2.2 The Engineer-in-charge, with a view to ensuring that the above provision has
been carried out, may require that the separate lengths of conduit etc. after they
have been prepared shall be submitted for inspection before being fixed.
27.4.1.2.3 Bends in Conduit
27.4.1.2.4 All bends in the system may be formed either by bending the pipes by an
approved method of heating, or by inserting suitable accessories such as bends,
elbows or similar fittings, or by fixing non-metallic inspection boxes, whichever is
most suitable. Where necessary, solid type fittings shall be used.
27.4.1.2.5 Radius of bends in conduit pipes shall not be less than 7.5 cm. No length of conduit
shall have more than the equivalent of four quarter bends from outlet to outlet.
27.4.1.2.6 Care shall be taken while bending the pipes to ensure that the conduit pipe is not
injured, and that the internal diameter is not effectively reduced.
27.4.1.3 Outlets
All switches, plugs, fan regulators etc. shall be fitted in flush pattern. The fan
regulators can be mounted on the switch box covers, if so stipulated in the tender
specifications, or if so directed by the Engineer-in-charge.
27.4.1.4 Painting
After installation, all accessible surfaces of metallic accessories shall be painted in
compliance with clauses 26.5
27.4.2 Additional Requirements for Surface Conduit Work
27.4.2.1 Conduit pipes shall be fixed by heavy gauge non-metallic saddles with base,
secured to suitable approved plugs with screws in an approved manner, at an
interval of not more than 60 cm, but on either side of couplers or bends or similar
fittings, saddles shall be fixed at a closer distance from the centre of such fittings.
Slotted PVC saddles may also be used where the PVC pipe can be pushed in
through the slots.
27.4.2.2 Where the conduit pipes are to be laid along the trusses, steel joists etc. the same

PAGE - 825
 shall be secured by means of saddles or girder clips as required by the Engineer-
in-charge. Where it is not possible to use these for fixing, suitable clamps with
bolts and nuts shall be used.
27.4.2.3 If the conduit pipes are liable to mechanical damage, they shall be adequately
protected.

27.4.3 Additional Requirements for Recessed Conduit Work

(i) Making Chase
(a) The chase in the wall shall be neatly made and of ample dimensions to permit
the conduit to be fixed in the manner desired.
(b) In the case of buildings under construction, the conduits shall be buried in
the wall before plastering, and shall be finished neatly after erection of
conduit.
(c) In case of exposed brick / rubble masonry work, special care shall be taken
to fix the conduit and accessories in position along with the building work.
(ii) Fixing Conduits in Chase
(a) The conduit pipe shall be fixed by means of staples, J-hooks, or by means
of saddles, not more than 60 cm apart or by any other approved means of
fixing.
(b) All threaded joints of conduit pipes shall be treated with some approved
preservative compound to secure protection against rust.

(iii) Fixing Conduits in RCC Work

(a) The conduit pipes shall be laid in position and fixed to the steel
reinforcement bars by steel binding wires before the concreting is done.
The conduit pipes shall be fixed firmly to the steel reinforcement bars to
avoid their dislocation during pouring of cement concrete and subsequent
tamping of the same.
(b) Fixing of standard bends or elbows shall be avoided as far as practicable,
and all curves shall be maintained by bending the conduit pipe itself with
a long radius, which will permit easy drawing in of conductors.
(c) Location of inspection / junction boxes in RCC work should be identified
by suitable means to avoid unnecessary chipping of the RCC slab
subsequently to locate these boxes.
(iv) Fixing Inspection Boxes
(a) Suitable inspection boxes to the minimum requirement shall be provided
to permit inspection and to facilitate replacement of wires, if necessary.
(b) These shall be mounted flush with the wall or ceiling concrete. Minimum
65 mm depth junction boxes shall be used in roof slabs and the depth of
the boxes in other places shall be as per IS 2667: 1988.
(c) Suitable ventilating holes shall be provided in the inspection box covers.

PAGE - 826
 (v) Fixing Switch Boxes and Accessories
Switch boxes shall be mounted flush with the wall. All outlets such as
switches, socket outlets etc. shall be flush mounting type, unless otherwise
specified in the Additional Specifications.

(vi) Fish Wire

To facilitate subsequent drawing of wires in the conduit, GI fish wire shall be
provided along with the laying of the recessed conduit.

(vii) Bunching of Cables

(a) Cables carrying Direct Current may, if desired, be bunched whatever their
polarity, but cables carrying alternating current, if installed in metal
conduit shall always be bunched so that the outgoing and return cables
are drawn into the same conduit.
(b) Where the distribution is for single phase loads only, conductors for these
phases shall be drawn in one conduit.
(c) In case of three phase loads, separate conduits shall be run from the
distribution boards to the load points, or outlets as the case may be.

27.4.3 Earthing Requirements

27.4.3.1 A protective (earth) conductor shall be drawn inside the conduit in all
distribution circuits to provide for earthing of non-current carrying metallic
parts of the installation. These shall be terminated on the earth terminal in the
switch boxes, and/or earth terminal blocks at the DBs.

27.4.3.2 Gas or water pipe shall not be used as protective conductors (earth medium).

TABLE III
Dimensional Details of Rigid Non-metallic Conduits
(All dimensions in mm)
S. No. Nominal Maximum Minimum Maximum Minimum
Outside Outside Inside Permissible Permissible
Diameter Diameter Diameter Eccentricity Ovality
(in mm) (in mm) (in mm) (in mm) (in mm)
1. 20 20 + 0.3 17.2 0.2 0.5
2. 25 25 + 0.3 21.6 0.2 0.5
3. 32 32 + 0.3 28.2 0.2 0.5
4. 40 40 + 0.3 35.8 0.2 0.5
5. 50 50 + 0.3 45.0 0.4 0.6

PAGE - 827
 TABLE IV
Ordinary Clips or Girder Clips

Size of Conduit Width Thickness

(1) 20 mm & 25 mm 19 mm 20 SWG (0.9144 mm)
(2) 32 mm & above 25 mm 18 SWG (1.219 mm)

28.0 LED LIGHT FITTINGS

28.1 SPECIFICATION OF LED LIGHT FIXTURES

S. Description Minimum Requirement for Minimum Minimum

No. Indoor Lights Requirements for Requirements for
Outdoor Lights Residential Lights
1 Efficiency of Min. 100 lumen / watt Min. 110 lumen / Min.70 lumen /
LED light watt watt
fitting
(Efficacy)
2 Life of LED Not less than 50000 Not less than 50000 Not less than
light fitting burning hrs. burning hrs. 35000 burning
hrs.
3 Approved NICHIA / CREE /OSRAM NICHIA / CREE / NICHIA / CREE /
makes for LED / PHILLIPS (LUMILED) / OSRAM/ PHILLIPS OSRAM/ PHILLIPS
SHARP / SEOUL / (LUMILED)/ SHARP (LUMILED)/
EVERLITE / CITIZEN / SEOUL / SHARP / SEOUL /
(JAPAN) / BRIDGELUX
EVERLITE / EVERLITE /
(USA) / SAMSUNG
CITIZEN (JAPAN) / CITIZEN (JAPAN)
BRIDGELUX (USA) /BRIDGELUX
/ SAMSUNG (USA) / SAMSUNG
4 CRI (Colour Min. 80 for Indoor Min. 70 for Outdoor Min. 70
Rendering application application
Index)
5 THD (Total Less than 10% Less than 10% Less than 20%
Harmonic
Distortion)
6 Voltage Range 140 V to 270 V 140 V to 270 V 140 V to 270 V
7 Type of Extruded Aluminum / High Pressured Die Extruded
housing CRCA / Standard Alloy Cast Aluminium / Aluminium / High
housing Standard Alloy for Pressured Die Cast
outdoor application Aluminium /
Standard Alloy

PAGE - 828
8 IP Category IP 20 or higher for indoor >IP 65 >IP 20
application
9 Surge Shall be provided >4 KV >2 KV
protection conforming to relevant IS
standard / IEC for LED
Driver (in-built): ENG
1000-4-5 or as specified in
BOQ
>2KV
10 Labeling / Manufactures Name / Manufactures Manufactures
identification Logo shall be engraved / Name / Logo shall Name / Logo shall
Mark Embossed on housing / be engraved / be engraved /
body on aluminum plate Embossed on Embossed on
Labels or Screen printed housing / body on housing / body on
on housing / body. aluminum plate aluminum plate
Labels or Screen Labels or Screen
printed housing. printed housing.
11 Warranty 5 years warranty from 5 years warranty 3 years warranty
period actual date of completion from actual date of from actual date of
of work on complete completion of work completion of
luminiar including driver on complete work on complete
/ control gear, LED, all luminiar including luminiar including
accessories etc. driver / control driver / control
gear, LED, all gear, LED, all
accessories etc. accessories etc.
12 Power Factor Equal to 0.95 or more Equal to 0.95 or Equal to 0.95 or
more more
13 Total Power Not More than 110% of Not More than Not More than
consumption rated capacity of LED 110% of rated 110% of rated
of fitting. Light fitting. capacity of LED capacity of LED
Light fitting. Light fitting.
14 Approved MEANWELL / MEANWELL / MEANWELL /
Make of INVENTRONICS / C &S / INVENTRONICS / INVENTRONICS /
Driver MOSO POWER / BAG / C &S / MOSO C &S / MOSO
PHILLIPS / WIPRO / POWER / BAG / POWER / BAG /
OSRAM / BAJAJ / PHAROS PHILLIPS / WIPRO
PHILLIPS /
/ FULLHAM / HELVER / / OSRAM / BAJAJ /
OEM of Light fixtures PHAROS / WIPRO / OSRAM
FULLHAM / / BAJAJ /
HELVER / OEM of PHAROS /
Light fixtures FULLHAM /
HELVER / OEM of
Light fixtures

PAGE - 829
15 Type of Driver Enclosed / Encapsulated Enclosed / Enclosed /
Encapsulated Encapsulated

16 Efficiency of >85% >85% >85%

Driver
17 Testing LED Luminaire LED Luminaire LED Luminaire
Facility manufacturers shall in manufacturers manufacturers
house NABL accredited shall in house shall in house
photometry lab. NABL accredited NABL accredited
photometry lab. photometry lab.

18 BIS All luminaires, drivers All luminaires, All luminaires,

Registration shall be BIS registered. drivers shall be drivers shall be
BIS registered. BIS registered.
19 Housing Housing of Luminaire Housing of Housing of
Thickness shall >0.5 mm for CRCA Luminaire shall Luminaire shall
or 1 mm for extruded >0.5 mm for CRCA >0.5 mm for CRCA
aluminium or 1.5 mm for or 1 mm for or 1 mm for
PDC aluminium or extruded luminium extruded
heavier if so required to or 1.5 mm for PDC aluminium or 1.5
meet the application aluminiumor mm for PDC
requirement. heavier if so aluminium or
required to meet heavier if so
the application required to meet
requirement. the application
requirement.
20 IK Rating IK 04 or above IK 07 or above NA
21 LED Binning <5 (SDCM) < 5 (SDCM) < 7 (SDCM)
(Standard
Deviation
Colour
matching)
22 Unified Glare < 19 NA NA
Rating (UGR)

PAGE - 830
28.2 TECHNICAL SPECIFICATIONS OF LED SOLAR LIGHT
A. BROAD PERFORMANCE SPECIFICATIONS OF LED SOLAR LIGHT
PV Module High Efficiency Mono Crystalline
Battery Lithium ion /Lithium Ferro phosphate battery
Light Source High Efficiency Long Life LED with customized Lens for proper light
distribution, dispersed beam, soothing to eyes with the use of proper
optics and diffuser.
Light Out put The illumination should be uniform without dark bands or abrupt
variations, and soothing to the eye. Higher light output will be
preferred.
Mounting of Pole mounted with suitable size of bracket as per site requirements.
light
Electronics Minimum 85% total
Efficiency
Duty Cycle Dusk to dawn
Operating -10 degree to + 55 degree
temperature
of battery
Automatic PIR motion sensor for dimming and brightness.
Light
control
Battery Reverse polarity protection for battery and solar panel.
management Over charge and deep discharge protection.
system Over voltage and over current protection from solar PV module.

Autonomy Minimum 03 days.

Other As per Technical parameters of LED para 28.1

Parameters

PV MODULE
i. Indigenously manufactured PV module shall be used.
ii. The PV module should have crystalline silicon solar cells and must have a
certificate of testing conforming to applicable latest standards and guidelines of
MNRE/IEC/BIS.
iii. The power output of the module (s) under STC should be at load voltage* of 16.4 ±
0.2 V
iv. The open circuit voltage* of the PV modules under STC should be at least 21.0 Volts.
v. The module efficiency should not be less than 14 %.
vi. The terminal box on the module should have a provision for opening it for

PAGE - 831
 replacing the cable, if required.
vii. There should be a Name Plate fixed inside the module which will give:
a. Name of the Manufacturer or Distinctive Logo.
b. Model Number
c. Serial Number
d. Year of manufacture
e. HAREDA logo (which is available on-line)
f. Made in India
*The load voltage and Voc conditions of the PV modules are not applicable for the
system having MPPT based charge controller.
BATTERY
i. Required Wh capacity Lithium Ion/ Lithium Ferro Phosphate Battery
ii. Battery should confirm to the latest BIS/ International standards.

LIGHT SOURCE
i. The light source shall be LEDs.
ii. The colour temperature of LED used in the system should be in the range of 4000
degrees K– 6500-degree K as per site requirement.
iii. LEDs should not emit ultraviolet light.
iv. The light output from the LED light source should be constant throughout the duty
cycle.
v. The lamps should be housed in an assembly suitable for outdoor use.
vi. The temperature of heat sink should not increase more than 20-degree C above
ambient temperature during the dusk to dawn operation.

ELECTRONICS
i. Electronics should operate at 12 V and should have temperature compensation for
proper charging of the battery throughout the year.
ii. No Load current consumption should be less than 20 mA.
iii. The PV module itself should be used to sense the ambient light level for switching
ON and OFF the lamp.
iv. The PCB containing the electronics should be capable of solder free installation and
replacement.
v. Necessary lengths of wires/cables, switches suitable for DC use and fuses should be
provided.
ELECTRONIC PROTECTIONS
i. Adequate protection is to be incorporated under “No Load” conditions e.g. when
the lamp is removed and the system is switched ON.
ii. The system should have protection against battery overcharge and deep discharge
conditions.
iii. Fuse should be provided to protect against short circuit conditions.
iv. Protection for reverse flow of current through the PV module(s) should be
provided.
v. Electronics should have temperature compensation for proper charging of the
battery throughout the year.

PAGE - 832
 vi. Adequate protection should be provided against battery reverse polarity.
vii. Load reconnect should be provided at 80% of the battery capacity status.
INDICATORS
i. The system should have two indicators, green and red.
ii. The green indicator should indicate the charging under progress and should glow
only when the charging is taking place. It should stop glowing when the battery is
fully charged.
iii. Red indicator should indicate the battery “Load Cut Off” condition.
QUALITY AND WARRANTY
i. The street lighting system (including the battery) will be warranted for a period of
five years from the date of supply.

OPERATION AND MAINTENANCE MANUAL

An Operation, Instruction and Maintenance Manual, in English and the local
language, should be provided with the Solar Street Lighting System. The following
minimum details must be provided in the Manual:
 Basic principles of Photovoltaic.
 A small write-up (with a block diagram) on Solar Street Lighting System - its
components, PV module, battery, electronics and luminaire and expected
performance.
 Type, Model number, Voltage & capacity of the battery, used in the system.
 The make, model number, country of origin and technical characteristics
(including IESNA LM-80 report) of LEDs used in the lighting system.
 About Charging and Significance of indicators.
 Clear instructions on regular maintenance and troubleshooting of the Solar Street
Lighting System.
 DO's and DONT's.

29.0 CABLE TRAY

29.1 PERFORATED TYPE
The cable tray shall be fabricated out of slotted / perforated MS sheets as channel
sections, single or double bended. The channel sections shall be supplied in
convenient lengths and assembled at site to the desired lengths. These may be
galvanized or painted as specified in SOQ.
Typically, the dimensions, fabrication details etc. are shown in CPWD General
Specification for Electrical Works Part-II-External-1994 & sizes described in
schedule of quantities.
The jointing between the sections shall be made with coupler plates of the same
material and thickness as the channel section. Two coupler plates, each of
minimum 200mm length, shall be bolted on each of the two sides of the channel
section with 8mm dia round headed bolts, nuts and washers. In order to maintain
proper earth continuity bond, the paint on the contact surface between the coupler
plates and cable tray shall be scraped and removed before the installation.

PAGE - 833
 The maximum permissible uniformly distributed load for various sizes of cable
trays and for different supported span are as per Table-IV of CPWD General
Specifications of Electrical Work Part-II - 1994. The sizes shall be specified
considering the same.
Factory fabricated bends, reducers, tee / cross junctions, etc. shall be provided as
per good engineering practice (Details are typically shown in figure-3 of CPWD
General specifications of Electrical Work Part-II – 1994). The radius of bends,
junctions etc. shall not be less than the minimum permissible radius of bending of
the largest size of cable to be carried by the cable tray.
The entire tray (except in the case of galvanized type) and the suspenders shall be
painted with two coats of red oxide primer paint after removing the dirt and rust,
and finished with two coats of spray paint of approved make synthetic enamel
paint.
29.2 LADDER TYPE
Ladder type cable tray shall be fabricated out of double bended channel section
longitudinal members with single bended channel section rungs of cross members
welded to the base of the longitudinal members at a centre to centre spacing of
250mm. The channel sections shall be supplied in convenient lengths and
assembled at side to the desired lengths. These may be galvanized or painted to the
desired lengths.
Typically, the dimensions, fabrication details etc. are shown in CPWD General
Specification for Electrical Works - Part II -External, 1994.
The jointing between the sections shall be made with coupler plates of the same
material and thickness as the channel section. Two coupler plates, each of minimum
200mm length, shall be bolted on each of the two sides of the channel section with
8mm dia round headed bolts, nuts and washers. In order to maintain proper earth
continuity bond, the paint on the contact surfaces between the coupler plates and
cable tray shall be scraped and removed before the installation.
The maximum permissible uniformly distributed load for various sizes of cables
trays and for different supported span are as per CPWD General Specification of
Electrical Work Part II - 1994. The sizes shall be specified considering the same.
The width of the cable tray shall be chosen so as to accommodate all the cable in
one tier, plus 25% additional width for future expansion. This additional width
shall be minimum 100mm.
Factory fabricated bends, reducers, tee / cross junctions, etc. shall be provided as
per good engineering practice. Details are typically shown in figure 3 of CPWD
General Specification of Electrical Work Part-II-1994. The radius of bends,
junctions etc. shall not be less than the
minimum permissible radius of bending of the largest size of cable to be carried by
the cable tray.
The entire tray (except in the case of galvanized type) and the suspenders shall be
painted with two coats of red oxide primer paint after removing the dirt and rust,
and finished with two coats of spray paint of approved make synthetic enamel

PAGE - 834
 paint.
The cable tray shall be bonded to the earth Terminal of the switch bonds at both
ends.
29.3 INSTALLATION & MEASUREMENT OF CABLE TRAY / LADDER
The cable tray shall be suspended from the ceiling slab with the help of 10mm dia
MS rounds or 25mm x 5mm flats at specified spacing as per of CPWD General
Specification of Electrical Work Part II -1994. Flat type suspenders may be used for
channels upto 450mm width bolted to cable trays. Round suspenders shall be
threaded and bolted to the cable trays or to independent support angles 50mm x
50mm x 5mm at the bottom end as specified. These shall be grouted to the ceiling
slab at the other end through an effective means, as approved by the Engineer, to
take the weight of the cable tray with the cables.
The cable trays shall be measured on unit length basis, along the center line of the
cable tray, including bends, reducers, tees, cross joints, etc, and paid for
accordingly.

30.0 UNDER FLOOR TRUNKING

30.1 Under Floor Trunking for convenience outlet points, telephone outlets and
computer outlet points shall be provided as per requirement. Ducts will be
manufactured from GI as mentioned in SOQ with a reinforcing web as per relevant
BS or relevant standards of the country of manufacture.
30.2 Three compartment system for convenience outlets, telephone outlets and
computer data outlets will be provided as specified in the SOQ. Type of trunking
shall be provided as under floor tracks as shown in the drawings or as specified in
the SOQ.
30.3 The junction boxes shall be constructed from same finish as the ducting, with cover
of heavy-duty stainless steel adjustable for height at each corner. Segregation of
compartments of the ducting shall be maintained through the boxes.
30.4 Each service outlet box shall have outlet units as indicated. Segregation shall be
provided between power outlets and telephone outlets, with separate lids and each
section shall be fitted with a cable guard or grommet. The complete assembly shall
comply with requirements of Indian Telecom.
30.5 Lids of service outlet boxes and floor ducting shall be of same make unless
otherwise indicated. Lids shall be arranged to accommodate the floor finish as
indicated.
30.6 Under floor ducting shall be straight and level and adjusted in height to relate to
the finished floor level, as indicated.
30.7 Where ducting cross expansion and settlement joints occur in the building
structure, suitable provision shall be made to allow for movement of the structure.
The Contractor shall submit his proposals for the approval of Engineer-in-Charge.
30.8 Open ends of ducts shall be temporarily plugged immediately after installation to
prevent ingress of water and solid materials. The boxes of under floor ducting shall
be fitted with temporary lids immediately after they are installed and they shall be

PAGE - 835
 maintained as effective protection against ingress of water and solid material until
the permanent lids are fitted after screeding is complete.
30.9 Method to be used for forming fire barriers at fire resistant structural elements
such as floors and walls shall be submitted for the Engineer-in-Charge's approval.
30.10 Installed ducts shall be cleaned internally with a swab before cables are drawn-in.
30.11 If the protective finish of ducting is damaged after fixing, the damage shall be made
good in a manner approved by Engineer-in-charge.

31.0 LIGHTNING PROTECTION SYSTEM

31.1 General
Installation of Lightning Protection System shall be strictly in accordance with BIS:
/ IEC 62305. The lightning protection installation shall consist of air termination
network, down conductors, earthing and bonding. The contractor shall prepare &
submit the drawings and get them approved from the Engineer-in-charge before
the start of the work. The approval of drawings however does not absolve the
contractor not to supply the equipments/materials as per requirement. The
drawing consists lay out drawings of the horizontal and vertical conductors
including its support details, sections, connections etc
i. Protection
LPL-1 shall be installed as per NBC, however contractor shall submit the Risk
Evaluation and the achieved Lightning Protection Level (LPL-1) calculation based
on IS / IEC 62305 – Part 2,. The Contractor shall then submit the shop drawings
based on the achieved LPL-1 and shall employ the air termination network as per
the protection level.
ii. Material
The materials of lightning conductor, down conductors, earth termination etc. shall
be aluminum and conform to IS / IEC 62305 (Part-I to IV)
iii. Joints and Bonds
The lightning protective system shall have as few joints as far as possible.
Wherever joints in the conductor are necessary they shall be mechanically and
electrically effective, and shall be riveted and brazed in case of copper and by
welding / bolting in case of GI in an approved manner.

iv. Earth Terminals

Each down conductor shall have an independent earth termination. All the earth
termination shall be inter connected and shall be capable of isolation for testing
using test links.
v. Earth Electrode
Earth pits shall be installed in accordance with IS: 3043. The resistance of earthing
system shall not exceed 10 ohms.
vi. Air Terminations Mesh (On the Roof)
As an alternative to vertical air termination, grid of horizontal air termination may
also be provided as per IS / IEC 62305 (Part-I to IV)
AIR TERMINATION MESH DETAILS

PAGE - 836
 Level of Mesh Size Wm in Protection angle
Protection meters
I 5X5

As per IS / IEC 62305 (part-I to

IV)

vii. Down Conductor

In order to reduce probability of damage it is often necessary to have several
parallel current paths. As recommended by BIS/ IEC 62305 equal spacing of
aluminum down conductors around the building perimeter depending on the level
of protection.
Level of Typical distance in
Protection meters
I 10
viii. Fasteners
Conductors shall be securely fixed to the building to be protected by fasteners
(insulating material) which shall be not more than 1.20 meter apart for horizontal
run and 1.0 meters for vertical run.

32.0 EARTHING
32.1 Scope
This section covers the essential requirements of earthing system components and
their installation. For details not covered in these specifications, IS Code of Practice
on earthing (IS: 3043-1987) CPWD General Specifications for Electrical works
(Part-I-Internal) as amended upto date and in the regulations of the local Electrical
Supply Authority shall be referred to.

35.1.1 Application
i) The electrical distribution system is with earthed neutral (i.e. neutral earthed at
the transformer / generator end). In addition to the neutral earthing, provision
is made for earthing the metallic body of equipments and non-current carrying
metallic components in the substation, as well as in the internal / external
electrical installations.
ii) Earthing requirements are laid down in Indian Electricity Rules, 1956 and
Indian Standard Specification IS: 3043:1987 with latest amendment as amended
from time to time, and in the Regulations of the Electricity Supply Authority
concerned. These shall be complied with.
32.2 Materials
The material of earth and earth conductor shall be as specified in SOQ.

32.2.1 Earth Electrodes

The earth electrode shall be Plate / Pipe earth electrode as specified in SOQ and

PAGE - 837
 the materials and size of earth electrodes shall be as specified
32.2.2 Earthing Conductor
35.2.2.1 The earthing conductor (protective conductor from earth electrode upto the main
earthing terminal/ earth bus, as the case may be) shall be of the same material as
the electrode, viz. GI or copper and in the form of wire or strip as specified. The size
of earthing conductor shall be as specified.
35.2.2.2 Each equipment shall be connected with two independent earth conductors to
earth bar located in respective area. Each earth bar shall be connected to Earth Grid
by two independent earth conductors. Earthing Grid shall be directly connected by
two independent earth electrodes. Earthing shall be of GI or Copper.

32.3 Hardware Items

All hardware items used for connecting the earthing conductor with the electrode
shall be of GI in the case of GI pipe and GI plate earth electrode and forged tinned
brass in case of copper plate electrodes.
32.3.1 Protective (Earth Continuity / Loop Earthing) Conductor
32.3.1.1 The material and size of protective conductors shall be as specified.
32.3.1.2 Unless otherwise specified, GI conductor should not be ordinarily used as protective
conductor within any circuit beyond a Distribution Board downstream.

32.3.2 Location for Earth Electrodes

Normally earth electrodes shall not be located closer than 1.5 m from any building.
Care shall be taken to see that the excavation for earth electrode does not affect the
foundation of the building; in such cases electrodes may be located further away
from the building, with the prior approval of the Engineering-In-Charge.
The location of the earth electrode shall be such that the soil has a reasonable
chance of remaining moist as far as possible. Entrances, pavements and roadways,
shall be avoided for locating earth electrodes.
When more than one electrode (plate / pipe) are to be installed, a separation of not
less than 2m shall be maintained between adjacent electrodes.

32.4 Installation
32.4.1 Electrodes
35.4.1.1 Pipe Electrode
Earthing electrode shall consist of a medium class GI Pipe of approved make not
less than 40 mm dia and 4.5 meters long. GI Pipe electrode shall be cut tapered at
the bottom and provided with holes of 12mm dia drilled at not less than 75 mm
interval upto 2 meters length from bottom. The electrode shall be buried vertically
in the ground as far as practicable below permanent moisture level with its top at
not less than 20 cm below ground level. The electrode shall be in one piece and no
joints shall be allowed in the electrode. Wherever possible earth electrodes shall
be located as near water tap, water drain or a down take pipe. Earth electrodes

PAGE - 838
 shall not be located in proximity to a metal fence. It shall be kept clear of the
building foundations and in no case shall be nearer than 2 meters from the outer
face of the wall.

The pipe earth electrode shall be kept vertically and surrounded with 150 mm
thick layer of charcoal dust and salt mixture upto a height of 2.0 meters from the
bottom. At the top of the electrode a funnel with a mesh shall be provided for
watering the earth. The main earth conductors shall be connected to the electrode
just below the funnel, with proper terminal lugs and check nuts.
In locations where the full length of pipe electrode is not possible to be installed
due to meeting a water table, hard soil or rock, the electrode may be reduced
length, provided the required earth resistance result is achieved with or without
additional electrodes, or any alternative method of earthing may be adopted, with
the prior approval of the Engineer-In- Charge. Pipe electrodes may also be installed
in horizontal formation in such exceptional cases.
35.4.1.2 Plate Earth Electrode
Earthing shall be provided with GI/ copper plate electrode as mentioned in SOQ
of following.
i. GI Plate Electrode. : 600 mm x 600 mm x 6 mm thick
ii. Copper Plate Electrode. : 600 mm x 600 mm x 3 mm thick
The electrode shall be buried in ground with its faces vertical and not less than
Three (3) meters below ground level. 20 mm dia medium class GI pipe shall be
provided and attached to the electrode. Earth electrode shall not effect the column
footing or foundation of the building. In such cases electrode shall be further away
from the building.
35.4.1.3 Watering Arrangement
i) In the case of plate earth electrodes, a watering pipe of 20 mm dia. medium class
GI pipe shall be provided and attached to the electrodes as shown in the drawing
and a funnel with mesh shall be provided on the top of this pipe for watering the
earth.
ii) In the case of pipe electrodes, a 40 mm x 20 mm reducer shall be used for fixing
the funnel with mesh.
iii) The watering funnel attachment shall be housed in a masonry enclosure of size
not less than 300 mm x 300 mm x 350 mm deep.
MS frame with 6 mm thick MS cover and having ALLEN Key locking arrangement
shall be suitably embedded in the masonry enclosure. The top enclosure shall be
provided of 50 mm thick PCC.

35.4.1.4 The details of Plate / Pipe earth electrode, a detailed drawing as referred in
CPWD specification of Internal EI shall be referred.

PAGE - 839
32.4.2 Earth Conductor
In the case of plate earth electrodes, the earthing conductor shall be securely
terminated on to the plate with two bolts, nuts, check nuts and washers.
In the case of pipe earth electrodes, wire type earthing conductor shall be secured by
using a through bolts, nuts and washers and terminating socket.
The earthing conductor from the electrode upto the building shall be protected from
mechanical injury by a medium class, 15 mm dia GI pipe in the case or wire, and by a
minimum of 40 mm dia, medium class GI pipe in the case of strip. The protection pipe
in ground shall be buried at least 30 cm deep (to be increased to 60 cm in case of road
crossing and pavements). The portion within the building shall be fixed on walls.
The earthing conductor shall be securely connected at the other end to the earth stud/
earth bar provided on the switch board by Soldered or preferably crimped lug, bolt,
nut and washer in the case of wire, and, Bolt nut and washer in case of strip conductor.
32.4.3 Earth Bus and Main Earthing Terminal
In all installations, main earthing terminal shall be provided at the main switchboard.
This may be in the form of earth stud or single earth bar depending on the type of the
switchboard. Following conductors shall be terminated on to the main earthing
terminal.
a) Earth connection from electric supply company (where provided)
b) Earthing conductor from electrode.
c) Protective conductors
d) Equi-potential bonding conductors.
32.4.4 Protective (Loop Earthing / Earth Continuity) Conductor
Earth terminal of every switchboard in the distribution system shall be bonded to the
earth bar / terminal of the upstream switchboard by protective conductors. Two
protective conductors shall be provided for a switchboard carrying 3 phase
switchgear thereon.
32.4.5 Earth Resistance
The earth resistance at each electrode shall be measured. No earth electrode shall
have a greater ohmic resistance than 5 ohms as measured by an approved earth
testing apparatus. In rocky soil the resistance may by upto 8 ohms.
Where the above stated earth resistance is not achieved, necessary improvement
shall be made by additional provisions, such as additional electrode (s), different type
of electrode, or artificial chemical treatment of soil etc., as may be directed by the
Engineer-In-Charge.
32.4.6 Marking
32.4.6.1 Earth bars / terminals at all switch board shall be marked permanently, as ‘E’.
32.4.6.2 Main earthing terminal shall be marked ‘SAFETY EARTH- DO NOT DISCONNECT’.

32.4.7 Measurement of Earth Electrode Resistance

35.4.7.1 Two auxiliary earth electrodes, besides the test electrode, are placed at suitable
distance from the test electrode. A measured current is passed between the

PAGE - 840
 electrode ‘A’ to be tested and an auxiliary current electrode ‘C’ and the potential
difference between the electrode ‘A’ and auxiliary potential ‘B’ is measured. The
resistance of the test electrode ‘a’ is then given by
R= V / I
Where,
R- Resistance of the test
electrode in ohms V- Reading of
the voltmeter in volts
I-Reading of the ammeter in amps
35.4.7.2 Stray currents flowing in the soil shall produce serious errors in the measurement
of earth resistance. To eliminate this, hand driven generator is used.
If the frequency of the supply of hand driven generator coincides with the
frequency of stray current, there shall be wandering of instrument pointer. An
increase or decrease of generator speed shall cause this to disappear.
35.4.7.3 At the time of test, the test electrode shall be separated from the earthing system.
35.4.7.4 The auxiliary electrodes shall be of 13 mm diameter mild steel rod
driven up to 1 m into the ground.
35.4.7.5 All the three electrodes shall be so placed that they are independent of the
resistance area of each other. If the test electrode is in the form of a rod, pipe or
plate, the auxiliary current electrode C shall be placed at least 30m away from it
and the auxiliary potential electrode’ B’ shall be placed mid-way between them.

35.4.7.6 Unless three consecutive readings of test electrode resistance agree, the test shall
be repeated by increasing the distance between electrodes A and C up to 50m, and
each time placing the electrode B mid-way between them.

33.0 TECHNICAL SPECIFICATION FOR MODULAR UPS

33.1 General:
This specification describes a modular three phase on line, continuous operation,
solid state uninterruptible power supply (UPS) with single phase / three phase
output as per requirement. The requirements of electrical power supply system are
specified herein on system design basis. The contractor shall be fully responsible
for Engineering and furnishing a complete and operational system fully meeting the
intent and requirements of this specification.

33.2 Application & Selection Rating of UPS:

The UPS installed shall be used for feeding uninterrupted power supply. The UPS
will run on standalone basis however UPS’s should have facility for up gradation in
order to run on parallel load sharing mode in future without changing any design
of the equipment.
It shall be the responsibility of the contractor / OEM to check the rating suiting to
its design of UPS considering the following factors before quoting for tenders:

PAGE - 841
 a. Nature of load & application
b. Load pattern
c. Extreme unbalance condition where one of phase carrying current which is
near or equal to zero whereas the other two phases loaded near or equal to
100% load and large unbalance current flowing in the neutral.
Based upon this agency may offer higher rated (KVA) UPS (taking into
consideration the available floor space at site) but should not be less than rated
(KVA) UPS. In case the contractor goes for higher rated (KVA) UPS, prior approval
should be obtained and no extra cost on account of this what so ever shall be
payable by AAI to the contracting agency.

33.3 General Requirements for the UPS:

The followings are the general requirement for UPS offered:
i. Nominal power: at power factor (COSØ) 0.9
ii. Topology: On line double conversion
iii. Technology: Hi Frequency PWM (Pulse Width Modulation) level 3
iv. Passing through neutral
v. Architecture: Modular
vi. Possibility to configure the system in N+X internal redundancy.
vii. Possibility to remove & replace battery modules switching the load on by
pass.
viii. Reverse phase sequence protection: This feature shall be capable of
correcting the input phase sequence and the UPS shall not go to battery mode
under such condition.
33.4 UPS system description:
i. Power module:
Each power module will be composed by following functional blocks:
 Inverter
 Battery charger
 Rectifier & PFC
 Automatic bypass
 Command module
 Batteries
 Digital display & alarm signal

ii. Inverter:
The inverter must be based on switching 3 level IGBT (Insulated Gate Bipolar
Transistor) circuit with high frequency PWM and must be able to transform DC
supply coming from rectifier/ PFC (Power Factor Corrector) in case of battery
run to AC voltage. Furthermore, must be present also in control circuits which
guarantees:
 Arrest and protection of inverter in case of strong & long overloads.
 Keep the harmonic distortion of the output voltage less than the
parameters mentioned in Technical Data Specification either in normal run
or in battery run.
 Arrest & protect the inverter in case of over temperature of power

PAGE - 842
 converter elements.
 Manage the speed of the fans accordingly with internal temperature and
applied load.

iii. Battery Charger:

The battery charger must be equipped with control and regulation circuit both
for charging voltage and current to batteries in order to have a controlled
battery charging to optimize battery life. The UPS must charge batteries with
an early boost charge followed by a constant charge and at the end floating
charge. During normal run the UPS will execute periodically a battery
equalizing in order to recover neutral charge leakages and keep all batteries at
the same capacity. This battery charging cycle will increase the batteries
lifetime over the expected five years with relevant reduction of the
maintenance costs. The battery recharge must be available also when UPS is
turned off.

iv. Rectifier / PFC:

The rectifier must include a control & regulating circuit (PFC) which in addition
to normal rectification function will also allow in
 Automatic correction of the PF to at value >0.99 (from 75% of the normal
load).
 Reduce the harmonic distortion of the input current obtaining THDi in <
3% with nominal load.

v. Automatic bypass:
The automatic bypass must be composed by following parts:
 Static switch with zero time for intervention, connected in parallel with an
electro- mechanic switch which needs a transfer time but with zero heat
dissipation among time.
 DSP/microprocessor logic command and control which will attend to
Automatically transfer the load to the mains as soon as following anomaly
of event occurs: Overload, Over temperature, Voltage runawaes on DC
buses, anomalies on the inverter. Automatically transfer back the load
from the mains to inverter as soon as anomalous even expires.
Automatically disable the bypass function in case of output voltage & mains
are not synchronized.

vi. Command board:

The command board shall be equipped with DSP (Digital Signal Processor)/
microprocessor of suitable computation power. This command board must
manage all functions of the UPS and will execute the following jobs:
1. Synchronization of output voltage with the input voltage.
2. Control of the PFC, inverter & booster circuits.
3. Management of automatic bypass.
4. Management of battery runtime.
5. Alarm and events memory with association of time & date of event.

PAGE - 843
 vii. Batteries:
The sealed maintenance free stationary batteries are housed in separate
cabinets of same shape and size. The positive and negative battery connections
are protected by an adequate battery circuit breaker isolating switch. The
battery racks shall be of MS angle iron structure duly painted with earthing
arrangement. The layout of battery racks and the arrangement of batteries in
racks shall be arranged in such a way that all the individual batteries shall be
fully accessible. The complete set of batteries so connected in series parallel
configuration so as to obtain the required voltage limits of inverter operations
to get a backup of minimum 30 minutes.
The battery management function consists of conduction of the battery test
either automatically or upon the user’s request. Battery efficiency test
conducted by making an automatic full discharge at programmed or periodic
frequencies as required by the user. Calculation of the residue battery runtime
during the discharge phase, depending on the load applied. Facilities to protect
the batteries from damage due to deep discharges shall be provided.
The minimum backup time mentioned above shall be guaranteed for period of
not less than 2 years. Extended guarantee period offered by the battery
manufacturer shall also be extended to AAI irrespective of the defect liability
period of the capital contract.

viii. Digital display and alarm signal:

UPS will be equipped with a back lighted touchscreen alpha numeric liquid
crystal display (LCD) with 20 characters on 4 lines. The display is built into the
front part of the UPS where there is also an ultra-bright operating status
indicator which shows the operating status and any alarm conditions by means
of code. Simple buttons situated near the display allow the user to
 Display the operating data
 Enter the operating parameters
 Select the language in which the messenger is given.

33.5 Operating Principle:

i. Normal service condition:
In normal conditions, UPS runs in the double conversion on-line mode, thus the
users are powered in an uninterrupted way by the inverter, which is powered
by the electricity main through the AC/DC converter (rectifier/ PFC) so that it
automatically corrects the power factor on the UPS input as well. The inverter
is constantly synchronized with the electricity main so as to allow the bypass to
function correctly doing mains/ inverter and inverter/ mains commutations.
There commutations may be necessary if an overload occurs or inverter stops.
ii. Inverter stopping:
If the inverter stops, the user is automatically transferred without
interruptions to the primary main by means of the automatic by pass.
iii. Overload:

PAGE - 844
 When a temporary overload occurs on the load side of the UPS, current
monitoring allows the UPS to withstand the situation within certain limits,
without automatic bypass having to be used. If the overload lasts a long time or
exceeds the limit present by the current monitoring device, the user is
transferred without interruptions to the primary mains by means of the
automatic bypass and their returns to the inverter once the over load has
terminated.
iv. Mains failure condition:
In a blackout or if the electricity mains values are off range the users are
powered by the batteries via the booster inverter pathway. The battery
functions in dis charged conditions in this operating mode. The UPS informs the
near about the operating status with clear visual and acoustic signals. The DSP
control will calculate the available residual time depending on the
instantaneously applied load. This display is shown on the frontal runtime
display.
v. After a Blackout:
When the main power supply returns within the tolerated limit after a voltage
drop or a blackout the UPS automatically returns to operate in normal service
condition taking power from mains. Even after the end of autonomy, at the
return of the mains, the battery charger should start automatically charging of
battery.
vi. Operation of UPS with generator supply as mains:
The output frequency of UPS is synchronized with the mains input frequency.
This synchronizing process is guaranteed by microprocessor control within a
± 2% range of the nominal frequency. Out of this range the UPS stops
synchronizing with the input frequency and guarantees a strictly constant
output frequency. To achieve optimum operation in combination of generators
or gen sets, typically characterized by frequency fluctuation exceeding ± 2%
range, the UPS must have the possibility to guarantee synchronism between
the input and output frequency for even wider frequency ranges (± 5%).

vii. Controls:
The UPS shall have the following controls
 UPS secure powering (protection against accidental powering)
 UPS stopping (to prevent accidental power offs while allowing UPS to
be quickly shutdown in emergency)
 Buzzer silencer arrangement.
 Keyboard to browse the means on the display set parameters,
confirming selected functions and gritting.

viii. Display:
The UPS should be capable of displaying the following parameters & relevant
valves:
Input / Output : Current voltage, frequency, power, power factor

PAGE - 845
 Other displays : Mains available/ rectifier operative Battery voltage OK
Bypass supply OK Inverter O/P (Output)OK Load on by pass
Load on inverter Load on mains Load on battery.

Batteries : Charging current Discharging current Battery operation time

Residue capacity Battery voltage Date & time of last
calibration of battery circuit

Miscellaneous : Ambient temperature

Historic date : Overall time of battery operation Main operation No. of

bypass interventions. No. of battery commendations No. of
total discharges No. of protection intervention with time and
date.

ix. Adjustment:
The UPS will allow the following adjustments

Output Voltage
Frequency
Redundancy N+X

Input Enable synchronizing

Extended synchronizing interval
Bypass Enabling
Forced
Actuation sensitively offline mode Load
waiting mode

Batteries Limits
Max. runtime with battery
Max. runtime with battery after reserve limit
Battery test enabling
Auto restart enabling.

x. Signal & alarm:

The UPS must be equipped with an operating status indicator along with an
acoustic alarm for following operating conditions.
 Output frequency not synchronized with the input
 Inverter Off/ failed
 Rectifier Off/ failed
 Emergency stop
 Over temperature
 Overload
 Battery circuit breaker open
 Output circuit breaker open
 Input circuit breaker open

PAGE - 846
  Inverter un-synchronized
 Main failure
An event log of all active alarms and history of recent alarms and status.

xi. Maintenance Bypass:

The UPS will be equipped with a manual maintenance bypass to allow the
service and the access to modules and battery, keeping the load powered. The
maintenance bypass can be activated manually and must be protected by a
door locked with a key. A dis-connectors system must isolate the internal parts
of the UPS from any energy source allowing the UPS maintenance, service &
access of modules without danger.

33.6 TECHNICAL PARAMETERS:

S. PARTICULARS PROPOSED STANDARDS
NO.
1 ENVIRONMENTAL:
1.1 Operating Temperature : 0 to 40 Deg. C (without De-rating)
1.2 Maximum Temperature : 40 Deg. C
1.3 Storage Temperature : (-25 to 70) Deg. C
1.4 Relative Humidity : 95%, Non condensing
1.5 Altitude : Upto 1000 mtrs. MSL (Above 1000
Mtr. Deration factor @ 1.5% at every
100 mtrs.)
2 INPUT
2.1 Standard Voltage : 380/400/415V. Three phase
2.2 Voltage tolerance : +15% at 400 V
2.3 Frequency : 50Hz
2.4 Frequency tolerance : + 10% at 50 Hz (Without UPS
tripping)
2.5 Rectifier Type (Inverter : IGBT Three level PWM Design
Technology)
2.6 Power Walk-in : 20-100 % in 45 Secs
2.7 Power factor at rated load : > 0.99
2.8 Input THDi at rated load : < 3%
3 OUTPUT
3.1 Output rating : As per requirement of the station.
3.2 Voltage : Single Phase upto 20 KVA & 3
Phase above 20 KVA
3.3 Frequency : 50 Hz
3.4 Voltage stability-steady state : + 0.5- 1% typical
3.5 Overload : 110% & for 60 mins.
125% for 10 mins.
150% for 1 min.
3.6 Non-linear load permissible : Yes
3.7 Voltage stability-transient : + 5%
state with 100% load
change
3.8 Frequency stability : 50 Hz + 0.25 Hz

PAGE - 847
 3.9 Crest Factor : 3:1 (Minimum)
3.10 Output voltage distortion :
with a. < 1%
a. Linear load (100%) b. < 5%
b. Non-Linear Load (100%)
3.11 Transfer time, inverter : 0 m sec
mains
Transfer & vice-versa with a.
Inverter synchronized
3.12 Power factor : > 0.90
3.13 Overall Efficiency at rated : > 95% (ECO mode > 98%)
load (ECO mode efficiency)
3.14 Heat dissipation @ 100% : As per OEM Standards
load at nominal PF &
charged batteries
3.15 Heat dissipation @ 100% : As per OEM Standards
load in
ECO mode at nominal PF &
charged batteries
4 DC CHARACTERISTICS
4.1 Voltage Links of inverter : As per OEM standards
operations
4.2 a. Float charge voltage : 2.25/ cell1.75/ cell1.75/ cell
b. End of Battery Voltage
c. Absolute maximum
voltage on manual charge
4.3 Voltage stability of the : + 1%
rectifier
4.4 Ripple Voltage (with battery : < 2%
disconnected)
4.5 Battery Ripple current : < 0.5%
4.6 Battery charging cycle : Boost/float charging with
Current limit and boost time
limiter
4.7 Max boost charge duration : 1-1.5 hours in settable steps
4.8 Battery Isolation : Through battery circuit breaker
(one for each module) with over
Current Short circuit and under
voltage protection)
5 MIMIC Display
5.1 Mains available/ Rectifier : Yes
operative
5.2 Battery Voltage : Yes
5.3 Bypass Supply : Yes
5.4 Inverter Output : Yes
5.5 Load on bypass : Yes
5.6 Load on inverter : Yes

PAGE - 848
6 ALARMS (Through LC
Display)
6.1 Inverter Off/ failed : Yes
6.2 Rectifier Off/ failed : Yes
6.3 Emergency stop : Yes
6.4 Over Temperature : Yes
6.5 Overload : 110% & for 60 mins.
125% for 10 mins.
150% for 1 min.
6.6 Battery Circuit Breaker open : Yes
6.7 Output Circuit Breaker open : Yes
6.8 Input Circuit Breaker open : Yes

7 WARNING DISPLAY
(Through LC
Display)
7.1 UPS on maintenance bypass : Yes
7.2 Inverter Unsynchronized : Yes
7.3 Battery on load : Yes
7.4 Mains failure : Yes
7.5 Load on bypass : Yes
8 CONTROL SWITCHES &
MONITERING
8.1 To Select and monitor
a) Voltage (i/p, o/p, bypass) : Yes
b) Current (i/p, o/p, bypass) : Yes
c) Frequency (i/p, o/p, bypass) : Yes
d) Load (kw, current, kva) : Yes
e) Frequency (i/p, o/p, bypass) : Yes
f) Battery voltage : Yes
g) Battery charge/display : Yes
current
8.2 Alarm reset switch : Yes
8.3 Inverter OFF Switch : Yes
8.4 Inverter on switch : Yes
8.5 Emergency stop switch : Yes
8.6 Static By-pass : Yes
8.7 Manual By-pass : Yes
9 PROTECTION
1 Input under voltage : Yes
2 Input over voltage : Yes
3 Output under voltage : Yes
4 Output over voltage : Yes
5 Phase rotation correction : Yes
6 Loss of input power : Yes
7 Output overload : Yes
8 Galvanic isolation : Yes
Transformer at output

PAGE - 849
 9 Back feed protection : Yes
10 Protection against surges : Yes
11 Battery circuit breaker : Yes
(BCB) for automatic
isolation on battery line in
case of battery under
voltage and over current
conditions.
12 Fully rated static switch in : Yes
inverter output.
13 RS 232 / RS 485 Serial Port : Yes
Computer Compatibility.
14 Network monitoring (SNMP) : Yes
15 External dry contacts Yes
16 Microprocessor based self- : Yes
diagnostics and monitoring
17 Isolators provided for : Yes
isolating
input & output.
18 For 1/2/3 phase UPS, the : Yes
output voltage is genuinely
generated directly from the
inverter itself.
19 Fuse line Protection for : Yes
input.
20 Protection against over : Yes
temperature
10 ENCLOSURE
The enclosure shall be built : Yes
in compliance with IP 20.
Class of insulation : Class ii
11 CABINET FINISH
Painting : Color : Siemens Gray/(RAL 9005)/RAL
7021
12 CABLE ENTRY
Top / Bottom : Yes
13 BATTERY CABINET
Battery shall have separate : Yes
enclosure with proper
staggering arrangement and
painted with
same colour of UPS cabinet.
14 Power Backup Min 30 Minutes
15 Charging System Float & Boost
16 Acoustic Noise < 65 dB @ 1 meter

17 CERTIFICATION
IEC- 62040-1 : Yes

PAGE - 850
 IEC- 62040-2 : Yes
IEC- 62040-3 : Yes
IS : 16242-1 : Yes
18 UPS topology Double conversion (Modular
Design)
19 Each module should of same capacity and not less than 10 KVA
capacity in each module

33.7 Approval of equipments / materials / components:

Followings shall be part of the installation work:
 Formal approval of model of UPS offered shall be taken prior to call of inspection
from EIC. Agency shall submit the necessary technical drawings, calculations
compliance of tendered technical specification in order to receive formal
approval of model of UPS/ batteries/ cables.
 Approval of GA drawing and finalization location of installation of UPS in co-
ordination with EIC.
33.8 Installation, Testing & Commissioning:
 Upon delivery of UPS and readiness of site shifting of the units from place of
storage to place of installation.
 Unpacking.
 Verification for transit damages/ availability of all items including accessories,
instruction manuals, drawings, test reports, etc. And take necessary action
wherever needed.
 Assembling of different sections of UPS, battery, battery cabinets.
 Positioning of UPS as per site requirement/ as per drawings.
 Alignment checks.
 Grouting/ securing to the floor/ bare channels etc., for stable installation.
 Undertaking all related minor civil works, mechanical works like chipping,
grinding, plastering, welding, drilling etc.
 Making minor additions/ alterations as per the requirement for satisfactory
installation.
 Touching up of damaged painted portion.
 Earthing of unit.
 Making interconnection with other equipments/ system where necessary.
 Connecting and ensuring efficient termination of cable as applicable using
proper sizes cable lugs, glands and appropriate sizes of GI/ zinc passivity
hardware with spring washer & plate washers.
 Ensuring proper tightness of all joints & connections.
 Providing proper supporting / protection arrangement to the cables/ units etc.
To avoid under stress on the termination.
 Providing required instruction/ information/ caution/ name plates for easy
operation and maintenance.
 Performing all pre commissioning checks and proper functioning of all required
units.

PAGE - 851
33.9 TESTS
a. Type test:
Bidder shall submit the following type test report along with final acceptance
report.
i. Battery as per IS-1652
ii. IP degree
iii. Type test of UPS as per IEC 62040-3
iv. Internal test report along with heat run test report. (48hrs. At 50°C +
120hrs at Amb. Temp.) Transformer winding temp. Measurement shall
be by change in resistance method & other test reports of transformer
as per IS.
v. Calibration certificate of measuring instruments.
vi. Routine test reports as per IEC 62040-Part-3.

b. Site test:
i. Full load test shall be demonstrated with the available load with CCR’s
ii. Battery backup test during mains failure condition
iii. Actual load condition test.
33.10 DRAWINGS / DOCUMENTS:
The following drawings/ documents (3 sets) shall be furnished along with UPS
i. Installation operation & maintenance manuals
ii. General layout including dimensions.
iii. Electrical drawings
iv. Other if any as per site requirements.

34.0 OUTDOOR AREA LIGHTING

34.1 OCTAGONAL STREET LIGHT POLES & BRACKETS
Construction:
The octagonal pole shall be designed to withstand the wind speed applicable as per
IS 875 (Part 3). The max stress at wind speed as per above IS shall not exceed 80%
of the strength of steel. The details of top loading i.e. weight and area of luminaries
are to be worked out based on this consideration. Max deflection of the pole shall
meet the requirement of relevant IS with up to date amendments.

The pole shaft shall have octagonal cross section and shall continuously taper with
aesthetically pleasing appearance. The pole shall be manufactured in single piece
construction from 3mm thick high tensile steel sheet. The pole shaft shall be
continuously tapered with single longitudinal welding. There should not be any
circumferential welding.

The steel used in the manufacturing of the pole shaft, base flange etc. shall be
suitable for such type of pole.

The pole shall be hot dip galvanized after fabrication, internally and externally in
accordance with relevant IS with up to date amendments. The average coating

PAGE - 852
 thickness of galvanization shall not be less than 65 micron. Hot dip galvanizing
shall be done in single dip operation.

A rigid flange plate of suitable thickness with provision for fixing minimum 4nos.
of foundation bolts shall be provided. This base plate shall be fillet welded to the
pole shaft from inside and outside.

The octagonal pole shall have door opening of suitable length at appropriate
elevation from the base plate. The door shall be flush, vandal resistance and shall
be weather proof to ensure safety of inside connections. The door shall be flush
with the exterior surface and shall have suitable locking arrangement. Suitable
earth stud(s) shall be provided for earthing the poles.

Required door reinforcement shall be provided to compensate for loss in section.

A terminal plate made of 5 mm thick Bakelite sheet with 32 A heavy duty
connector/terminal studs (suitable for loop in loop out connection of upto 2 nos.
armoured cables of size up to 4 C x 25 sq.mm or as specified in schedule of
quantities) and 1 no. 2 A DP MCB (or as specified in schedule of quantities) for ON
/ OFF operation of the luminaries shall be provided inside the door.

Octagonal Pole shall be of flanged type to be fixed on the foundation bolts. Material
for octagonal pole shall be as per BSEN 10025 grade S355Jo. Exposed portion of
foundation bolts shall be hot dip galvanized.

2 no. Earthing stud for connecting earth wire shall also be provided opposite side
of poles.

BRACKET FOR OCTAGONAL POLE

The bracket shall be suitable for installation of LED luminarie of required wattage
(as specified in schedule of quantities) so as to achieve that specified lux level. The
brackets shall have a suitable tilt angle and shall be galvanized internally and
externally by hot dip galvanizing process.

The octagonal poles and brackets should be from same manufacturer to ensure
proper matching and alignment of the pole and bracket.

34.2 GRP light poles: (Decorative Light Pole)

Shall be constructed of polyester blend resin systems & fiberglass rowing with
more than 70% of reinforcing fiberglass in the axial vertical plane which increases
desired rigidity & axial strength as per IS standards.
The pole shaft shall be manufactured by CNC Filament Winding process.
Additional circular winding shall be provided for compression strength.

Shall be one-piece, composite pole with a uniform surface along its entire length.
The same shall be coated with specially formulated polyurethane coating with UV
inhibitor to protect the pole & to keep them look good & long life.
GRP shall be non-conductive, thereby reducing the possibility of electric shocks.

PAGE - 853
 Poles should not deteoriate in salty air climates, acid rains or acid soil.

Poles shall be engineered to withstand the specified winds with the calculation of
its wind load conforming to AASHTOLTS-21985.

Poles should be semi-textured finish, which shall be uniform & almost as pleasant
as a typical smooth finish.

Pole surface free from crack/ bubbles or damage. Any exposed fiber and smooth
surface shall be uniformly coloured.
Pole length tolerance not exceeding 0.1m per 10m.
Deflection of the pole as per the AASHTO LTS – 4 will not exceed a 10% of the
length of the pole above the ground line when subject to maximum wind loading &
will not have more than 1% permanent deflection.

Pole should be provided with Anchor Base (Size 350mm X 350mm & thickness 15
mm) and it should be heavy duty, mild steel Material duly painted with Epoxy
paint.
Standards to be followed:
ANSI C 136.20 – 1990: Fiberglass Reinforced Plastic Lighting Poles
IS 875 (Part 3) – 1987: Code of Practice for Design Loads for Buildings & Structures
– WIND LOAD.

34.3 SPECIFICATION FOR INSTALLATION OF POLES

FOUNDATION
a) Design & Approval:
The foundation shall be designed to withstand the wind velocity applicable as
per relevant IS and maintaining the maximum deflection of the pole as specified
with bracket & fixtures within limits of specified standard. Foundation for the
pole shall be made as per the design of manufacturer & should be suitable for
site.
b) Cable Guard pipe:
50 mm dia. ISI marked DWC HDPE pipe including bending / coupling as required
shall be provided for laying of loop-in loop-out cables in soil / concrete for easy
laying & relaying of cable without any change to the CC work. The end of the pipe
shall be sealed after cable is laid & tested. Separate pipe will be used for laying of
separate cables.
c) Wiring to Light Fixtures:
Each street light fixture shall be wired from SP MCB provided on loop-in-loop-out
box of pole by means of a separate flexible unarmored 3 core, 2.5 sq. mm, copper
conductor, PVC insulated cable.

34.4 Lux Level Measurement

Before taking up the work, the contractor shall furnish the typical lux level
calculation sheets for the given fixtures, type of fixture, pole height & bracket
mentioned in the schedule of work for approval of the Engineer In-charge.

PAGE - 854
 On completion of work the contractor shall demonstrate & furnish the same as
final lux level of typical areas and submitted for acceptance of Engineer In-
charge.
34.5 Pre-Commissioning and Commissioning Test of Street light
a) Check erection and alignment of poles, bracket and fixtures.
b) Incoming and outgoing cables are brought with ample clearance.
c) Terminal plate is tightly held to pole / mast etc.
d) Terminal connections of incoming and outgoing wires / cables are O. K.
e) Meggar of incoming and outgoing cable and wire going to fixtures etc.
f) Pole junction box covers are water tight and lockable.
g) Foundations are firm and approved by competent authority.
h) Electrical load balancing is properly carried out and readings to be taken and
submitted.
i) Taking lux level reading of typical areas & its submission.
j) Numbering of poles and proper nomenclature on MV panels, feeder pillars
indicating Incoming and outgoing etc.

35.0 TESTING OF INSTALLATION

35.1 Scope
This section describes the details of test to be conducted in the completed internal
electrical installation, before commissioning.
35.2 General
35.2.1 Tests
On completion of installation, the following tests shall be carried out: -
35.2.1.1 Insulation resistance test.
35.2.1.2 Polarity test of switch.
35.2.1.3 Earth continuity test.
35.2.1.4 Earth electrode resistance test.

35.2.2 Witnessing of Tests

Testing shall be carried out for the completed installations, in the presence of and
to the satisfaction of the Engineer-In-Charge by the Contractor. All test results shall
be recorded and submitted to AAI.

35.3 Insulation Resistance

The tests described below shall be made before the installation is permanently
connected to the supply. For these tests large installations may be divided into
groups of outlets, each containing not less than 50 outlets. For the purposes of this
code the term ‘outlet’ includes every point and every switch except that a socket
outlet, appliance or luminaire incorporating a switch is regarded as one outlet. The
test voltage for insulation resistance measurement shall be 500 V.
When measured with all fuse links in place, all switches (including, if practicable,
the main switch) closed and, all poles or phases of the wiring electrically connected
together, the insulation resistance to earth shall be not less than 1 mega ohm.
When measured between all the conductors connected to any one phase or pole of
the supply and, in turn, all conductors connected to each other phase or pole the
insulation resistance shall be not less than 1 mega ohm. Wherever practicable, so
that all parts of the wiring may be tested, all lamps shall be removed and all
current-using equipment shall be disconnected and all local switches controlling

PAGE - 855
 such lamps or other equipment shall be closed. Where the removal of lamps and/or
the disconnection of current-using equipment is impracticable, the local switches
controlling such lamps and/or equipment shall be open. Particular attention shall
be given to the presence of electronic devices connected in the installation and
such devices shall be isolated so that the test voltage does not damage them.
Where equipment is disconnected for the tests prescribed above, and the
equipment has exposed conductive parts required by these clauses to be
connected to protective conductors, the insulation resistance between the exposed
conductive parts and all live parts of the equipment shall be measured separately
and shall comply with requirements of the appropriate Indian Standard and the
insulation resistance shall not less than 0.5 mega ohm.

35.4 Polarity Test of Switch

In a two wire installation, a test shall be made to verify that all the switches in every
circuit have been fitted in the same conductor, throughout, and such conductor,
shall be labeled or marked for connection to the phase conductor, or to the non-
earthed conductors of the supply.
In a three wire or a four wire installation, a test shall be made to verify that every
non-linked single pole switch is fitted in a conductor which is labeled, or marked
for connection to one of the phase conductors of the supply.
The installation shall be connected to the supply for testing. The terminals of all
switches shall be tested by a test lamp, one lead of which is connected to earth.
Glowing of test lamp to its full brilliance, when the switch is in ‘ON’ position
irrespective of appliance in position or not, shall indicate that the switch is
connected to the right polarity.

35.5 Testing of Earth Continuity Path

The earth continuity conductor, including metal conduits and metallic envelops of
cables in all cases, shall be tested for electric continuity. The electrical resistance
of the same along with the earthing lead, but excluding any added resistance, or
earth leakage circuit breaker, measured from the connection with the earth
electrode to any point in the earth continuity conductor in the completed
installation shall not exceed one ohm.

35.6 Measurement of Earth Electrode Resistance

As described in specification of section ‘Earthing’ above.

35.7 Test Certificate

On completion of an electrical installation or an extension to an installation, a
certificate shall be furnished by the Contractor, countersigned by the certificate
supervisor under whose direct supervision the installation was carried out. The
certificate shall be in the prescribed form in addition to test certificate required by
the local Electricity supply authorities.

PAGE - 856
36.0 FIRE HAZARDS

36.1 The main pre-requisites of a fire hazard free building are: -

(a) Installation based on sound design and use of quality materials and
equipments.
(b) Good housekeeping.
(c) Proper maintenance based on skilled personnel, proper supervision and
preventive maintenance.
(d) Periodic inspection from fire hazard point of view by a qualified engineer.

36.2 Following instructions should be followed. Besides, based on the requirement of a

particular building, other instructions may be issued for avoidance of possible fire
hazard.
(i) No over loading of main board, DB, submain, wiring.
(ii) No loose wiring.
(iii) One socket outlet to feed one appliance only and do not use multiple outlets.
(iv) The AAI representative will have an annual inspection of the building and list
out deficiencies and report to higher officials who will take necessary
remedial action.
(v) Only MCB type DBs to be provided, so that overload, short circuit currents are
interrupted immediately. Rewirable type fuses not to be used.
(vi) Change old/ outlived wiring, switchboard, and appliance.
(vii) Extension to wiring / EI only after proper design and capacity of
augmentation of the existing installation.
(viii) Record Room – No power outlet / switches should be provided inside the
room. Use flameproof electrical fittings. In case it is a must to provide
switches / outlets in a record room, they should be flameproof.
(ix) Fire Protection
(a) The building should have a comprehensive fire protection system in
conformity with CFO’s requirement, backed by proper manning and
maintenance.
(b) Important building will have a fire control room, for monitoring and
control of fire safety of the building.
(c) Local fire extinguishers for various electrical Switchgears Locations, Lift
Machine Room, Electrical Sub-station, Generating Rooms, Pump Houses
etc.
(d) Get CFO’s annual inspection of the building done.
(e) Organize fire drill periodically, at least once in six months.

(x) Maintenance
Maintenance by qualified / licensed (as applicable) personnel. When
maintenance is done by contract system, only properly prequalified and
skilled contractors to be deployed. Such contract should have preventive
maintenance items.
(xi) Only quality and genuine material should be used.
(xii) When repairs are needed, act immediately, don’t postpone repairs.
(xiii) Keep telephone / address details of Fire Station / Police / Hospital/
Departmental Officials / Client Department Officials, both Office and

PAGE - 857
 Residence (in case of emergency).
(xiv) All switch rooms / electrical shafts to be kept clean and duly locked. All locks
will have common key, with keys available to all authorized personnel.
(xv) Keep appliances ‘OFF’ after office hours. Instruction to be issued, so that all
switches and appliances are ‘OFF’ after office hours.

37.0 ENERGY CONSERVATION

Energy is very costly. Guidelines for energy conservation:
40.1 Lighting and Controls
40.1.1 Lighting Design
Interior Lighting
Proper lighting level is to be maintained as per NBC 2016 .

Lighting Power Density

Lighting Power Density is the ratio of the total lighting load of a space to the total
lit space area. The installed interior lighting power for a building shall not exceed
the interior lighting power allowance determined in accordance with either
Building Area Method or Space Function Method. The installed interior lighting
power shall include all power used by the luminaires, including lamps and ballast.
Building Area Method
Determination of interior lighting power allowance (watts) by the building area
method shall be in accordance of ECBC 2017 with upto date amendments.
(a) Determine the allowed lighting power density for each appropriate building
area (Refer Table 6-1 for ECBC Buildings, Table 6-2 for ECBC+ Buildings and
Table 6-3 for Super ECBC Buildings).
(b) Calculate the gross lighted area for each building area type.
(c) The interior lighting power allowance is the sum of the products of the gross
lighted floor area of each building area times the allowed lighting power
density for that building area type. Space Function Method
Determination of interior lighting power allowance (watts) by the space
function method shall be in accordance of ECBC 2017 with upto date
amendments.

(d) Determine the appropriate building type and the allowed lighting power
density (Refer Table 6-4 for ECBC Buildings, table 6-5 for ECBC+ Buildings and,
table 6-6 for Super ECBC Buildings). In cases where both a common space type
and building specific space type are listed, building specific space type LPD
shall apply.
(e) For each space, enclosed by partitions 80% or greater than ceiling height,
determine the gross lighted floor area by measuring to the center of the
partition wall. Include the area of balconies or other projections. Retail spaces

PAGE - 858
 do not have to comply with the 80% partition height requirements.
(f) The interior lighting power allowance is the sum of the lighting power
allowances for all spaces. The lighting power allowance for a space is the
product of the gross lighted floor area of the space times the allowed lighting
power density for that space.

40.2 Lighting Controls

40.2.1 Automatic Lighting Shutoff
Interior lighting systems in buildings larger than 500 Sqm (5380 Sq.ft.) shall be
equipped with an automatic control device. Within these buildings, all office areas
less than 30 m2 (300 ft2) enclosed by walls or ceiling-height partitions, all meeting
and conference rooms, all school classrooms, and all storage spaces shall be
equipped with occupancy sensors.

For other spaces, this automatic control device shall function on either:

40.2.1.1 A scheduled basis at specific programmed times. An independent program

schedule shall be provided for areas of no more than 2500 Sqm (26900 Sq.ft.) and
not more than one floor,
Or
Occupancy sensor that shall turn the lighting off within 3 minutes of an occupant
leaving the space. Light fixtures controlled by occupancy sensors shall have a wall
mounted, manual switch capable to turning off lights when the space is occupied.
Exception to above: Lighting systems designed for 24-hour use.

40.2.2 Space Control

Each space enclosed by ceiling-height partitions shall have at least one control
device to independently control the general lighting within the space. Each control
device shall be activated either manually by an occupant or automatically by
sensing an occupant. The maximum coverage area for each control device is given
in the table below:
Space Area and Lighting Control

Sl. No. Space Area (m2) Maximum Coverage Area for each Control Device
(m2)
1 < 1000 250
2 > 1000 1000
Each control device shall be capable of overriding the required shut off control for
no more than 2 hours. It should be readily accessible and located such that the
occupant can see the control.
Exception to above: The required control device may be remotely installed if
required for reasons of safety or security. A remotely located device shall have a
pilot light indicator as part of or next to the control device and shall be clearly
labeled to identify the controlled lighting.

PAGE - 859
40.2.3 Day-lighting Controls
Luminaires in day lighted areas greater than 25 Sqm (269 Sq.ft.) shall be equipped
with either a manual or automatic lighting control device that is capable of
reducing lighting output of the luminaires in the day lighted areas by at least 50%
and controls only the luminaires located entirely within the day lighted area.

40.2.4 Exterior Lighting Control

Lighting for exterior applications shall be controlled by a photo sensor or
astronomical time switch that is capable of automatically turning off the exterior
lighting when daylight is available or the lighting is not required.

40.2.5 Lighting Control Devices

Following is a description of different types of control devices available for
controlling the lighting:

Timers: These are the simplest type of controls and are most popular. Some areas
in buildings may require lighting for specific durations like security lighting,
landscape lighting or building floodlighting. Timers allow this type of control by
switching ‘on’ and ‘off’ as per preset times. These can have one setting (same time)
for the whole year or several (seasonal / weekly / daily) settings to take care of the
changing sunset times.
Photocell Lighting Control: These measure the amount of natural light available
and suitable for both indoor and outdoor applications. When available light falls
below a specified level, a control unit switches the lights on (or adjusts a driver to
provide more light). Photocells can be programmed so that lights do not flip on and
off on partially cloudy days.
Occupancy Sensors: These devices – also known as ‘motion detectors’ – turn lights
off and on in response to human presence. Once sensitivity and coverage area is
established, sensors are selected from two predominant technology types.
Passive Infrared Sensors: These detect the motion or heat between vertical and
horizontal detection zones. This technology requires a direct line of sight and is
more sensitive to lateral motion, but it requires layer motion as distance from the
sensor increases. The coverage pattern and field of view can also be precisely
controlled. It typically finds its best application in smaller spaces with a direct line
of sight, such as restrooms.
Ultrasonic Sensors: These detect movement by sensing disturbances in high-
frequency ultrasonic patterns. Because this technology emits ultrasonic waves that
are reflected around the room surfaces, it does not require a direct line of sight. It
is more sensitive to motion towards and away from the sensor and its sensitivity
decreases relative to its distances from the sensor. It also does not have a definable
coverage pattern or field of view. These characteristics make it suitable for use in
layer-enclosed areas that may have cabinets, shelving, partitions, or other
obstructions. If necessary, these technologies can also be combined into one

PAGE - 860
 product to improve detection and reduce the likelihood of triggering a false on or
off mode.

40.3 Efficient Motors

Motors shall comply with the following:
All permanently wired poly-phase motors of 0.375 kW or more serving the
building and expected to operate more than 1500 hours per year and all
permanently wired polyphase motors of 50 kW or more serving the building and
expected to operate more than 500 hours per year. Three phase induction motors
shall conform to Indian Standard (IS) 12615 and shall fulfil the following efficiency
requirements:
(i) ECBC Buildings shall have motors of IE 2 (high efficiency) class or a higher class.
(ii) ECBC+ Buildings shall have IE 3 (premium efficiency) class motors or higher
class.
(iii) Super ECBC Buildings shall have IE 4 (super premium efficiency) class motors.

• Motors of horsepower differing from those listed in the table shall have
efficiency greater than that of the listed kW motor.
• Motor horsepower ratings shall not exceed 20% of the calculated maximum
load.
• Motor nameplates shall list the nominal full load motor efficiencies and
the full load power factor.
• Motor users should insist on proper rewinding practices for rewound motors.
If the proper rewinding practices cannot be assured, the damaged motor
should be replaced with a new, efficient one rather than suffer the significant
efficiency penalty associated with typical rewind practices.
• Certificates shall be obtained and kept on record indicating the motor
efficiency. Whenever a motor is rewound, appropriate measures shall be
taken so that the core characteristics of the
motor is not lost due to thermal and mechanical stress during removal of
damaged parts. After rewinding, a new efficiency test shall be performed and
similar records shall be maintained.
• Motors should be installed with soft start energy savers and Variable Speed
drives based on the application required.

40.4 Metering
• Services exceeding 1000 KVA shall have permanently installed electrical
metering to record demand (kVA), energy (kWh), and total power factor. The
metering shall also display current (in each phase and the neutral), voltage
(between phases and between each phase and neutral), and total harmonic
distortion (THD) as a percentage of total current.
• Services not exceeding 100 kVA but over 65 kVA shall have permanently
installed electric metering to record demand (kW), energy (kWh), and total
power factor (or kVARh).
• Services not exceeding 65 kVA shall have permanently installed electrical

PAGE - 861
 metering to record energy (kWh).
• Electrical meters shall be installed to measure the energy units generated on
site through DG / GG sets.
• Separate electrical sub-meters shall be installed to measure energy
consumption by HVAC plant, AHU fans and indoor lighting.
• BTU meters* shall be installed for each chiller at the entry and leaving points
to measure the cooling generated by chillers.
• BTU meter* shall be installed on the chilled water loop to measure the
building’s total cooling demand.
*BTU Meter: BTU is the acronym for British Thermal Unit, which is a traditional unit
of energy. BTU meters are used for thermometric billing as they measure heat in
terms of BTU. These meters are used for measuring energy consumption of heating
and cooling systems. By installing BTU meters at individual chillers, cooling generated
by individual chillers can be measured and by installing the BTU meter on the chilled
water loop, building’s total cooling demand can be measured.

40.5 Steel Wire Rope Hangers & Supports:

Wire Hangers shall be used to suspend all static Electrical services.
Wire Hangers should consist of a pre-formed wire rope sling with a range of end
fixings to fit various substrates and service fixings, these include a ferruled loop,
permanently fixed threaded M6 (or M8, M10, M12) stud/eyebolt, permanently
fixed nipple end with toggle, at one end or hook or eyelet, cladding hook, barrel,
wedge anchor, eyebolt anchor or any other end fixture type or size as per
manufacturers recommendation and design. The end fixings and the wire must be
of the same manufacturer with several options available. The system should be
secured and tensioned with a Hanger self-locking grip at the other end. Once the
grip is locked for safety purpose unlocking should only be done by using a separate
setting key and should not be an integral part of the self-locking grip. Only wire
and/or supports supplied and/or approved, shall be used with the system.
a. Wire Hangers should have been independently tested by Lloyds Register.
APAVE, TUV, CSA, ADCAS, Intertek, ECA, and SMACNA, approved by CSA and
comply with the requirements of DW/144 and BSRIA – wire Rope Suspension
systems. Wire rope should be manufactured to BSEN 12385: 2002.
b. Wire Hangers shall be independently tested by reputed third party testing
organization to sustain safe working load for 120min at elevated temperature
of 175 deg. C or above.
c. The contractor shall select the correct specification of wire hanger to use for
supporting each particular service from table 1 below. Each size is designated
with a maximum safe working load limit (which incorporates a 5:1 safety
factor).
The correct specification of wire hanger required is determined using the
following formula.
Weight per meter of object suspended (kg) X distance between suspension points
(m) = weight loading per Hanger suspension point (kg).

PAGE - 862
 Where the installed wire rope is not vertical then the working load limit shall
be reduced in accordance with the recommendations give in the manufacturer’s
handbook.
The contractor shall select the correct length of wire rope required to support the
service. Lengths from 1-10m lengths. Specials can be made, check with
manufacturer. No in–line joints should be made in the rope.
Table. 1
Wire Hanger Safe Working Loads

size workingloadlimit(kg/lbs)

No. 1 0-10 kg / 0-22 lbs

No. 2 10-45 kg / 23-100 lbs

No. 3 45-90 kg / 101-200 lbs

No. 4 90-225 kg / 210-495 lbs

No. 5 225-325 kg / 496-715 lbs

No. 6 325-500 kg / 715-1100 lbs

The standard range of Hanger Kits should contain galvanized high tensile steel
wire rope or stainless-steel wire rope as per the application, the minimum
specification is as above and should be manufactured to BS 302 (1987),
BSEN12385. Comply with manufacturer's load ratings and recommended
installation procedures. Rigid support must also be used in conjunction with wire
rope hangers with electrical services as per Support GFC/design drawings. The
testing shall be done to the minimum breaking load of the wire thus giving a
minimum safety factor of 5: 1.

 Supports can be provided for: Busbar, Cable Ladder, Cable Tray, Cable Basket,
Channel, Trunking, Light Rafts, Luminaires, Secondary Supports, Safety Lines,
High Bay/Low Bay Lights, Electrical Cables, CCTV and Catenary Supports: Y-Fit
solution shall be used to a maximum width of 500mm Cable Tray. For Tray over
500mm cradle support method or independent supports must be taken as
appropriate based on load. Any other solution can be used based on
manufacturer’s recommendation on site conditions after prior approval.
 Catenary Supports: Refer to manufacturer’s recommendations on Catenary
supports with C-clip, special care should be taken with tensioning of the wire
and angles at which the installation of services are made.
 Stainless Steel Supports should be available for food, chemical and High

PAGE - 863
 Corrosion areas near coastlines.

Refer to manufacturers catalogue and installation guide for further technical

information. Comply with manufacturer's load ratings and recommended
installation procedures.
All supporting system to be provided by same manufacturer.

38.0 MAINTENANCE
38.1 Organized maintenance based on preventive maintenance is essential to
ensure:
(i) Un-interrupted service
(ii) No break-down
(iii) Safety, no mishaps
(iv) Economic operation
(v) Lower energy bills
(vi) Long useful life.
Therefore, due importance is to be given for maintenance.
38.2 General Guidelines
41.2.1 Persons engaged in maintenance works should be competent for the type of
work involved and should possess necessary license.
41.2.2 Safety procedures as indicated should be duly followed.

41.2.3 41.2.3 (a) In any building, additions and alterations are bound to occur at any time.
When such additions/ alterations are to be undertaken, it is very important to
check in advance the likely loading of the distribution system and to strengthen the
system as necessary before allowing the extra load to be connected, so as to avoid
overloading of any part of the system. Even phase balancing may need to be redone
so as to keep the neutral current low. To enable compliance to this safety aspect,
the detailed distribution schematic diagram indicating also the wire/cable sizes,
current rating of switchgear/ fuses, loading on individual circuit etc. should be
available at site. This may be kept up even in a register form, with different pages
for different floors / wings, for ready reference at any time. This should be
supplemented with detailed inventory.
(b) These should be updated, as and when additions / alterations are carried out
so that the data may be fully relied upon, for further references. In fact, if any
major additions alterations / rewiring is carried out, proper record should be
kept in the history book for the installation.
(c) It is necessary that those responsible for the site maintenance should have a
clear knowledge about the distribution system.

41.2.4 The number of items to be maintained in a building may be many like fittings, fans,
DBs, earth sets etc. In order to achieve compliance to the prescribed periodicities
for the various activities on them as per this schedule, each of these items may be
divided into convenient numbers, to carry out the respective activities in sub
periods, in a cyclic (sequential) order. For example, if DB’s are to be checked every
month, and there are 50 DBs in a building, these may be checked at the rate of 2 or

PAGE - 864
 3 DBs every day in a sequential order (programmed in advance) so that all DBs are
checked in a month.
41.2.5 Maintenance activities carried out as per this schedule should be noted in the
Maintenance Register. When tests are carried out, the test results should be
recorded with appropriate identification references (For Example: SDB7; Earth pit
No.4; R/M- Wing A etc.)

41.2.6 (a) The voltage of supply, total load current and PF should be noted in logbook
every day, preferably during peak loading time of the day. (In the case of isolated/
unattended buildings where it is not feasible to log daily, the period may be
increased to weekly or fortnightly as feasible).
(b) If any instrument is not provided, provide the same now. If any of the
instruments is defective, get it repaired early.
41.2.7 Inspection of electrical installations is intended primarily from fire safety
considerations.
Following points need to be observed as part of inspection, and corrective
action as necessary should be taken immediately, including coordination with
the client departments concerned, as may be required.
41.2.7.1 Check that there is no sign of heating up, burning smell, de-colouration or
sparking at any of the boards (SDBs as well as main boards), and Rising Mains.
These may occur due to overloading or loose terminations. Highly unbalanced
loading may cause heavy neutral currents and consequent heating of neutral
conductors and terminals.
41.2.7.2 No temporary wiring exists anywhere in the building.
41.2.7.3 There is no joint in cords connecting the WTAC units / voltage regulators /
office equipment like photocopier, PC etc.
41.2.7.4 No bare wiring exists over the flooring without mechanical protection by a
metallic conduit / channel.
41.2.7.5 There is no misuse of socket outlets, such as connecting power load to light socket,
connection of multiple loads to one socket, use of heaters in record room, library
etc. In such cases of additional demands of outlets, these should be provided early,
after taking approval of the competent authority.
41.2.7.6 All DBs should be only of MCB type and all sockets for WTAC units should be of
industrial type controlled by MCB.
41.2.7.7 The shafts / spaces for electrical services are not misused, for storage or for
dumping rubbish.
41.2.7.8 The spaces in front of DB’s and sockets are free (without any storage of files /
papers etc.)
41.2.7.9 No additions/ alterations are done by the user departments to the electrical
installations by themselves.

41.2.8 (a) A record of loading upto DB level (in each phase in case of 3 phase DBs) should
be maintained, after measurements using a clip on ammeter. Such measurement
should be done, as far as possible during peak season (summer and winter), when
the loads are likely to be the highest.
(b) The PF should be maintained above 0.8 (or any higher value fixed by the licensee

PAGE - 865
 without penalty). Examine the adequacy of capacitors (if any) accordingly.
(c) Note down from the electricity bills, details of maximum demand, energy & PF to
examine the trend of loading, penal charges if any being paid etc. (Even if the bills
are paid directly by client Depts.) review of contract demand, strengthening of
system, PF correction requirements etc. should be done with this review.
41.2.9 (a) While cleaning fittings and fans, the fixing / suspending arrangements should
also be checked and attended to as necessary. Care should be taken that the
alignment is not disturbed.
(b)(i) In the case of ceiling fans, remove the blades, and wash the same with detergent,
without causing any deformation of blade angle. Check the shackle and replace if
damaged. Check that down rod is fully screwed upto the last thread on both ends
and that threads are not loose. If so required, replace with new down rod of the
same size, thickness and length of threading (not less than 20 mm). Check split pins
and replace if any strain deformation or damage is observed. If any other system
of suspension had been adopted, check the soundness of the same and tighten as
necessary. Fix fan blades tightly to the body. Operate the fan at different speeds;
the run should be without wobbling/ noise.

(ii) As per specifications, lubrication needs to be done as necessary. In such cases, the
fan needs to be brought down, after removing the blades. The old grease should be
replaced with a fresh one, after cleaning the bearing. If damaged, the bearing
should be replaced. When reinstalling the fan, the suspension bolts should be well
tightened.

41.2.10 (a) Insulation test should be done during monsoon season, as per clause 16.2 of
CPWD General Specifications for Electrical Works Part I Internal, 2013.
(b) Earth continuity test and earth electrode resistance test should be conducted
during summer season, as per clauses 16.4 and 16.5 of the above specifications.
(c) Record the test results giving identification references. If results are not
satisfactory in any part of the installation, reason should be checked and
corrective action be taken immediately.

39.0 PREVENTIVE MAINTENANCE

39.1 Cleanliness is the mother of preventive maintenance. Keep areas clean.
39.2 Have schematic diagram for each installation.
39.3 No loose wiring.
39.4 No overloading.
39.5 Preventive maintenance of switchboards, DBs every six months.
39.6 For multi-storied building go for fuse less switchgear like ACBs, MCCBs, and MCBs,
as a precaution against fire on account of short circuit.
39.7 Prepare preventive maintenance schedule for each installation.
39.8 Proper manning/ supervision of installation.
39.9 Maintenance of logs records and history sheet of events and breakdowns. Ensure
working of all measuring and indicating instruments.
39.10 Take safety measures.

PAGE - 866
 39.11 Annual inspection to ensure system adequacy, safety, efficiency and take remedial
measures.
39.12 Replacement of old/outlived equipments.
39.13 Six monthly survey report of dismantled materials.
39.14 Display important telephone numbers.

39.15 Entrust repairs and maintenance to only skilled personnel and firms.
39.16 No short circuit to problem like patchy repairs.
39.17 Compound Lighting
Annual painting of poles. 3 monthly cleaning of fittings. Weekly check of working
of all fittings. This ensures a bright and safe premises during night.
39.18 For proper maintenance of electrical installations, the following items of work shall
be carried out regularly as per periodicity stated below and a proper record of such
work shall be maintained.
42.18.1 Earth testing - Once in a year
42.18.2 Insulation test - Once in a year
42.18.3 Cleaning of E.I.
42.18.3.1 Residential Buildings - Once in a year
42.18.3.2 Non-residential Buildings - Once in a year
42.18.4 Painting of E.I.
42.18.4.1 Residential Buildings - Once in 3 years
42.18.4.2 Office Buildings - Once in 2 years.
42.18.4.3 Important Public Buildings - Once in a year
42.18.4.4 Spray painting of ceiling fans - Once in 5 years.
42.18.5 Painting of outdoor metallic items - Once in a year like MS poles,
Feeder pillars etc.
42.18.6 Oiling and greasing of fans - As and when required
42.18.7 Checking of regulators, replacement
of carbon brushes etc. - Once in a year.
42.18.8 Polarity test - Once in 5 years.

PAGE - 867
 APPENDIX
FORM OF COMPLETION CERTIFICATE

I/We certify that the installation detailed below has been installed by me/us and
tested and that to the best of my/our knowledge and belief it complies with Indian
Electricity Rules, 1956, as well as the C.P.W.D. General Specifications of Electrical
Works 2013.
Electrical installation at .................................................................................................................
Voltage and system of supply .........................................................................................................

I. Particulars of work:
(a) Internal Electrical Installation
No. Total Type or system
Load of wiring
(i) Light point

(ii) Fan point

(iii) Plug Point

(a) 3 pin 5 Amp.

(b) 3 pin 15 Amp.
(b) Others Description HP/KW Type of
Starting
(a) Motors:

(i)
(ii)
(iii)
(b) Other plants:

(c) If the work involves installation of overhead line and/or underground

cable.

(d) (i) Type & description of overhead line.

(ii)Total length and no. of spans.
(iii) No. of street lights and its description.

(e) (i) Total length of underground cable & its size.

(ii) No. of joints: End joint:
Tee joint:
St. through joint:

PAGE - 868
 II. Earthing
(i) Description of earthing electrode.
(ii) No. of earth electrodes.
(iii) Size of main earth lead.
III. Test results:
(a) Insulation resistance
(i) Insulation resistance of the whole system of Conductors
to earth – Mega ohms
(ii) Insulation between the phase conductor and neutral
Between Phase R and neutral – Mega ohms
Between Phase Y and neutral – Mega ohms
Between Phase B and neutral – Mega ohms
(iii) Insulation resistance between the phase conductors in case of

polyphase supply.

Between Phase R and Phase Y – Mega ohms

Between Phase Y and Phase B – Mega ohms

Between Phase B and Phase R – Mega ohms

(b) Polarity test

Polarity of linked single pole branch switches.
(c) Earth continuity test
Maximum resistance between any point in the earth continuity
conductor including metal conduits and main earthing lead Ohms
(d) Earth electrode resistance
Resistance of each earth
electrode
(i) Ohms
(ii) Ohms
(iii) Ohms
(iv) Ohms
(e) Lighting protective system
Resistance of the whole of lightning protective system to earth before
any bonding is effected with earth electrode and metal in/on the
structure …… Ohms.
Signature and name of Signature and Name of
the Junior Executive (E) / AM (E) Contractor

PAGE - 869
SECTION-11 - ADDRESSABLE FIRE DETECTION & ALARM SYSTEM
1.0 GENERAL DESCRIPTION AND SCOPE OF WORK

1.1 This section covers the requirement of intelligent analog addressable fire alarm system
as per specification laid down below and as per description of item given under the
schedule of quantities.

1.2 The work described in this specification consists of all labour, materials, equipment and
services necessary and required to complete, test and commission the fire detection and
alarm system. Any material not specifically mentioned in this specification but required
for proper performance and operation shall be provided and installed for a complete
and operational system, by the contractor without any extra cost to AAI.

1.3 The contractor shall furnish, and install complete and ready for intended use and
operation, an intelligent, addressable fire detection and alarm system including Fire
alarm panel(s), initiating devices (manual call stations, addressable multi sensor
detectors, beam detectors etc.) indicating devices (sounders, bells, visual warning
signals etc.) and supervisory devices, annunciators, wiring apparatus and accessories.

1.4 The installation and locations of equipment and devices in the building shall be
governed by the relevant codes / standards with due regard to actual site conditions,
manufacturers' recommendations, ambient factors affecting the equipment and other
operations in the vicinity. If any deviation from the specifications is necessary, approval
shall be obtained from AAI before work is started thereon.

1.5 Materials and equipment supplied shall be new, standard; current models of the
manufacturer and shall be suitable for this system. Where two or more pieces of
equipment performing the same function are required, they shall be exact duplicates
produced by the same manufacturer.

1.6 All materials, devices, and equipment shall be compatible with the circuits or systems
in which they are utilized.

1.7 Provision shall be made for interfacing Fire System Panel(s) through BMS / PA. The
panel shall be capable of inter-connected with BMS and shall have open code
architecture / open protocol.

2.0 In addition to SITC of Fire detection and alarm system, the following work shall also
be deemed to have included in the scope of work to be executed by the bidder within
his quoted amount.
i) It includes obtaining approvals from Chief Fire Officer / Fire Department
concerned and all other statutory authorities for complete scope of work as per the
prevailing rules & regulations etc.
ii) The Fire Detection and Alarm System of the building shall be integrated with
respective to the zoning of PA system so that, in case of fire, the PA system shall
automatically come in announcement mode of that particular zone and play pre-
recorded evacuation messages from PA system.
iii) Providing repeater panel at Main Fire Station Control Room and interconnecting
the same with main FACP installed in the building.

PAGE - 870
3.0 REQUIREMENTS
a. This installation shall be made in accordance with the specifications i/c local codes
and local fire authorities having jurisdiction over this project.
b. Fire Detection & Alarm System Installation work shall be carried out in accordance
with Indian Standard Code of Practice for Electrical Wiring Installation IS: 732 -
1989, IS: 2274-1963 and IS 2189-2008 with upto date amendment. The control
cable used shall be of Fire Retardant, Low Smoke, Halogen Free type.
c. It shall also be in conformity with the current Indian Electricity rules and
regulations and requirements of the Local Fire Authority. Proposed Intelligent
Addressable Fire Detection & Alarm system in general shall be carried out as per
following Specifications-
d. Reference Standards
All equipment and installation shall be installed in compliance with the following
codes and listing with update amendments:
LOCAL CODES
CPWD – General Specifications for Electrical Work – Part VI : Fire Alarm and
Detection System - 2018
 National Building Code- 2016 : Fire and Life safety
IS: 2175 : Specification for Heat Sensitive Fire Detectors for Use
In Automatic Fire Alarm System
IS : 2189 : Selection, installation and Maintenance of automatic
fire· detection and alarm system code of practice
IS: 11360 : Specification for smoke detectors for use in automatic
electrical fire alarm system
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) - USA:
 NFPA 71 & 72 : National Fire Alarm Code
 UL 464 : Audible Signaling Appliances
 UL 38 : Manually Actuated Signaling Boxes
BRITISH STANDARD (BS EN54) – EUROPE:
 BS 5839 : Fire alarm system Design
Wherever these specifications calls for a higher standard of material and or
workmanship than those required by any of the above mentioned regulations and
specification then the specification here under shall take precedence over the said
regulations and standards.

e. Test at Site
i) All commissioning tests at site will be in line with NFPA / EN (Latest).
ii) Following test shall be conducted: -
- Loop Checking.
- Checking of multi sensor detectors etc. by simulation/functional test by
Aerosol Spray or as recommended by the manufacturer.
- Functional tests for fire alarm panel.
- The Mock trial of the complete Fire Detection and Alarm system.

PAGE - 871
 f. Tests Certificates

Tests certificates will be furnished for all Fire alarm system devices by the
manufacturer.

4.0 SHOP DRAWINGS

On the basis of GFC drawings issued by the department along with soft copy (CD / Pen
Drive), the Contractor shall submit three (3) sets of Shop drawings containing the
following within 30 days of issue of GFC drawings for approval of Engineer –In – charge.

• Block Diagram showing all detectors and devices area wise, their connectivity to
the panel including wire description.
• Point-to-point wiring diagrams showing the points of connection and terminals
used for all electrical field connections in each system, all equipment or systems
which are supervised and controlled by the fire alarm system. Diagrams shall show
all connections from field devices to the control panel initiating modules, output
modules, switches, relays and terminals. Diagrams shall show interconnection of
all devices, modules, output modules, switches, relays and terminals.
• The Contractor shall submit specific catalogue for each of the item specified in SOQ
for approval from AAI before procurement.

5.0 POWER SUPPLY

a. The control panel shall drive from 230 Volts main power supply. In case of failure
of main power supply, the panel shall be automatically switched over to standby
power supply i.e. battery. The standby battery as secondary supply shall be such
that when charged by associated battery charging equipment it can operate
independently for a period of 24 hours normal working and then be capable of
operating the system for 30 minutes during an emergency / fault conditions.
Batteries shall be of Lead Acid type sealed Maintenance free / Li-ion.
b. In addition to the batteries, an automatic battery charger suitable for operation on
the auxiliary power available in the plant as specified above. The capacity of the
charger shall be such that the same can charge the battery (within 12 hrs) while
supplying the rated load of the fire detection system. Facilities shall be provided to
limit the voltage supplied to fire detection and alarm system to their rated values
during the time of charging. The charger shall normally supply the battery trickle
charging current and the DC load of the fire detection and alarm system. In case the
AC supply on the input side of the charger fails the necessary power for the
complete fire detection and alarm system shall be supplied by the battery.
c. Visible and audible annunciation for troubles or failure in the power supply system
like "charger Failure", "Battery Low Voltage", etc. shall be provided.
d. Battery fault indication/annunciation shall be included in the panel.

6.0 DESIGN REQUIREMENT

a) The system shall be provided with multiple loops and distributed as per GFC
drawing issued by the department on award of work. All devices shall be connected
directly to the loop with 2x1.5 sq. mm Armored copper FRLSZH cable. The system
shall be compatible to integrate with the PA / BMS system.
b) Addressable Multi-Sensor Detectors (smoke + heat), Addressable smoke Detectors

PAGE - 872
 Addressable Heat Detectors, Addressable Beam Detectors Addressable Manual Pull
Station, Fault Isolators, Control Modules, Monitor Module, Response Indicators,
Addressable Hooters cum strobe etc.
c) The Panel shall have necessary Logic Software and Hardware built into it for time
delay starting of strobe.
d) Suitable racks shall be provided for housing control equipments etc.

7.0 SPECIFICATION
The design, supply, installation testing & commissioning of entire fire alarm system
shall conform to BS / NFPA 72. All devices including Main Fire Alarm Panel shall be UL
/ EN listed.

7.1 ADDRESSABLE MAIN FIRE ALARM PANEL

a) The Fire Alarm Control Panel shall be Modular Microprocessor based
expandable fully intelligent Addressable Control Unit which shall control all
intelligent addressable detectors, manual call stations Control / Monitor module
etc. connected to it.
b) All Addressable Units shall be connected to the Panel through the Loop Cards and
shall be addressed through individualized numbers. The Panel shall be able to
obtain intelligent value for all detectors in the circuit through a pulsed digitalized
current data. The panel shall be able to analyze all intelligent inputs from all
addressable units and through its own software and ambient level screening the
panel shall be able to identify fire, possible fire or fault conditions. The unit
supervision shall be dynamic and continuous.
c) The Fire Alarm Panel itself shall have all loop cards in it. No isolated mother board
or transponder is allowed. Each loop shall be able to access a minimum of 240
addressable detectors / devices (in any combination) per loop.
d) The Panel shall also give adequate warning signal whenever there is Dust
Accumulation in Detectors, and upto the point of its replacement it should be
possible to change the level of ambient alarm calibration condition either by the
use of software programme operable by the Owner or by resetting the detector.
e) Short circuiting, loose wiring or missing units shall also be reported at the panel
with pin point or segment-wise location. In such cases, the system through the use
of Fault Isolators shall be able to isolate that segment between the two Fault
Isolators.
f) The panel shall have a liquid crystal display type on it to indicate immediately all
conditions. In case of testing of the system from the panel, the display shall be able
to give readouts of intelligent value of all detectors being tested. The panel shall
also be able to carry out continuous self-monitoring when in normal condition.
g) Number of detectors / devices per loop should not be exceeding 90 percent of the
full capacity of each loop as per IS code.

The panel shall have either an in-built or external printer coupled to the panel which
shall log all events with time. The printer shall be suitable for printing panel’s event
logs or as per the configuration to print automatically any of the events such as

PAGE - 873
Fire, Fault, Alarm or Test, the unit address, time along with option for printing the
Inputs, Outputs, Disablements, Network Faults etc.
h) The panel shall also be able to discriminate between false alarms and fire
conditions, as well as priority selection of alarm address in case alarm activates in
two or more remotely located units simultaneously. In such cases, the manual call
box shall be reported first, group of sequentially laid detectors (in one room for
example) second and a detector with the greatest obscuration over a period of time
third.
i) Any time, the operator shall have following manual capacities at fire alarm panel
under password control:
 Operator privileges & ID number of upto four digits shall be assignable only by
the main operator or designated official.
 Action taken by operator shall be automatically printed on FAP printer with
operator initial, date and time.
j) The panel shall also be able to actuate switches automatically in case of fire
condition that of AHUs and power supply or other systems. The bidder will be
required to design and install the system in operation in coordination with the
associate contractor for air conditioning / other work. The bidder will not be
allowed to charge extra on this account, and such charges shall be included in his
package.
k) The system shall be fail safe and adequate safe guards should be under taken that
in the event of a failure of a part of the system it shall not handicap the complete
system. The mother board shall be of modular construction.
l) The Bidder shall undertake the responsibility of the complete installation,
commissioning, user trials, training and maintenance of the system as required.
The software shall be such so as to be easily operated by the departmental
Personnel, is secured against Software errors, ability to be upgradable so as to
incorporate more detector units or replacement / changing of detector units, can
incorporate more features at a later date such as illumination control, security etc.
m) It shall be able to withstand temperature variations from 0 degree to 49 degree
Centigrade. The acceptable Relative Humidity (non condensing type) shall be upto
93%. The voltage rating shall be from as per OEM, though the voltage may be
changed depending upon the working voltages of a proprietary fire alarm panel.
n) The panel shall be totally enclosed dust and vermin proof type made of suitable
gauge dust inhibited sheet with finish. The panel shall be of completely solid state
design.
o) The logic circuitry shall be based on high noise immunity solid state hardware
employing modular construction. Logic cards shall be of epoxy fiber glass
construction.
p) The system shall meet the BS / NFPA 71 & 72 standards and shall be listed with UL
/ EN (Latest Versions).
q) Further, the system shall be expandable.

PAGE - 874
7.2 INTELLIGENT ADDRESSABLE MULTI SENSOR DETECTOR
a) The detector shall have both optical and thermal sensor and shall be capable of
working in combined mode (Optical + Thermal) or heat mode (only Thermal) or
smoke mode with inbuilt fault isolator / isolator base.
b) The combined modes of operation both the inputs from the optical and thermal
sensors are processed using special algorithms before an alarm decision are made.
If the presence of smoke is detected above a threshold value for a period of time or
if heat sensor temperatures rise above certain fixed temp or rate of rise, than an
alarm condition will be generated. In “heat only” mode only temperature above
certain fixed level will generate an alarm conditions.
c) The microprocessor design shall be capable of selecting the appropriate sensitivity
levels based on the environment type it is in (office, kitchen etc.) and then have the
ability to automatically change the setting as the environment changes in order to
avoid nuisance alarm.
d) The multi sensor detector shall be a combination of smoke & heat and it can be used
as a smoke detector, as a heat detector or as a combined smoke/heat detector upon
demand and is programmed and set-up specifically for the environmental
conditions that it is part of. It should detect smoldering and open fires at an initial
stage by being able to detect and evaluate the characteristics of fire and smoke
(Tyndall or relevant applicable principle) as well as heat (NTC sensor / thermistor
principle). The sensitivity of the detector can be adjusted, if required as per site
conditions.
e) The multi sensor detector shall activate on receiving smoke particles in the 0.5
to 10 micro meter range or as manufactured specified. The detector shall be
completely solid state with LED indication.
f) The detector shall be able to sense incipient fire by detecting the presence of visible
and invisible products of combustion. The detector shall be suitable for low voltage
two wire supply as per OEM. The sensitivity of the detector shall not vary with
change in ambient temperature, humidity, pressure and voltage variation.
g) Neither its performance shall be affected by air current upto 10 mtr. per second.
The detector shall be suitably protected against dust accumulation / ingress and it
shall be free from maintenance and functional test at intervals. All detectors shall
be identical in construction design and characteristic to facilitate easy replacement.
The detector housing shall be damage resistant made of polycarbonate or
proprietary self extinguishing material.
h) The coverage per detector shall be as listed with UL / EN. This coverage area will
reduce depending upon structural configurations or partitions etc. The sensitivity
of detector shall be set adjusted by the supplier to suit the site requirement.
i) The multi sensor detector shall be intelligent addressable detector with electronic
addressing or manually-set digital code and be able to give intelligent output to the
fire alarm panel regarding its condition.
j) The Base of the detector shall be interchangeable with other detectors and the
construction shall be of polycarbonate or any approved flame retardant material.
The enclosure shall at least meet IP 54 protection grade.
k) It shall be able to withstand temperature variations from 0 degree Centigrade to
50 degree Centigrade. Relative humidity (non condensing type) upto 93% shall not
hamper its performance. The voltage rating shall be from as per OEM, though the
voltage may be changed depending upon the working voltages of a proprietary Fire
Alarm Panel.

PAGE - 875
 l) The Detector shall meet the requirements of UL / EN and be approved by UL / EN.
It shall be possible to test the detector’s working both from the Panel as well as
locally by means designed by the bidder.

7.3 ADDRESSABLE MANUAL CALL POINT

Manual Call Station shall be of Pull / Push down Resettable type units and inbuilt fault
isolator or isolator module, completely encased in a cast aluminium housing or in 16
gauge MS / LEXAN / Polycarbonate, with provision for cable or conduit coupling. The
Manual call station shall have the word prescribed in clear bold letters on facia window
“In Case of Fire / Push In / Pull Down / as per OEM”. Its casing shall be of red color:
The Manual Call Box Station shall be fully addressable with its own set code and
operated by digitized signals sent from the Panel. The Voltage range shall be as per
OEM. It shall have protection as per IP 54 for indoors & IP 65 enclosure for outdoor
applications. The operating temperature range shall be from 0 degree C to 50 degree C.
Relative Humidity (non condensing) range for performance parameters shall be
between 0 to 93%.

7.4 ADDRESSABLE HOOTER CUM STROBE

The wall mounted Hooters cum Strobe and inbuilt fault isolator or isolator module,
shall be suitable for indoor and outdoor application with adjustable sound level of 90
db to 120 db at 1M distance. Strobe shall be of red colour. It shall flash at 1Hz over the
strobe’s entire operating voltage. The Hooters cum Strobe shall be addressable and
loop powered.

7.5 ADDRESSABLE DUCT SMOKE DETECTOR

The smoke detector housing shall accommodate an intelligent photoelectric detector,
of that provides continuous intelligent monitoring and alarm verification from the
panel. The Duct Casting Units shall be directly installed in the air conditioning ducts
(Return air) for detecting any hazardous quantity of products of combustion being
carried through the ducts.
The complete unit shall consist of a housing to accommodate Photo Electric Detector
with plug - in facility and sampling tubes, one for air inlet and other as the air outlet.
The Inlet tube shall extend into and across the duct width (from 0.5 meter to 3.0 meter),
the outlet tube shall be of fixed length of 7.5 cm length.
When the AHU blower fan operates, a continuous cross sectional sampling of air from
the duct shall flow through the housing containing the Detector. The outlet tube shall
return the sampled air into the duct.
The housing shall be mounted outside the duct; the probe tubes shall be inserted
through the duct by cutting precision sized holes into the duct and sealed with rubber
gaskets.
7.6 ADDRESSABLE NETWORK REPEATER PANEL
The Network Repeater Panel shall be provided to display all system intelligent points
(Devices). It shall be capable of displaying all information for all points (devices) on the
network.
Network repeater panel shall have with minimum 320-character LCD (minimum) touch
screen coloured LCD display / HMI Display with touch sensor. It shall be possible to

PAGE - 876
 silence alarms, evacuate and reset.

7.7 ADDRESSABLE MOTORISED AUTO ALIGN BEAM DETECTOR

a) Addressable motorised auto align type linear optical beam smoke beam detector
having control panel at low height designed to operate as components of fire alarm
systems. It should be the combination of transmitter/receiver units that can be
connected to a detector loop.
b) The Infra-Red transmitter generates a beam of light towards a high efficiency
reflector. The reflector returns the beam to the receiver where an analysis of the
received signal is made. The change in the strength of the received signal is used to
determine the alarm condition.
c) The sensitivity of the detector can be set to between 25% and 60% obscuration,
providing application flexibility to suit the environment in which the detector will
be installed. In addition to four fixed value alarm thresholds, there are two variable
thresholds that automatically compensate for changes in the environment which
could otherwise result in unwanted alarms while remaining within a known
sensitivity range.
d) The detector incorporates automatic drift compensation, whereby the detector will
adjust its detection thresholds in line with any long term signal reduction of the
beam caused by contamination of the optical surfaces.
e) Different alert for Fault and Fire condition.
f) The detector can be adjusted up to 10 degrees vertically and horizontally for
alignment. Where greater angular adjustment is required, the multi-mount
accessory will be provided.
g) The detectors have a range of 9 m to 50m, extending to 100m with a long-range
reflector kit.
a. Tested and approved to FM / LPCB / UL / BS / VdS
b. Voltage Range As per OEM
c. Temperature Range (Nominal Range) 0 deg C to (+) 50 deg C
d. Humidity (Nominal Range) 10 to 93% RH (non-condensing)

7.8 MODULES
7.8.1 MONITOR MODULE (FOR INPUT TO FIRE ALARM PANEL)
The Input Device and inbuilt fault isolator or isolator module shall provide an
addressable input for N.O. or N.C. contact devices such as manual water flow switches,
pressure switches, etc. The input device shall provide a supervised initiating circuit.
An open-circuit fault shall be annunciated at the Fire Alarm panel (Subsequent alarm
shall be reported.) The device shall contain an LED which blinks upon being scanned
by the Fire Alarm panel. Upon determination of an alarm condition, the LED shall be
latched on. The operating voltage shall be in the range of 15 to 32 VDC, Maximum
current draw 5.0 mA (LED on).

7.8.2 CONTROL MODULE (FOR OUTPUT FROM FIRE ALARM PANEL)

The control module and inbuilt fault isolator or isolator module shall provide an
addressable output for a separately powered alarm indicating circuit or for a control
relay. The control module shall provide a supervised indicating circuit where indicated
on the plans. An open circuit fault shall be annunciated at the Fire Alarm panel.

PAGE - 877
 The Output Device shall provide a control relay where indicated on the plans. The relay
contacts shall be SPDT rated at one amps / as per OEM, 24 V DC. The device module
shall contain an LED which blinks upon being scanned by the Fire Alarm panel. Upon
activation of the device, the LED shall be latched on.

8.0 Fire Cable

Multi core Copper conductor cable shall be PVC insulated, FRLSZH type
conforming to BIS specification.

9.0 TESTING

9.1 RANDOM SAMPLE TESTING:

About 5% of all fire alarm components shall be subjected to random testing by
connecting to the panels. All smoke detectors shall be tested as given above and later
cleaned with a vacuum cleaner. Hooters shall also be tested through direct 24V supply
for 10 minutes.
9.2 TESTING OF EARTHING SYSTEM:
The earth continuity conductor including metallic parts of the equipments shall be
tested for earth to electrical continuity. All tests shall be carried out as per IS 3043 and
resistance of complete installation shall not be more than one ohm.
9.3 TESTING AT SITE:
Following testing shall be conducted: -
a. Loop Checking
b. Checking of smoke detectors, Heat detectors etc. by simulation.
c. Functional tests for fire alarm panel.
d. The Mock trial of the complete Fire Detection and Alarm system.

10.0 COMMISSIONING AND ACCEPTANCE TESTS

The commissioning and acceptance tests shall be apart from the standard or routine
tests prescribed and normally conducted by the manufacturer / Design- Build
Contractor and will be irrespective of the fact whether the same are covered by such
tests or not. All commissioning tests at site will be in line with NFPA 71 and 72.
a. Each sounder circuit shall be energized separately and the sound level reading
taken to check for conformity with the minimum standards.
b. Mains failure performance.
c. Battery disconnection test.
d. Open circuit of each sounder circuit to be tested.
e. Short circuit of each sounder circuit to be tested.

The results of the above tests either by fault warning or fire alarm shall be recorded in
the log books which will be signed both by the Contractor and the AAI’s Representative.

PAGE - 878
11.0 ASPIRATING SMOKE DETECTION SYSTEM
11.1 Scope of Work
Note: System shall be designed for high ceiling areas of Terminal Building and
critical areas i.e. ATC, Server / Equipments rooms etc.
This specification covers the requirements of design, supply of materials, installation,
testing and commissioning of Aspirating Smoke Detection System. The system shall
include all equipment’s, appliances and labour necessary to install the system,
complete with highly sensitive Smoke Detectors with aspirators connected to network
of sampling pipes.
11.1.1 The Bidder shall also make provision in the Aspirating Smoke Detectors to give trip
alarm to trip AHU and to shut fire dampers in the event of fire through the relay
contacts.

11.2 Codes and standards

The entire installation shall be installed to comply one or more of the following codes
and standards:
NFPA Standards-75 / 76 / 72
British Standards, BS 12839 part: 1

11.3 Approvals
All the equipments shall be designed, tested, approved or listed by: LPCB
(Loss Prevention Certification Board), UK /
FM (Factory Mutual), US /
UL (Underwriters Laboratories Inc.), US /
ULC (Underwriters Laboratories Canada) / Canada VDS (Verband der
Sachversicherer e. V), Germany

11.4 Design Requirements

11.4.1 System shall be designed and validated by OEM or its authorized System Integrator and
shall submit the detailed flow modeling calculation report from UL / EN listed software
tools for design validation of system.
11.4.2 The System shall consist of a highly sensitive smoke detector, aspirator, and filter.
11.4.3 It shall have a display featuring LCD / LEDs and Reset / Isolate button. The system shall
be configured by a programmer that is either integral to the system, portable or PC
based.
11.4.4 The system shall allow programming of:
a) Multiple Smoke Threshold Alarm Levels.
b) Time Delays.
c) Faults including airflow, detector, power, filter block and network as well as an
indication of the urgency of the fault.
d) Configurable 4 relay outputs for remote indication of alarm and fault Conditions.
11.4.5 It shall consist of an air sampling pipe network to transport air to the detection system,
supported by calculations from a FM approved computer- based design modeling tool.
Maximum transport time shall not exceed 90 seconds.
11.4.6 Optional equipment may include intelligent remote displays and/or a high level
interface with the building fire alarm system and a dedicated System Management
graphics package.

PAGE - 879
11.4.7 Performance Requirements
a) Shall provide very early smoke detection and provide multiple output levels
corresponding to Alert, Action, Fire 1 & 2. These levels shall be programmable and
shall be able to set sensitivities ranging from 0.0015– 20% obscuration / meter.
b) Shall report any fault on the unit by using configurable fault output relays or via
the graphics Software.
c) Shall monitor for filter contamination automatically.
d) Shall incorporate a flow sensor in each pipe and provide staged airflow faults.
e) Shall have a clean air supply to maintain chamber clean all the time.

11.5 Materials and Equipment’s

11.5.1 Both Light Scattering and Particle Counting shall be utilized in the device as follows:
The detection Chamber shall be of the mass Light Scattering type and capable of
detecting a wide range of smoke particle types of varying size. A particle counting
method shall be employed for the purposes of
a) Preventing large particles from affecting the true smoke reading.
b) Monitoring contamination of the filter (dust & dirt etc.) to notify
automatically when maintenance is required.

11.5.2 The Detection Chamber shall incorporate a separate secondary clean air feed from the
filter; providing clean air barriers across critical detector optics to eliminate internal
detector contamination.
11.5.3 The detector shall not use adaptive algorithms to adjust the sensitivity from the set
values during commissioning. A learning tool shall be provided to ensure the best
selection of appropriate alarm thresholds during the commissioning process.

11.6 Detector Assembly

11.6.1 The Detector, Filter, Aspirator and Relay Outputs shall be housed in a mounting box
and shall be arranged in such a way that air is drawn continuously from the fire risk
area by the Aspirator and a sample passed through the Dual Stage Filter and then to the
detector.
11.6.2 The detector shall have an obscuration sensitivity range of 0.0015 – 20% obscuration
per meter.
11.6.3 The detector shall have four independent field programmable smoke alarm thresholds
across its sensitivity range
11.6.4 The Detector shall also incorporate facilities to transmit the following faults
a) Detector
b) Airflow
c) Filter
d) System
e) Zone
f) Network
g) Power
h) Urgent and Minor faults. Minor faults shall be considered as servicing or
maintenance signals. Urgent fault shall indicate that the unit may not be able to
detect.

PAGE - 880
11.6.5 The detector shall have four pipe inlets which must contain a flow sensor. Both Minor
and Urgent flow faults shall be reported.
11.6.6 The filter must be a two-stage disposable filter cartridge. The first stage shall be capable
of filtering particles in excess of 20 microns from the air sample. The second stage shall
be ultra-fine, removing more than 99% of contaminant particles of 0.3 microns or
larger, to provide a clean air barrier around the detector’s optics to prevent
contamination and increase service life.
11.6.7 The aspirator shall be a purpose-designed rotary vane air pump. It shall be capable of
allowing / supporting for a single pipe run / multiple sampling pipe runs with a
transport time of less than 90 seconds.
11.6.8 The Assembly must contain relays for fire alarm and fault conditions.
The relays shall be software programmable (latching or non-latching). The relays
must be rated at 2 A at 30V DC. Remote relays shall be offered as an option and either
configured to replicate those on the detector or programmed differently.
11.6.9 The Assembly shall have built-in event and smoke logging. It shall store smoke levels,
alarm conditions, operator actions and faults. The date and time of each event shall be
recorded. Each detector (Zone) shall be capable of storing up to minimum 18,000
events.

11.7 Displays on theDetector Assembly

11.7.1 The detector shall have a LCD / LED / Bar graph display for the multiple alarm
threshold levels indicated and faults such as detector fault, airflow fault and indication
for Isolate and Reset.

11.8 Programmers
11.8.1 Programmer module may be located within the detector, or in remote mounting box.

11.8.2 Each Programmer at a minimum shall support the following features:

a) Programming of any device on the system.
b) Viewing of the status of any device in the system.
c) Adjustment of the alarm thresholds of a nominated detector.
d) Setting of Day/night, weekend and holiday sensitivity threshold settings.
e) Initiation of Auto Learn, to automatically configure the detectors alarms threshold
settings to suit the current environment.
f) Multi-level password control.
g) To Program latching or non-latching relay operation.
h) To Program energizing or de-energizing relays.
i) To Program high and low flow settings for airflow supervision.
j) To Program aspirator speed control.
k) To Program maintenance intervals.
l) Facilities for referencing with time dilution compensation.
m) Testing of relays assigned to a specific zone to aid commissioning.

11.9 Network
The devices in the smoke detection system shall be capable of communicating with each
other via twisted pair RS4812 cable. The network shall be able to support up to 2120
devices (detectors, displays units and programmers), of which at least 100 detectors
can be supported.

PAGE - 881
 The network shall be capable of being configured in a fault tolerant loop for both short
circuit and open circuit. Any communication faults shall be reported unambiguously
and shall be clearly attributable to an individual device or wire link in the fault
messages.

PC based configuration tools shall be available to configure and manage the network of
detectors.

Digital Communication Port shall comply with EIA RS4812 Protocol.

11.10 System Manager Graphic Software for Complete MONIOTIRING and Control of Very
Early Warning Smoke Detection System:

The software package shall centrally monitor and configure very early warning smoke
detection and fire protection systems in multiple local or remote locations.
The software package shall be compatible with smoke detection and fire protection
systems that are approved by global approvals bodies and meet all local codes,
standards and regulations.
The software shall consist of monitoring and configuration components:
The configuration component shall allow users to configure all detectors remotely by
using a connected PC.
The monitoring component shall allow users to monitor individual detectors, multiple
detectors connected via a HLI (High Level Interface) or multiple HLIs.

11.10.1 System Description

11.10.1.1 Access and Usability
The software shall support local and remote password-based access control: Three
local password-protected levels of software access: designer, user and
administrator.
Multiple user accounts with unique user-ID and password based access control.
Remote password-management of remote fire networks
The software shall have a user-friendly graphics user interface.
The software shall support cut and paste functionality for common tasks. The
software shall provide support for multiple languages including English.
The software shall support translations of messages from one supported language to
another. The software shall support disk space monitoring.

11.10.1.2 Monitoring Functionality

The software shall have the capacity to monitor multiple connections: The software
shall enable one or more workstations to monitor and configure multiple detector
systems in multiple buildings and multiple sites.
The software shall provide an event list that provides a single integrated view of all
events (faults / troubles and alarms) across multiple sites.

The software shall prioritize all events presented in the event list according to logical
precedence rules.

The software shall allow management of all events from the event list including

PAGE - 882
acknowledgement of events and resetting of devices.
The software shall allow colors to be assigned to different event types. The software
shall allow printing of event lists.

The software shall be able to provide an all-in-one monitoring solution:

Using standard RS232 ports (or Ethernet) on existing and future monitoring and
control systems, PCs using the software shall connect to and interpret status change
data transmitted from the ports and provide graphic annunciation, control, history
logging and reporting as specified herein.
Network systems that cannot interface to Network systems or systems requiring the
use of a “dry contact” or “voltage monitoring” interfaces to connect to Network shall
not be accepted.

The software shall be able to connect to multiple remote sites via IP- based LAN or
WAN using virtual serial port emulation. The software shall communicate with one
or more Network-compliant detectors via a high level interface (HLI) natively using
the Network protocol without the necessity for using protocol translation or other
communications equipment. The software shall be able to monitor up to 2120
devices. The software shall be compatible with 4 alarm levels:

Alert (Alarm Level 1) – may be used to activate a visual and audible alarm in the fire
risk area.

Action (Alarm Level 2) – may be used to activate the electrical/electronic equipment

shutdown relay and activate visual and audible alarms in the Security Office or other
appropriate location.

Fire 1 (Alarm Level 3) – may be used to activate an alarm condition in the Fire Alarm
Control Panel to call the Fire Brigade and activate all warning systems.
Fire 2 (Alarm Level 4) – may be used to activate a suppression system and/or other
suitable countermeasures (e.g. evacuation action or shutdown of systems).

The software shall allow importation of .wav files for event notification.
The software shall have a text-to-speech option to allow natural language
annunciation of all faults and alarms:
The text-to-speech component of the software shall use Nuance’s Real Speak speech
engine.

The text-to-speech functionality shall be available in a number of different languages.

The software shall support sophisticated floor plan development and management
functionality:

The software shall enable floor plan drawings to be used in the software to
graphically notify users where a smoke event is occurring in their monitored system.

PAGE - 883
 The software shall allow development of multiple levels of interconnected floor plans.

The software shall allow importation of AutoCAD, jpg, bmp and other common image
files.

The software shall include software to allow designers to create and manipulate CAD
images for incorporation in meaningful context- sensitive multi-level floor plans the
software shall allow for multiple device smoke trending on a single graph. The
software shall support printing on a printer such as a line printer that supports
Unicode.

The software shall support sophisticated event log management functionality: Event
logs from all networked detectors shall be able to be retrieved and viewed. Event logs
for each monitored site and / or combined event logs for multiple sites.

Event logs shall be able to be archived and sorted

Total event integration, consolidation and archiving across multiple networks shall
be provided. All system, network and device events shall be stored in an ODBC-
compliant database.

A remote notification facility shall enable the use of email (or SMS) to provide
immediate and up-to-date information the system’s operational status irrespective of
location.

The software shall enable presentation of unique customized corporate response

procedures upon occurrence of specific events in defined parts of the facility

11.10.1.3 Configuration Functionality

The software shall allow configuration of all models of detectors: Full remote
programming of all detector functions. Saving of detector configurations for safe
storage.

The software shall allow creation of off-line configurations for all such detectors and
allow a merge and compare of off-line configuration with on-line configurations.

11.10.1.4 Performance Requirements

The software shall operate on either Windows 2000 Professional or Windows XP

Professional.

The software shall function on the following minimum PC specifications: Processor –

Pentium. Minimum configuration: P4 2.8 GHz 1MB cache RAM – 2 GB

Hard Disk – 1 by 80 GB system Disk; 2 by 80 GB if connected to Raid Storage Display –

Preferred: Dual Monitor AGP Card with 2126 MB memory. Minimum: Single Monitor
128 MB memory.

PAGE - 884
11.11 Sampling Pipe (UL / LPCB listed pipes)

11.11.1 The sampling pipe shall be smooth bore with outer dia. of 25 mm. and inner diameter
of 21mm.
11.11.2 The pipe material should be suitable for the environment in which it is installed, or
should be the material as required by the specifying body.
11.11.3 All joints in the sampling pipe must be air tight and made by using solvent cement,
except at entry to the detector.
11.11.4 The pipe shall be identified as Aspirating Smoke Detector Pipe along its entire length
at regular intervals not exceeding the manufacturer’s recommendation or that of local
codes and standards.
11.11.5 All pipes should be supported at not less than 1.12 m at centres, or that of the local
codes or standards.
11.11.6 The far end of each trunk or branch pipe shall be fitted an end cap and drilled with a
hole appropriately sized to achieve the performance as specified and as calculated by
the system design.

11.12 Sampling Holes

11.12.1 Sampling Holes of 2mm, or otherwise appropriately sized holes, shall not be separated
by more than the maximum distance allowable for conventional detectors as specified
in the local codes & standards. Intervals may vary according to calculations.
11.12.2 Each sampling point shall be identified in accordance with Codes or Standards.
11.12.3 Consideration shall be given to the manufacturer’s recommendations and standards
in relation to the number of Sampling Points and the distance of the Sampling Points
from the ceiling and roof structure and forced ventilation systems.

11.13 Installation
11.13.1 The Contractor shall install the system in accordance with the manufacturer’s
recommendation.
11.13.2 Where false ceilings are available, the sampling pipe shall be installed above the
ceiling and Capillary Sampling Points shall be installed on the ceiling and connected
by means of a capillary tube.
11.13.3 The minimum internal diameter of the Capillary tube shall be 12mm, the maximum
length of the capillary tube shall be 2m unless the manufacturer in consultation with
the engineer have specified otherwise.
11.13.4 The Capillary tube shall terminate at a ceiling Sampling Point specifically approved
by AAI. The performance characteristics of the sampling points shall be taken into
account during the system design.
11.13.5 Air Sampling Piping network shall be laid as per the approved pipe layout. Pipe work
calculations shall be submitted with the proposed pipe layout design for approval.

PAGE - 885
 11.14 Testing
11.14.1 Commissioning Test
11.14.1.1 Commissioning of the entire installation shall be done in presence of AAI
representative.
11.14.1.2 All necessary instrumentation, equipment, materials and labour shall be provided by
the Contractor.
11.14.1.3 The Contractor shall record all tests and system calibrations and a copy of these
results shall be retained on site in the system Log Book.

11.14.2 Functional Test

11.14.2.1 Introduce Smoke into the Detector Assembly to provide a basic functional test.
11.14.2.2 Introduce smoke to the least favorable Sampling Point in each Sampling Pipe.
Transport time is not to exceed 90 Secs.

PAGE - 886
SECTION-12… FIRE FIGHTING SYSTEM (AUTOMATIC SPRINKLERS AND HYDRANT
SYSTEMS)

FIRE FIGHTING SYSTEMS

This section deals with the requirements of provision of fire fighting
services. The pumps, prime movers & Control panels etc. shall be installed
in the pump house. Following is the broad scope of work:
 Automatic Fire Hydrant System
 Automatic Sprinkler System
 Water curtain pumps
 Terrace Pumps
 Fire Extinguisher
 Pumps & prime movers
 Electrical panels etc.
The manufacture, material and testing of equipment covered in this
specification shall comply with the latest editions as on date of opening of
tenders of the appropriate standards given below and mentioned
subsequently. Unless otherwise specified, CPWD General Specifications for
Wet Riser & Sprinkler System 2020 with upto date Amendments and Indian
Standards are preferred. All the appliances and accessories shall carry IS or
International certification as applicable and shall be of approved make.
IS: 1239 Mild steel, black ERW pipes up to 150 mm dia, with fittings.
IS: 3589 Mild steel, black ERW pipes 200 mm dia and above, with fittings.
IS 4984 HDPE pipes
IS 4985 PVC pipes
IS: 10221 Code of practice for coating and wrapping of underground mild steel
pipelines
IS: 823 Welding procedure
IS: 2062 Steel for General Structural Purposes
IS: 780 Cast iron sluice valve
IS: 903 Nozzle, Branch pipe, Female and Male couplings (Gun metal)
IS: 5290 Fire hydrant valve, gunmetal with cap & GI chain.
IS: 908 Fire hydrants
IS 13095 Butterfly valve
IS: 5312 Non return valve
IS: 636 RRL hose pipe
IS: 884 First aid hose reel
IS: 325 Induction motors
IS: 900 Installation of motors
IS: 694 PVC insulated cables (light duty) for working voltage upto 1100
volts.
IS: 1554 PVC insulated cables (heavy duty) for voltage upto 1100 volts.
IS: 1554 — do — for voltage 3.3 kV to 11 kV

PAGE - 887
 IS: 5959 Specification for polyethylene insulated PVC sheathed heavy-duty
electric cables, voltage not exceeding 1100 V
IS: 5959 — do — voltage 3.3 kV to 11 kV
IS: 5578 Guide for marking of insulated conductors
IS: 1255 Code of practice for installation and maintenance of power cables.
IS: 3043 Code of practice for earthing.
IS: 5216 Guide for safety procedures and practices in electrical work.
IS: 7098 XLPE insulated cables

CPWD General Specifications for Wet Riser & Sprinkler System 2006 with upto
date Amendments.
1.0 Scope of work
The scope of work shall cover the design, selection of proper equipments,
engineering, supply, installation, testing, commissioning, performance
demonstration etc. of all the equipments as required as per best engineering
practices at site and shall include provision of the scope of work as described in
schedule of quantities enclosed.
1.1 Designs, Drawings and technical submittal:
a) After Award of the Work:
On the basis of GFC drawing issued by department with soft copy, the Contractor
shall submit 03 (Three) sets of shop drawings, pump selection etc for the entire
pumping installations to be provided under this contract along with supporting
calculations, charts etc, and proposed General Arrangement drawings for major
equipments for Fire Hydrant and Sprinkler Systems within 30 (Thirty) days for
approval of AAI before proceeding with the work. The contractor shall also
furnish all clarifications and explanations as may be desired by AAI promptly for
early finalization of the design.
The work to be executed as per approved shop drawings &
technical submittal/specification.
b) On Completion of Work:
The contractor shall submit 4 (Four) sets of O & M manuals for Hydrant and
Sprinkler System including pumps, motors, diesel engines, MCC panels, Circuit
Diagram, Manufacturers technical catalogues, detailed specifications of items
provided along with soft copy of As-built drawings and copies of Test
Certificates of all major equipments duly bound in neat and presentable booklet
forms within 30 days of completion of the work.
1.2 Approval by local fire service
It shall be the responsibility of the contractor to get the approval in stages from the
Local Fire Service as required. This shall be without any liability to the Engineer-in-
charge.
On successful completion of work, the contractor shall incorporate all changes as

PAGE - 888
 approved by the fire service department that might have been effected during
execution of the work in as –built drawings.
On completion of work, the contractor has to obtain necessary approval from Local
Fire Services as required by submitting necessary completion certificates, drawings,
equipment details, test results, etc. before energization.
1.3 Coordination
The Contractor shall be required to co-ordinate his activities with all other agencies
executing Air Conditioning, Electrical, Civil and other works at site.
1.4 Civil Works
All associated civil works are included in Contractor’s scope of work unless
otherwise specified. Civil works like excavation for pipe laying underground with
pedestal supports or chase cutting in the wall/ceiling or making hole in the RCC
floor/ceiling or in brick wall for piping, grouting etc. including making good the
same after completion, small size pedestals or any other minor civil works required
in connection with the installation of the system are included in the scope of work
of this contract.
Foundation for pumps, panels and other installations as required in pump room is
also in the scope of contractor. The rates quoted by the agency shall be inclusive of
all the above scope of work. Hence nothing extra shall be paid on this account.
2.0 PIPING
2.1 The scope of this section comprises the Supply, Laying, Erection, Testing and
Commissioning of pipes required for this work.
2.1.1 All piping laid shall be black steel unless otherwise stated. Pipes shall be given one
primary coat of red oxide paint before being installed. Pipes and jointing shall be as
follows:

Pipe Size Material Jointing Method

Upto 50mm MS tube heavy class as Fittings with threaded /
per IS-1239 screwed joints

65mm to MS tube heavy class as Fittings with Welded Joints

150mm per IS-1239/ Slip on flanges

200mm to Welded MS class-2 as per Fittings with Welded Joints

350mm IS- 3589 Thickness- Slip on flanges
6.35mm/
Pipe threads and flanges shall be as per IS.
2.1.2 All Fittings shall be new and from list of approved makes, Fittings shall be of
malleable castings of pressure ratings suitable for the piping system. Fittings used
on welded piping shall be of the weld-able type.
2.1.3 Flanges shall be new and from list of approved makes and as per I.S.6392- 1971,
Table 17 with appropriate number of G.I. Washers, Nuts and Bolts, with minimum 3
mm insertion neoprene gasket complete. Flange thickness shall be as under:

PAGE - 889
 Pipe dia Flange Thickness
200 mm 24 mm
150 mm and 125 mm 22 mm
100 mm and 80 mm 20 mm
65 mm 18 mm
40 mm and below 16 mm
2.1.4 Tee off connection shall be through reducing tees, wherever possible. Otherwise
ferrules welded to the main pipe shall be used. Drilling and tapping of the walls of
the main pipe shall not be resorted to.
2.1.5 All equipment and valve connections shall be through flanges (Welded or screwed
for galvanized steel)
2.1.6 All welded piping is subject to the approval of the Engineer in charge. Sufficient
number of flanges and unions shall be provided.

2.2 PIPING INSTALLATION

2.2.1 The drawings indicate schematically the size and location of pipes. Pipes runs and
sizes may, however, be reviewed to meet the site conditions. The Contractor on the
award of the work shall prepare detailed working drawings showing the cross
section, longitudinal section, detail of fittings, locations of isolating drain and air
valves etc. They must keep in view the specific openings in buildings and other
structures through which the pipes are designed to pass.
2.2.2 Piping shall be properly supported on or suspended from stands, clamps, hangers
etc, as specified and as required. The tenderer shall adequately design all the
brackets, saddles, clamps, hangers etc. and be responsible for their structural
integrity. Shop Drawings of all proposed supports to be submitted for approval
before execution of work.
2.2.3 Pipe supports shall be of steel, adjustable for height and primer coated with rust
preventive paint and finish coated black. Where pipe and clamp are of dissimilar
material, a gasket shall be provided in between. Spacing of pipe supports on main
headers shall not exceed 3.0 meters in any case, and additional supports shall be
provided on all bends, tees, and valves etc as per requirements. For the Sprinkler
branching, the pipe supports shall be installed as per I.S. 15105.
Pipe hangers shall be fixed on walls and ceiling by means of metallic rawl plugs.
Pipe supports in pump house shall be floor mounted and of mild steel / GI spacing
of pipe supports shall not be more than that specified below: -

Nominal Pipe Size (mm) Spacing (m.)

20 and 25 2.00
32 to 125 2.50
150 and above 3.00
Extra supports shall be provided at the bends and at heavy fittings like valves to
avoid undue stress, on the pipes.

PAGE - 890
2.2.4 Vertical risers shall be parallel to walls and column lines and shall be straight and
plumb. Risers passing from floor to floor shall be supported at each floor by clamps
or collars attached to pipe and with a 12mm thick rubber pad or any other approved
resilient material. Where pipes pass through the terrace floor, suitable curbing shall
be provided to prevent water leakage. Risers shall also have a suitable concrete pipe
support at the lowest point.
2.2.5 Pipe sleeves of diameter larger than the pipe by least 50mm shall be provided
wherever pipes pass through walls and the annular spaces shall be filled with felt
lead wool and finished with retaining rings.
2.2.6 Piping work shall be carried out with minimum disturbance to the other works
being done at the site. A program of work shall be chalked out in consultation with
the Engineer-in-charge.
2.2.7 In pipe above ground level, expansion loops or joints shall be provided to take care
of expansion or contraction of pipes due to temperature changes.
2.2.8 All pipes using screwed fittings shall be accurately cut to the required sizes and
threaded in accordance with IS: 554 and burrs removed before laying. Open ends of
the piping shall be locked as the pipe is installed to avoid entrance of foreign matter.
Wherever reducers are to be made in horizontal runs, eccentric reducers shall be
used if the piping is to drain freely, in other locations, concentric reducers may be
used.
2.2.9 To facilitate detection of leak and isolation of defective portion of pipe, valves shall
be provided in underground pipe at suitable locations. As far as possible such valves
shall be provided over ground. If the valves are to be provided below ground,
suitable masonry chamber with cover plate shall be provided. Locations where
vehicles can pass shall be avoided for provision of valve below ground.
2.2.10 Contractor shall provide suitable cement concrete, anchor blocks of adequate
dimensions as per spacing mentioned above & at all bends, tee connection and other
places required and necessary for overcoming pressure thrusts in pipes wherever
pipes are installed underground. Anchor blocks shall be of cement concrete 1:2:4
mix (1 cement: 2 coarse sand: 4 stone aggregate) 20 mm nominal size.

2.3 PIPE PROTECTION

2.3.1 All pipes above ground and in exposed locations shall be painted with one coat of Red
Oxide Primer immediately after bringing the pipes to site and shall be painted with
one coat of red oxide primer after erection & proper hydraulic testing and two or
more coats of Synthetic Enamel Paint of approved shade on finishing.
All black steel pipes under floors or below ground shall be provided with protection
against corrosion after proper hydraulic testing by application of 100mm wide and
4mm thick layer of anti-corrosive protection tape over the pipe, with overlap of
25mm minimum as per manufacturers specifications.

PAGE - 891
2.3.2 Where pipes are buried under ground, after treated, the same shall be back filled
with the excavated soil. The top of the pipes shall not be less than 100cms below the
ground level. Where this is not possible, the permission of Engineer-In – charge shall
be obtained for burying the pipes at lesser depth. Underground pipe shall be laid at
least 2M away from the face of the building preferably along the roads and footpaths.

2.4 INSPECTION AND TESTING-Hydrant System

2.4.1 Inspection – General
All site fabricated work / material shall be subject to inspection in cleaned condition,
prior to erection. At no event, site fabricated work / material shall be installed in
position without inspection and approval by AAI. The Contractor shall ensure that
each stage of fabrication is carried out in compliance with the procedures specified
in the IS / NBC standards as applicable and / or specified in this document.
The contractor shall conduct sample tests of all the materials supplied at reputed
laboratories / agencies as directed by AAI at his own cost and test reports are to be
submitted. Inspecting officials of AAI and Local Authorities shall have the right to
access the premises of the work at any time with or without giving prior notice. All
the formalities or procedures for conducting the inspections by the authorities as
required by them shall be arranged by the contractor free of cost.
All testing shall be carried out in the presence of AAI / statutory authorities and test
registers shall be maintained by the contractor. The contractor shall provide all
material, tools, equipment, instruments, services and personnel required to perform
the tests and remove debris / water resulting from cleaning and after testing free of
cost
The original test certificates of all tests conducted are to be submitted to AAI. After
conducting the tests, any defects found on materials, equipment, piping, etc. shall be
got rectified / repaired by the Contractor without any extra cost.
Before energizing electrically operated equipment, care shall be taken to meet the
local electrical rules and regulations, earthing of the body, verifying availability of
safe insulation resistance value, etc. Also confirm the motor enclosure to the level of
protection required for the particular application.
2.4.2 Pumps
The pumps shall be tested according to the standard recommendations of the
manufacturer. The following parameters are to be recorded and plotted and
submitted to AAI.
a. Discharge Q
b. Pressure P or Head H
c. Motor voltage and current.
d. Efficiency
The power consumption is to be computed and cross checked with manufacturer’s
data. Any abnormalities, if noted, shall be brought to the notice of the manufacturer
and necessary corrective action be taken before commissioning and handing over,
without any extra cost. Manufacturers test certificates shall also be submitted to AAI
for verification.

PAGE - 892
2.4.3 Piping
All piping shall be tested by filling water, removing air locks, foreign materials, etc.
and applying pressure at 1.5 times of the maximum working pressure and see that
the pressure drop is within 0.5 Kg per Sq. cm over a period of 2 hours.
The testing shall be carried in sections by blocking both ends or closing the valves
provided. After completion of the installation and connecting to the mains of
pumping system the installation shall once again tested and rectify breakage if any
or replace the defective material, free of cost.
At least 10% of the total weld joints on pipes shall be tested by radiography. Holiday
tests shall preferably be carried out by flexible and detachable ring probe, which shall
enable the entire 360 deg. of the surface of the pipe to be scanned.
2.4.4 Electrical system
The following tests are recommended: -
i) Earth resistance
ii) Cable Insulation
Resistance of metal conduits/sheaths (Earth continuity test)
Insulation of the cables shall be not less than one mega ohm when tested with a 500
volts meggar for any particular section of the wiring.
In case of cables encased in metal conduit or metallic sheathing, the total resistance
of the conduit or sheathing from the earthing point to any other position in the
completed installation shall not exceed 2 Mega Ohms.
Trial run and testing of diesel engine as per manufacturers standard also need to be
conducted separately.
2.4.5 Hydrant system
The entire hydrant system shall be tested in the presence of AAI to ascertain the
functioning of each system, equipment, etc. as desired by AAI. The contractor shall
hand over the system only if it is proved that the system performs as per the
specifications.
2.4.6 Operation of pumps
All the pumps shall be operated by both auto / manual modes, and shall have
automatic starting and stopping arrangements to maintain the system pressure.
Jockey pump shall not be in operation while the main pump is in operation. Under
normal conditions, the water pressure in the hydrant lines is 7 kg / sq.cm, and the
auto/manual switch shall be in the auto mode. When the pressure drop is upto 6 kg
/ sq.cm, the jockey pump shall start automatically through pressure switches
arrangements and when pressure develops to 7 kg / sq.cm the pump shall stop
automatically. The jockey and main pumps shall not be in operation simultaneously.
2.5 PAINTING
2.5.1 After the piping has been installed, tested and run for at least ten days. The piping
shall be given two finish coats of approved color.

PAGE - 893
2.5.2 The direction of flow of fluid in the pipes shall be visibly marked in white arrows or
as directed by the Engineer-in-charge.

3.0 VALVES & ACCESSORIES

Sluice valve conforming to IS: 780 or butterfly valve conforming to IS:13095 shall be
provided. All valves shall be suitable to with-stand the pressure in the system and
rating shall be PN 1.6. All valves shall be right handed (i.e. handle or key shall be
rotated clock wise to close the valve), the direction of opening and closing shall be
marked and an open / shunt indicator fitted.
3.1 SLUICE / GATE VALVES
Sluice Valves above 65 mm (inside screw and non raising screw type) shall be of Cast
Iron body and Gunmetal seat with double flanged ends and valve wheel. They shall
conform to type PN 1.6 of IS 14686. Sluice valves upto 65mm (outside screw raising
spindle type) shall be of Gunmetal Full way Valve with wheel tested to 20 Kg /cm2
class-II as per I.S: 778 with female screwed ends. Valve wheels shall be of right hand
type and have an arrow head engraved or cast thereon showing the direction for
turning open and close.

3.2 BUTTERFLY VALVES

3.2.1 The Butterfly Valve shall be suitable for waterworks.
3.2.2 The material of valves shall be as under: -
Body - Cast iron
Disc - Cast Bronze or Stainless Steel
Seat - Either integral or nitrile rubber
O-ring - Nitrile / Silicon
3.2.3 The Valve shall be fitted between two flanges on either side of pipe flanges. The
Valve edge rubber shall be projected outside such that they are wedged within the
pipe flanges to prevent leakages.

3.3 NON-RETURN VALVE

Non-return valves shall be of Cast Iron body and gun metal seat. They shall conform
to IS 5312 and have companion flanges. They shall be Dual Plate Type suitable for
both horizontal and vertical installation. An arrow mark in the direction of flow shall
be marked on the body of the valve.
3.4 AIR RELEASE VALVE
Air release valve shall be provided at all highest points in the piping system for air
vent of the double float type with G.M. body, vulcanite balls, rubber sealing, etc. Air
release valves shall be of the sizes specified and shall be associated with an equal
size forged ball valve.
3.5 BALL VALVE
3.5.1 The Ball Valve shall be made from forged brass conforming to PN 1.6. The valve shall
be internally threaded to receive pipe connections.
3.5.2 The Ball shall be made from brass and machined to perfect round shape and
subsequently chrome plated. The seat of the valve body bonnet gasket and gland
packing shall be of Teflon.

PAGE - 894
3.5.3 The handle shall be of chrome plated steel with PVC jacket. The handle shall also
indicate the direction of ‘open’ and ‘closed’ situations. The gap between the ball and
the Teflon packing shall be sealed to prevent water seepage.
3.5.4 The handle shall also be provided with a lug to keep the movement of the ball valve
within 90 degrees.
3.6 STRAINER
Strainers shall be preferably of the approved type with fabricated steel bodies.
Strainers shall be fabricated by minimum 1.0 mm thick stainless steel sheet with 3
mm dia. perforation holes. Strainers shall be provided with flanges or threaded
sockets as required. They shall be designed so as to enable blowing out accumulated
dirt and facilitate removal and replacement of screen without disconnection of the
main pipe.

3.7 PRESSURE GAUGES

Pressure gauges shall be of 150mm dia. dial with Bourdon tube element of SS 316
and of appropriate range and scale division shall be in metric unit marked in black
on white dial etc. complete with all accessories including shut off gauge valve etc.
duly calibrated before installation. Care shall be taken to protect pressure gauges
during pressure testing.
3.8 PRESSURE SWITCHES
It shall be of industrial type, single pole, double throw electric pressure switching
designed for starting or stopping equipment within the pressure of the system drops
or exceeds the pre-set limits. All switches shall have ¼” BSP (F) inlet connection and
screwed cable entry for fixing cable gland. The pressure switch shall have a rating
of 4-20 kg/cm2 with 0.8 to 3 kg. differential pressure setting. Maximum working
pressure shall be 28 kg/cm2 with auto reset.

3.9 FLEXIBLE CONNECTION FOR PUMPS

All suction and delivery lines shall be provided with double flanged reinforced
neoprene flexible pipe connectors. Connectors should be suitable for a working
pressure of each pump. Length of the connector shall be as per manufacturer’s
details.
4.0 EXTERNAL YARD HYDRANTS
4.1 The Contractor shall provide External Fire Hydrant in the Ring or on External Fire
Line as per requirement. The spacing of the hydrants and the distance from the
building shall be maintained as per latest relevant codes, unless specified.
Yard hydrants shall be located at a minimum distance of 2 m. but not more than 15
m from the building face. They yard hydrants shall be accessible and should
normally be provided near boundary wall / along road. While locating yard hydrants
it should be ensured that same do not become hindrance in vehicular movement or
entrance to the building. Yard hydrants, should be located around the building in
such a way that it should be possible to fight fire on any face of the building from the
nearest hydrant. A distance of 45m. from hydrant to hydrant will be adequate.

PAGE - 895
4.2 Fire Hose Cabinet (FHC) shall be fabricated of 2 mm thick M.S. sheet of suitable size.
The fire hose cabinet shall have glass front double door with common lock & keys and
break glass recess for keys, all complete.
Yard Hydrant will include the following accessories:

(i) Connection from ring main with 80 mm dia MS Pipe

(ii) 63 mm dia single head landing valve - 1 No.
(iii) Butterfly / Sluice Valve 80 mm dia - 1 No.
(iv) Hose pipe 63 mm dia 15m. long with male and female - 2 Nos.
coupling at both ends
(v) Branch pipe 63 mm dia with 20 mm (nominal internal - 1No.
diameter) nozzle and suitable for instantaneous
connection.

The FHC shall be painted with post office red colour or as per requirement. The
words “yard hydrant” or “hydrant” shall be lettered on the glass of 75mm high in
white or red paint. Top surfaces shall be slopped for water discharge. Vents shall also
be located on sides of the Hose Box.
A brick pedestal shall be constructed for supporting the hose box. All surfaces shall
be plastered with 1:4 ratios (1 cement: 4 fine sand) mortar. The cabinet shall be
installed near the External Hydrant.

5.0 INTERNAL HYDRANTS

5.1 Every Riser will be provided with the following at every floor including terrace and
basement over and above Sprinkler System:

(i) Single Headed Outlet - 2Nos.

(ii) First Aid Hose Reel (Length of pipe shall be such that - 1 No.
nozzle of the hose can be taken into every room and within
6 Mtrs. of any part of the rooms keeping in view layout and
obstruction.)
(iii) Hose pipe 63 mm dia 15m long with male and female coupling - 2 Nos
at both ends.
(iv) Branch pipe 63 mm dia with 20 mm (nominal internal - 1 No
diameter) nozzle and suitable for instantaneous connection.
6.0 FIRST-AID HOSE REEL EQUIPMENT
6.1 First aid hose reel equipment shall comprise reel, drum which can swing upto 180
degrees with hose, guide fixing wall bracket, hose tubing, globe valve, stopcock and
nozzle. The water inlet is connected to the riser pipe by means of 37 mm socket and
valve. The hose tube can be pulled out easily for the purpose of discharge of water
on fire. The length of hose tube shall be such that the nozzle of the hose can be taken
into every room and within a range of 6 M from any part of the room. This shall
conform to IS: 884 - 1969. The hose tubing shall confirm to IS: 12585 (Thermoplastic
textile reinforced) type - 2. The drum shall be fabricated from GI sheet of minimum
18 gauge thickness.
i) The hose tubing shall be 20 mm (nominal internal) dia and 30 m long (Min).

PAGE - 896
 The G.M nozzle 5mm and shutoff valve shall be of 25 mm size to shut off the
water supply to the Hose Reel.
ii) The fixing bracket shall be of swinging type. Operating instructions shall be
engraved on the assembly. This heavy duty mild steel and cast iron brackets
shall be conforming to IS: 884 - 1969. The first-aid hose reel shall be connected
directly to the M.S. pipe riser through a 25mm dia pipe.
iii) A MS bracket shall be fixed on the wall to which the first aid hose reel shall be
bolted. The bracket shall be of 40x40x5mm thick MS angle to form a square of
400x400 mm (approx). The units shall be fabricated in factory and all joints
shall be finished with grinder and shall be spray painted after single coat of
primer.
iv) The water flow rate shall be not less than 24 lpm and the range of jet shall be
not less than 6 m.
7.0 HOSE PIPES, BRANCH PIPES AND NOZZLES
7.1 HOSE PIPES
i) Two nos. hose pipes for External and 2 Nos hose pipes for Internal hydrants
shall be provided. The hose pipe shall be rubber lined woven jacketed (RRL)
and 63mm in dia. & 15m long, (non-percolating Reinforced rubber lined)
conforming to IS:636 (Type B). The hose shall be sufficiently flexible and
capable of being rolled.
ii) Each run of hose shall be complete with necessary Male & Female Gun Metal
coupling at the ends to match with the landing valve or with another run of
hose pipe or with branch pipe. The couplings shall be of instantaneous spring
lock type. This shall be conforming to IS: 903. Spare hose pipes along with
branch pipe shall be kept in the fire control room/ pump room.

7.2 BRANCH PIPES

i) Standard short sized Branch pipe shall be constructed from SS material of 63
mm dia and be complete with male instantaneous spring lock type coupling for
connection to the end of hose pipe. The branch pipe shall be externally
threaded to receive the nozzle conforming to IS:903. The branch pipe shall be
tested to 20 kg/ cm2 pressure.

7.3 NOZZLES
i) The nozzle shall be of SS of 20 mm nominal internal diameter. The screw
threads at the inlet connection shall match with the threading on the branch
pipe. The inlet end shall have a hexagonal head to facilitate screwing of the
nozzle on to the branch pipe with nozzle spanner.
ii) End Couplings, Branch pipe, and Nozzles shall conform to IS:903 - 1985.

8.0 ORIFICE PLATE

The pressure in a Fire Fighting system varies from point to point. The pressure will
be maximum in the pump house and minimum at the farthest hydrant at TOP level.
To reduce pressure to operating pressure at every internal /external hydrant, orifice

PAGE - 897
 plates are provided before connection of landing valve between the flanges of
landing valve and pipe flange. It should be made of 6mm thick SS and shall have an
identification tag projecting beyond any flange between which it is clamped. The
orifice shall be plain central hole without burs and diameter not less than one half
of the internal diameter of the pipe to which it is fitted. The size of orifice shall be
calculated as per CPWD specifications.
9.0 FIRE BRIGADE INLET CONNECTIONS
9.1 Fire Brigade Inlet connection shall be provided near the pump house and to the
external fire ring system for the following purposes:
i) Fire Brigade suction draw out connection for fire static tank with provision of
foot valve.
ii) Fire brigade inlet connection to fire static tank.
iii) Fire brigade inlet connection to the external ring main. Each connection shall be
with similar dia of Sluice valve and Non return valve.
9.2 The locations of these fire brigade connections shall be suitably decided with the
approval of Engineer-in-charge and with a view that these are easily accessible to
the fire brigade, without any hindrances.
10.0 VALVE CHAMBERS
Contractor shall provide suitable Brick Masonry Chamber in cement mortar 1:4 (1
cement: 4 coarse sand) with 150mm thick cement concrete foundations in 1:5:10
mix (1 cement: 5 fine sand: 10 graded stone aggregate) 40 mm nominal size. The
brick masonry work shall be plastered with 12 mm thick finished with a floating coat
of neat cement inside. The TOP of chamber shall be covered with cast iron surface
box as approved by Engineer- In -Charge.

11.0 PORTABLE FIRE EXTINGUISHER

Portable fire extinguishers shall be provided as per Bill of Quantities and shall
conform to IS: 2190-1979.
11.1 ABC TYPE DRY POWDER EXTINGUISHER
11.1.2 The Extinguisher shall be filled with ABC Grade 40, Mono Ammonium Phosphate
(MAP base) from approved manufacturer. It shall bear IS 15683 marking.
11.1.3 The Capacity of the extinguisher when filled with Dry Chemical Powder (First
filling) as per IS 4308, part II 8/ IS 2171, shall be 6 kg +2 %.
11.1.4 It shall be operated upright, with a squeeze grip valve to control discharge. The
plunger neck shall have a safety city, fitted with a pin, to prevent accidental
discharge. It shall be pressurized with Dry Nitrogen, as expelling. The Nitrogen to
be charged at a pressure of 15 kg / cm².
11.1.5 Body shall be of mild steel conforming to relevant IS Standards. The neck ring shall
be also mild steel and welded to the body. The discharge valve body shall be forged
brass or leaded bronze, while the spindle, spring and siphon tube shall be of brass.
The nozzle shall be of brass, while the hose shall be of braided nylon. The body shall
be cylindrical in shape, with the dish and dome welded to it. Sufficient space for
Nitrogen gas shall be provided inside the body, above the powder filling.
11.1.6 The Neck ring shall be externally threaded the threading portion being 1.6 cm. The

PAGE - 898
 filler opening in the neck ring shall not less then 50 mm. Discharge nozzle shall be
screwed to the hose. The design of the nozzle shall meet the performance
requirement so as to discharge at least 85 % of contents upto a throw of 4 meters,
continuously at least for 15 seconds. The hose, forming part of discharge nozzle,
shall be 500 mm long, with 10 mm dia internally for 5 kg capacity and 12 mm for
10 kg capacity. It shall have a pressure gauge fitted to the valve assembly or the
cylinder to indicate pressure available inside. The extinguisher shall be treated
with anti corrosive paint, and it shall be labeled with words ABC 2.5 cm long, within
a triangle of 5 cm on each face. The extinguisher body and valve assembly shall
withstand internal pressure of 30 kg / cm² for a minimum period of 2 minutes. The
pressure Gauge shall be imported and suited for the purpose.

11.2 WATER TYPE EXTINGUISHER (GAS PRESSURE TYPE)

11.2.1 The Extinguisher medium shall be primarily water stored under normal pressure.
11.2.2 The capacity of Extinguisher, when filled upto the indicated level, shall be 9 liters
and shall be IS 15683 marked.
11.2.3 The skin thickness of the cylinder shall be fabricated from Mild Steel sheet, welded
as required, with dish and dome, being of same thickness, and of size not exceeding
the diameter of body. The diameter of body to be not less than 150 mm and not
exceeding 200 mm. The neck shall be externally threaded up to minimum depth of
16 mm, and leaded tin bronze.
11.2.4 The cap shall be of leaded tin bronze, and screwed on the body upto a minimum of
1.6 cm depth, with parallel screw thread to match the neck ring. The siphon tube
to be of brass or G.I and the strainer of brass. The cartridge holder, knob, discharge
fittings and plunger to be of Brass/Leaded tin bronze, and spring of stainless steel.
It shall have a snifter valve to act as breather. The cap shall have handle fixed to it.
The discharge hose shall be braided nylon, of 10 mm dia and 600 mm long, with a
nozzle of brass fitted at end.
11.2.5 The extinguisher shall be treated for anti corrosion internally and externally, and
externally painted with Fire Red paint. The paint shall be stove enameled / powder
coated. The cartridge shall be as per IS. The extinguisher, body and cap shall be
treated to an internal hydraulic pressure of 25 kg/cm². It shall have external
marking with letter A, of 2.5 cm height, in block letters within a triangle of 5 cm each
side. The extinguisher shall be upright in operation, with the body placed on
ground, and discharge tube with nozzle held in one hand to give a throw of not less
than 6 meter, and continue so for at least 60 sec. The extinguisher body shall be
clearly marked with ISI stamp (IS 940).

11.3 CARBON DIOXIDE EXTINGUISHER

11.3.1 The Carbon Dioxide Extinguisher shall be as per IS: 15683.
11.3.2 The Body shall be constructed of seamless tube conforming to IS: 7285, and having
a convex dome and flat base. Its dia shall be maximum 140 mm, and the overlay
height shall not exceed 720 mm.

PAGE - 899
11.3.3 The discharge mechanism shall be through a control valve conforming to IS: 3224.
The internal siphon tube shall be of copper or aluminum conforming to relevant
specifications.
11.3.4 Hose pipe shall be high pressure braided Rubber hose with a minimum burst
pressure of 140 kg/cm², and shall be approximately 1.0 meters in length having
internal dia. of 10 mm. The discharge horn shall be of high quality unbreakable
plastic with gradually expanding shape, to convert liquid carbon dioxide into gas
form. The handgrip of Discharge horn shall be insulated with Rubber of
appropriate thickness.
11.3.5 The gas shall be conforming to IS: 307 and shall be stored at about 85 kg/cm². The
expansion ratio between stored liquid carbon dioxide to expanded gas shall be 1:9
times and total discharge time shall be minimum 10 sec. and Maximum 25 sec.
11.3.6 The Extinguisher shall fulfill the following test pressures:
a) Cylinder: 236 kg/cm²
b) Control Valve: 125 kg/cm²
c) Burst pressure of Hose: 140 kg/cm² minimum.
11.3.7 It shall be an upright type. The cylinder, including the control valve and high-
pressure Discharge Hose must comply with relevant Statutory Regulations, and be
approved by chief Controller of Explosives, Nagpur and also bear IS marking.
11.3.8 The Extinguisher including components shall be ISI Mark.

12.0 SPRINKLER SYSTEM

12.1 SYSTEM DESIGN
12.1.1 Automatic sprinkler system shall be provided for all areas as per requirement with
permitted exceptions e.g. electrical switch rooms, power transformers and D.G.
rooms, Panel rooms, Electrical rooms, staircase & lift well, wash rooms, toilets, WC
or any other area / room where the water discharged from sprinkler may pose a
hazard as identified.
a) Sprinkler heads shall be provided at approximate spacing to cover 12 m2 for
ceiling sprinkler per Sprinkler head or as per specific requirements to meet
the approval of the authority having jurisdiction. The spacing shall also be in
conformity with the drawings and properly coordinated with Electrical
Fixtures, Ventilation Ducts and Grills and other services along the ceiling.
b) Types of sprinklers to be used shall be as given in specifications, SOQ and
approved by the Engineer-in-charge.

12.2 SPRINKLER HEADS

12.2.1 Sprinkler heads shall be Chrome finished Brass / Gunmetal with quartz bulb with
a temperature rating of 68°C. Sprinkler heads shall be of type and quality approved
by the local fire brigade authority. The inlet shall be screwed. Sprinkler heads shall
be pendent, recessed or special application side wall Sprinkler types as shown in
drawings. All Sprinklers should have the Specifications as far as possible as per
NFPA requirements and shall be UL approved.

12.2.2 The nominal bore shall be 15 mm dia and colour of bulb liquid shall be red. The
below false ceiling shall also be provided with a double plate captive rosette
assembly to seal the junction between the pipe and the false ceiling.

PAGE - 900
12.3 ALARM VALVE & AUTOMATIC WATER MOTOR GONG VALVE
The alarm valve & water motor gong valve is to be provided on all the Sprinkler
main delivery pipes (or Installation Control Valves) as per approval of authority
having jurisdiction.
12.3.1 The Installation Control valve (ICV) shall be double seated clapper type check
valve. The Body and cover shall be made from Cast Iron to IS: 210 Grade FG 200.
The seat and seat clamp shall be made from bronze to IS: 318, LTB II grade. The
sealing to the seat shall be neoprene gasket. The hinges pin and ball shall be from
stainless steel.
12.3.2 It shall be vertically mounted and the direction of water travel shall be indicated
on the surface. It shall be rated to 12 kg / cm² and tested to 25 kg / cm² pressure.
12.3.3 A By-pass check valve shall be fitted to adjust minor and slow variations in water
pressure for balancing so as to avoid any false alarm.
12.3.4 The valve shall also be provided with a Test Control Box. The Box shall house a
lever to test and operate the ICV. A brass strainer shall also be provided at the point
of water supply to the Alarm gong. A Retarding Chamber shall also be provided.
The Chamber shall be able to balance the water pressure in case of water line
surges.
12.3.5 Each Installation Control Valve shall have two sets of pressure Gauges with brass
ball valve type shut off.
12.3.6 A Water Motor Alarm shall be mechanically operated by discharge of water
through an impeller. The drive bearing shall be weather resistant. A strainer shall
be provided on line before the nozzle. The Gong piece shall be constructed from
bronze to IS 318, 2 TB II Grade & base of cast iron. The motor Housing, Rotor and
Housing Cover shall be pressure die cast aluminum.
12.3.7 A brass automatic ball drop valve with the retard chamber shall be provided.

12.4 INSPECTOR TEST VALVES

The Inspectors Test Valve assembly is to be provided on the Sprinkler System
pipes in location as per approval of authority having jurisdiction.
12.5 FLOW SWITCHES
The Flow Switches are to be provided on the Sprinkler System pipes for each zone
complete with all necessary wiring upto monitor modules as per instructions of the
Engineer –In-Charge.

12.6 INTELLIGENT TYPE SPRINKLER ANNUNCIATION PANEL & MONITOR MODULE

For detailed specification kindly refer Package of Addressable type Fire
Alarm and detection system.

13.0 FIRE FIGHTING PUMPS

The general requirement of water pumps for main fire pump, jockey
(pressurization) pump and sprinkler pump are detailed below. The discharge and
head of the pumps shall be as mentioned in Bill of Quantities.

PAGE - 901
13.1 FIRE, SPRINKLER, JOCKEY & TERRACE PUMPS
13.1.1 Pumping sets shall be multi/ single stage horizontal centrifugal single outlet with
cast iron body and bronze dynamically balanced impellers.
13.1.2 Connecting shaft shall be stainless steel & shall be accurately machined. Shaft
shall be balanced to avoid vibrations at any speed within the operating range of
the pump & with bronze sleeve and grease lubricated bearings. The centrifugal
pump shall conform to IS: 1520.
13.1.3 Pumps shall be connected to the drive by means of spacer type love-joy coupling
/ flexible coupling, which shall be individually balanced dynamically and statically.
13.1.4 The coupling couples the prime mover with the pump shall be provided with a
sheet metal guard.
13.1.5 The shaft seal shall be mechanical type, so as to allow minimum leakage. A drip
well shall be provided beneath the seal.
13.1.6 The bearings shall be heavy duty ball / roller type suitable for the duty involved.
These shall be grease lubricated and shall be provided with grease nipples/cups.
The bearing shall be effectively sealed against leakage of lubricant or entry of dust
or water.
13.1.7 Main / Diesel Engine driven Fire Pumps shall be capable of delivering not less
than 150% of the rated capacity of water at a head of not less than 65% of the
rated head. The shut-off head shall not exceed 120% of the rated head.

13.2 MOTORS FOR ELECTRIC DRIVEN PUMPS

13.2.1 Electrically driven pumps shall be provided with totally enclosed fan cooled
induction motors.
13.2.2 Motors for Main fire pumps shall be at least equivalent to the horse power
required to drive the pump at 150% of its rated discharge and shall be designed
for continuous full load duty and shall be design proven in similar service.
13.2.3 Motors shall be suitable for 415 volts + 10%, 3 Phase, 50 Hz, A.C supply with class
–F insulation, TEFC and conform to IS: 325.
13.2.4 Motors shall be capable of handling the required starting torque of the pumps.
13.2.5 Water curtain pump forms a curtain to isolate/ prevent spread of smoke / heat /
flame from the area engulfed with fire to no fire area. In the
aspect of fire & life safety, compartmentation of building plays an important role.
Compartmentation can be made by providing barrier in a large area so that fire /
heat / smoke cannot spread to no fire areas. The barrier can be fire rated wall (or
any assembly) or fire curtains or water curtain.
Water Curtain Pump is connected to the water curtain nozzle through deluge
valve. From water curtain pump to deluge valve, the pipelines are normally
flooded (flooded here means the pipe line contains pressurized water). From
deluge valve to water curtain nozzle, the pipelines are dry (no-water) When
the fire or smoke is detected in one compartment, corresponding fire detection
device located in the area will send signal / command to deluge valve to open and
subsequently will switch on the pump. Water starts gushing in to the water
curtain system and reach those nozzles. These nozzles has special
properties of forming a curtain from water preventing smoke / flame / fire / heat
to spread to other compartment / zone.

PAGE - 902
 13.3 ACCESSORIES AND FITTINGS
13.3.1 The following accessories shall be provided with each pump among other
standard accessories required:-
a) Coupling guard for horizontal split casing pumps.
b) Lubrication fittings and seal piping.
c) Test and / or air vent cocks

13.3.2 Following fittings shall be provided with each pump among other standard fittings
required:
a) Butterfly / Sluice valves on suction & discharge. Reducers to match the
sizes of the connected pipe work. NRV at discharge.
b) Suction and discharge pressure gauges not less than 100 mm dia. dial size
and of the appropriate rating with gauge valves etc. Suction gauge shall be
of compound type.
c) 25mm GI gland drains.

13.4 INSTALLATION
13.4.1 Pump and motor /engine assembly shall be mounted & arranged for ease of
maintenance and to prevent transmission of vibration and noise to the building
structure or to the pipe work or as per manufacturer’s recommendations. Pump
sets shall be mounted on machinery isolation cork or any other equivalent
vibration isolation fittings. Concrete floating foundation shall be provided as per
approved shop drawings and specifications. The height of foundation shall be so
decided that the total weight of foundation on block is 1.5 times the operating
weight of the pump assembly. The isolation pads, foundation bolts etc. shall be
supplied by the Contractor. Contractor shall ensure that the foundation bolts are
correctly embedded. Angle iron frame of size 35mm X35mm X 3mm shall be
provided on the top edges of the foundation. The length & width of the foundation
shall be such that 100mm space is left all around the base frame.
13.4.2 Pump sets shall preferably be factory aligned, wherever necessary, site alignment
shall be done by competent persons. Before the foundation bolts are grouted and
the couplings are bolted, the bed plate levels and alignment results shall be
submitted to the Engineer-in-charge. The suction / discharge pipe shall be
independently supported and their weight shall not be transferred to the pump. It
should be possible to disconnect any pump for repair without disturbing the
connecting pipe line.

13.5 INSPECTION AND TESTING - SPRINKLER SYSTEM

SPRINKLERS
It shall be factory tested for operation characteristics and chemical tests. Necessary
test results shall be submitted before supply. The contractor shall establish the
discharge of the sprinkler during the testing at site.
Sprinkler alarm valve

PAGE - 903
 The pump shall start automatically and maintain pressure at the appropriate flow
rate. The drain valve fitted above the alarm valve shall be opened and the time
taken for the alarm gong to operate be noted. There shall not be a significant
variation in the timing. The pressure at the “C” gauge of the alarm valve shall be
noted at the full load condition of the pump and the value should match with that
of the specification. The proper functions of the alarm gong associated with the
alarm valve and its level of audibility shall be checked. An audibility level of 85 db
above the background noise level is required. Necessary testing equipment shall
be arranged by the contractor free of cost.
While conducting the tests, the water flowing through the test valve shall be
equivalent to the flow through one sprinkler. It should auto start the pumps and
activate the alarm motor and gong. When the test valve is closed, the water flowing
through the test valve should stop.

13.6 PAINTING
After complete installation and testing, pumps accessories and fittings shall be
given two coats of approved finishing paint.
13.7 AIR VESSEL FOR FIRE PUMPS
13.7.1 Provide an air vessel fabricated from M.S. sheet with dished ends and suitable
supporting legs, air vessel shall be provided with a 100mm dia flanged connection
from pump, one 50mm dia drain with valve, one gunmetal water level gauge and
25mm sockets for pressure switches. The vessel shall be 450mm dia x2000mm
high and tested to 1.5 times of the working pressure or 12 Kg/Cm2, whichever is
greater.
13.7.2 The fire pumps shall operate on drop pressure in the mains automatically or
manually as specified below:

Fire Service Nos. Operating Operating Remarks

Pump Pressure Pressure Cut
Cut In Out
(ln Kg / (in Kg / cm²)
cm²)
Jockey pump One 8 9 To auto start and auto stop
(Hydrant / on pressure switch on air
Sprinkler) vessel.
Main pump One 7 Push button To auto start on pressure
manual switch on air vessel and
manual off.
Main pump One 7 Push button To auto start on pressure
(Sprinkler) manual switch on air vessel and
manual off.
Diesel Fire One 5 Push button To auto start on pressure
Pump manual switch on air vessel and
manual of

PAGE - 904
(The above ratings will be adjusted finally at the time of commissioning
as per site requirement and final setting shall be kept as per approval of
Engineer-in-Charge).
13.8 DIESEL FIRE PUMP
13.8.1 Scope
The details of requirements of the standby fire pump, operated by a diesel engine
are detailed below:
13.8.2 General
The diesel pump set shall be suitable for automatic and manual operation complete
with necessary automatic starting gear for starting on wet battery system and shall
be complete with all accessories. Both engine and pump shall be assembled on a
common base plate, fabricated from mild steel channel.
13.8.3 Drive
The pump shall be only direct driven by means of a hollow set / flexible coupling.
Coupling guard shall also be provided. The speed shall be 1500 RPM.
a) Fire Pump
i) The fire pump shall be horizontal split casing multi-stage centrifugal
type. It shall have a capacity to deliver the discharge as specified,
developing adequate head so as to ensure a minimum pressure of 3.5 Kg
/cm2 at the highest and the farthest outlet. The pump shall be capable of
giving a discharge of not less than 150% of the rated discharge at a head
of not less than 65% of the rated head. The shut off head shall be within
120% of the rated head.
ii) The pump casing shall be of cast iron to grade FG 260 / 200 to IS: 210
and parts like impeller shaft sleeve, wearing-ring etc. shall be of non-
corrosive metal like bronze. The shaft shall be of stainless steel. The
pump shall be provided with mechanical seal.
iii) The pump casing shall be designed to withstand 1.5 times the working
pressure.
iv) Bearings of pump shall be effectively sealed to prevent loss of lubricant
or entry of dust or water.

13.9 DIESEL ENGINE

13.9.1 Environmental Conditions - The engine shall be required to operate under the
conditions of ambient temperature and humidity suitable at site.
13.9.2 Engine Rating - The engine shall be multi cylinder / vertical four stroke cycle, water
cooled, developing suitable HP at the operating speed specified to drive the fire
pump. cold starting type without the necessity of preliminary heating of the engine
cylinders or combustion chamber (for example, by wicks, cartridge, heater plugs
etc). Continuous capacity available for the load shall be exclusive of the power
requirement of auxiliaries of the diesel engine, and after correction for altitude,
ambient temperature and humidity for the specified environmental conditions as
mentioned. This shall be at least 20% greater than the maximum HP required to

PAGE - 905
 drive the pump at its duty point. It shall also be capable of driving the pump at
150% of the rated discharge at 65% of rated head. The engine shall be capable of
continuous non-stop operation for 8 hours and at least 3000 hours of operation
before major overhaul. The engine shall have 10% overload capacity for one hour
in any period of 12 hours continuous run. The engine shall accept full load within
15 seconds from the receipt of signal to start. The diesel engine shall conform to BS
649 / IS 1601 / IS 10002, all amended upto date.

13.9.3 Engine Accessories - The engine shall be complete with the following accessories:-
 Flywheel dynamically balanced.
 Direct a coupling for pump and coupling guard.
 Radiator with hoses, fan, water pump, drive arrangement and guard.
 Corrosion Resister.
 Air cleaner dry type.
 Fuel service tank support, semi-rotary pump and fuel oil filter with necessary
pipe work.
 Pump for lubricating oil and lub. oil filter.
 Elect. starting battery (12 V / 24V).
 Exhaust silencer with necessary pipe work.
 Governor.
 Instrument panel housing all the gauges, including Tachometer, hour meter
and starting switch with key (for manual staring).
 Necessary safety controls.
 Winterization arrangement.
 Hand operated semi rotary pump for filling the service tank.

13.9.4 Fuel System: The fuel shall be gravity fed from the engine fuel storage tank to the
engine driven fuel pump. The engine fuel storage tank shall be floor mounted with
proper support etc.
All fuel tubing in the engine shall be with copper and fuel piping from day oil tank
to engine shall be MS and or with Reinforced flexible hose connection at engine
side. Plastic tubing shall not be permitted.
The fuel tank shall be welded Steel Construction (3mm Thick) and of 200 Ltrs.
capacity or of capacity sufficient to allow the engine to run on full load for at least
8 hours. The tank shall be complete with necessary supports, level indicator
(Protected against mechanical injury) inlet, outlet, overflow connection and drain
plug and piping to the engine fuel tank. The outlet shall be so located as to avoid
entry of any sediment into the fuel line to the engine.
Tank shall be provided with epoxy coat from inside and outside with one coat of
Red oxide primer and two or more Coats of Synthetic enamel paint of approved
shade.
A semi rotary hand pump for filling the daily service tank together with hose pipe
of 5 m long with a foot valve etc shall also form part of scope of supply with the
quoted cost.

PAGE - 906
13.9.5 Starting system - The starting system shall comprise necessary batteries 12V /
24V volts starter motor of adequate capacity and axle type gear to match with the
toothed ring on the flywheel. Bi metallic relay protection to protect starting motor
from excessively long cranking runs suitably integrated with engine protection
system shall be included within the scope of the work.
The battery capacity shall be suitable for meeting the needs of the starting system.
The battery capacity shall be adequate for 10 consecutive starts without
recharging with cold engine under full compression.
Three attempt starting facility shall be provided if engine fails to start after third
attempt, the engine shall be locked out and suitable audio-visual alarm shall be
given to indicate engine failure.
The scope shall cover all cabling, terminals, initial charging etc.

13.9.6 Exhaust system - The exhaust system shall be complete with silencer suitable for
outdoor installation, and silencer piping including bends and accessories needed
to be taken out of the building as per statutory requirement. The Contractors are
advised to see the drawing and site to assess the length and size of exhaust pipe
required. The total backpressure shall not exceed the engine manufacturer’s
recommendation. The exhaust piping shall be suitably lagged with 50 mm thick
glass wool & 1 mm thick Al. sheet cladding within the quoted cost.

13.9.7 Engine shut down mechanism - This shall be manually operated and shall return
automatically to the starting position after use.

13.9.8 Governing System - The engine shall be provided with an adjustable governor to
control the engine speed within 5% of its rated speed under all conditions of load
up to full load. The governor shall be set to maintain rated pump speed at maximum
pump load.
An over speed shutdown device to shutdown the engine at a speed approximately
20% above rated engine speed with manual reset, so that the automatic engine
controller will indicate an over speed signal until the device is manually reset to
normal operating position.

13.9.9 Cooling System: The engine shall be radiator water cooled. The radiator assembly
shall be mounted on the engine. The radiator fan shall be driven by the engine as its
auxiliary with multiple fan belts. When half the belts are broken, the remaining
belts shall be capable of driving the fan. Cooling water shall be circulated by means
of an auxiliary pump of suitable capacity driven by the engine in a closed circuit.

13.9.10 Engine Instrumentation - Engine instrumentation shall include the following:

 Lub. oil pressure gauge.
 Lub. oil temperature gauge
 Water pressure gauge
 Water temperature gauge
 Tachometer
 Hour meter
The instrumentation panel shall be suitably mounted on the engine.

PAGE - 907
 (i) Engine Protection Devices – The following engine protection and automatic
shutdown facilities shall be provided: -
 Low lub. oil pressure
 High cooling water temp
 High lub. oil temperature
 Over speed shut down
(ii) Pipe work - All pipe lines with fittings and accessories required shall be
provided for fuel oil, lub. oil and exhaust systems.
The fuel tubing to the engine shall be MS C – class pipe with flexible hose
connections where ever required.
(iii) Anti Vibration Mounting - Suitable anti-vibration mounting duly approved
by Engineer-in-charge shall be employed for mounting the unit so as to
minimize transmission of vibration to the structure.
(iv) Battery Charger - Necessary float and boost charger shall be incorporated in
the control section of the power and control panel, to keep the battery under
trim condition. Voltmeter to indicate the state of charge of the batteries shall
be provided.
14.0 MOTOR CONTROL SYSTEM
The main switchboard shall be floor mounted, free standing, cubical type,
compartmentalized and shall be factory built fabricated by one of the approved
switch board manufacturer. The board shall be fabricated from 2mm thick CRCA
sheet and powder coated after seven tank process. The board shall be fabricated with
IP 54 degree of protection suitable for operation of 415 volt ± 10%, 3 phase, 4 wire,
50Hz, AC supply. The switch board shall have provision for termination of cables
from top as well as bottom with suitable knockouts. The layout shall be designed for
convenient connections and inter-connections with various switchgears.
Connections from individual compartments to cable alleys shall be such as not to
shut down healthy circuits in the event of maintenance work becoming necessary on
a defective circuit. A base channel of 75mm  5mm thick shall be provided at the
bottom. A maximum of 200mm space between the floor and bottom most panel of
unit shall be provided. The bus bar shall be of aluminium complete with heat
shrinkable PVC sleeves. The fabrication of switch board shall be taken up only after
the drawings for the fabrication of the same are approved by the Engineer –in –
charge.
Control panel shall contain starters and safety protection for hydrant, sprinkler,
jockey pump motors and diesel controls etc. It shall also house the switchgears for
incoming as well for outgoings supply. Provision of voltmeter (for incomer) &
ammeter for incomer as well as for measuring the current drawn by each motor with
selector switch, a set of LED indicating light for incoming phases as well as status
indication of each equipment. The voltmeter & LED indication lamps shall be
protected by MCBs.
All the motors shall be provided with fully automatic Star Delta starters with motor
duty MCCBs for short circuit protection only (ICS = 100% ICU) & Overload Relays
with contactors of suitable range & ratings for overload protection. Single phase
preventers shall be provided for all 3 phase motors. Single phase preventer shall be
in conformity with relevant ISI standards. Single phase preventers shall act when

PAGE - 908
 failure of one or more phases. Single phase preventer shall be voltage operated and
of approved make.
The MCCB for incomer shall be with Thermal magnetic release & should provide
adjustable setting for overload and short circuit protection with ICS = 100% ICU.
Interlocking shall be provided between switch and the door in such a way that the
door of the panel cannot be opened when the supply is ON.
The panel shall be provided all identification tags, danger board etc as per standard.
All control panels shall be provided with detailed control circuit diagram indicating
the terminal numbers and color coding of the wires used in the panels. This diagram
shall be pasted on the inner side of the cover and protected with PVC transparent
lamination.
For detailed specification of switchgears & accessories, tenderer shall refer package
A for MV panel.
15.0 CONTROL SYSTEM
The system shall be designed for operation automatically so that as and when water
is drawn from the system through any hydrant, the pumps will operate
automatically and feed water in to the system. However once a fire pump starts
working, it will be stopped manually (except jockey pump) or on account of any fault
or non availability of power supply to electrical pumps or low water level in UG tank.
Facility shall also be provided for manual operation. A selector switch for auto /
manual selection shall be provided in each pump.
The Control system shall be designed to provide the following sequence of
operation.

15.1 The Jockey pump for Hydrant system / Sprinkler System shall maintain pressure in
the hydrant system / Sprinkler System and shall operate only on account of slow
pressure loss. In case of sudden pressure loss the Jockey pump shall not operate.
The pump shall start when the water pressure in the system falls to a Cut out value
about 1 Kg / cm2 below normal system pressure and shut down when the system
pressure reaches the set value. Both limits shall be adjustable.
15.2 Main Electric Hydrant fire pump shall operate on account of sudden pressure loss.
So long as Main electric fire pump is working the diesel Fire pump will not operate.
The pump shall start when the water pressure falls to the pre-set in the system.
15.3 Main Electric Sprinkler pump shall operate on account of sudden pressure loss in
the sprinkler line. So long as Main electric fire pump is working the diesel Fire pump
will not operate. The pump shall start when the water pressure falls to the pre-set
in the system.
15.4 The Diesel Fire pump (Standby Pump) will start on sudden pressure loss, only in
case supply to Main Electrical Sprinkler or Hydrant Fire pump is not available or
within a pre-set time the Main Electric fire pump fails to start or fails during
operation. Audio-visual Alarm shall be available to indicate failure of Main electric
pump.
15.5 A three attempts starting facility will be provided for diesel pump.
15.6 If within a pre-set time, the standby pump also fails to start or fails to develop
pressure, an audio visual alarm indication shall be given at the control panel.
15.7 Only one pump will be working at a time. In manual mode more than one pump can

PAGE - 909
 be started.
15.8 Water level in UG shall be monitored and in case of low water level, pumps
connected with the tank shall not operate (even on manual mode) or stop operation
as the case may be. An audio-visual alarm shall be given at control panel.
16.0 SYSTEM CONTROLLER
For Controlling operation of pumps as mentioned in above clauses and indicating
fault, system controller shall be provided. The system controller shall consist of
Relay timers, contractors etc. and shall be designed to operate the Fire pumps with
interlocking and fault indication describe in above clauses. Annunciation window
shall be provided to indicate the following faults:
Low water level in UG tank.
Hydrant / Sprinkler Pump failed to Start.
Hydrant / Sprinkler Pump failed during operation. Diesel pump failed to Start.
Diesel pump failed during Operation. Supply to Hydrant / Sprinkler Pump failed.
Supply to Jockey Pump failed.

17.0 POWER CABLING

Contractor shall provide all power /control cables from the motor control centre to
various motors, level controllers and other control devices. All power cables shall be
aluminum conductor XLPE insulated armored and PVC sheathed and control cables
of copper conductor PVC insulated armored and PVC sheathed. All Power
/ Control cables shall have FRLS outer Sheath and stranded conductors of 1100 Volt
grade. The cables shall be in drums as far as possible and bear manufacturer’s name.
Specification of cable laying shall be followed as described in Internal EI package of
this tender.
18.0 CABLE TRAYS
Specification of cable trays shall be followed as described in Internal EI package of
this tender.
19.0 EARTHING
Main Electrical power upto the Electrical panel(s) in Fire fighting Pump Room along
with earthing shall be provided by other agency.
All three phase motors / equipment shall be earthed with two independent earth
conductors as per the requirement of Indian Electricity Rules and Regulation - 1956.
Earthing specifications shall be followed as described in Internal EI package of this
tender.
20.0 MEASUREMENTS
Measurements of plumbing work shall be on following basis: -
I. Piping for hydrant lines, headers & branches for sprinkler system, risers, suction
& delivery header and mains shall be measured along the center line of installed
pipes including all pipe fittings and accessories but excluding valves and other
items for which quantities are specifically indicated in the schedule of work. No
separate payment shall be made for fittings and accessories.
The rates for piping work shall include all wastage allowances, flanges pipe
supports, hangers, excavation, refilling, testing, nuts and check nuts, vibration
isolators for suspension where specified or required, and any other item
required completing the pipe installation. None of these items will be separately

PAGE - 910
 measured and paid.
II. Pumps and equipment shall be measured by numbers and shall include all items
as given in the bill of quantities.
III. Cable trays and cables shall be measured per linear meter.
IV. No separate payment shall be made for making connections of the existing
service lines to the pumps. Vibration eliminator pads are included in the scope
of this work.

21.0 COMMISSIONING
After the completion of testing and obtaining statutory approval, the system shall
be commissioned. During commissioning the contractor shall establish the head,
discharge, efficiency, drive connected load etc of the pumps. The discharge from the
hydrant valves, sprinklers etc shall also be demonstrated. The commissioning will
be for a continuous period of 7 days. The system shall be put in automatic mode and
checked. The automatic operation shall be verified by releasing system pressure by
opening of valves. Sprinkler system shall be tested by opening the drain valve.
Automatic operation of jockey pump and main pumps (electric and diesel engine
driven pumps) shall be verified. The system operation shall not be affected during
the continuous operation period of 7 days. If defects noted in the system during the
seven days period the same shall be rectified by the contractor in a time bound
manner without any additional cost to AAI. Leakage in the piping network, if any,
noted during the commissioning shall also be attended by the contractor and
rectified without any additional cost to AAI. The system shall be operated in manual
mode also to confirm manual operation of the system. The commissioning of the
system shall be carried out in close coordination with AAI. All equipments, tools,
tackles, materials, personnel etc. required for the system commissioning shall be
arranged by the Contractor at no extra cost to AAI.

PAGE - 911
SECTION -13 FIRE SUPRESSION SYSTEM

1.0 Purpose:
This specification is for procurement of Clean Agent Based Fire Suppression System
comprising of Gases/Agents approved NOVEC 1230 as the extinguishing agent. It shall
be used as a standard for the system Equipment, System Installation and Acceptance
testing.
1.1 Specific Technical Requirements:
 The Storage Container offered shall be of Seamless type, meant for exclusive use in
the above gas systems, with FM/UL/ULC/VDS component approval. Welded
cylinders are not permitted.
 The Seamless storage cylinder shall be approved by PESO, Nagpur and shall have
NOC from PESO, Nagpur for import of the same. Documentary evidence to be
provided for earlier imports done by the Indian bidder.
 Only those Cylinders whose Capacities are mentioned on the FM/UL/ ULC / VDS
approval certificates of the OEMs are acceptable for this project.
 The Valve operating actuators shall be of Electric (Solenoid) type, and it should be
capable of resetting automatically/ manually.
 The Valve operating actuators shall be PESO / BIS / VDS / UL approved.
 The Individual Bank shall also be fitted with a manual mechanism operating facility
that should provide actuation in case of electric failure.
 The system flow calculation shall be carried out on certified software, suitable for the
Seamless Steel Cylinder being offered for this project. Such system flow calculations
shall be also approved by UL / FM /ULC / VDS.
 The system flow calculation software developed for Welded Cylinder parameters,
and subsequently modified to suit the Seamless Cylinder parameters, shall not be
admissible. Such Modified Software and System Designs shall be admissible only if
the modifications too, are tested, certified and listed by UL / FM /ULC / VDS.

1.2 GENERAL TECHNICAL REQUIREMENTS.

 The designer shall consider and address possible Fire hazards within the protected
volume at the design stage. The delivery of the above system shall provide for the
highest degree of protection and minimum extinguishing time.
 The design shall be strictly as per NBC 2016 & NFPA standard with up-to date
amendments.
 The suppression system shall provide for high-speed release of Gas based on the
concept of total Flooding protection for enclosed areas. A Uniform extinguishing
concentration shall be as applicable and approved by the manufacturer/NFPA
2001/UL/ULC/FM/ VDS of the gases for 70 deg F, or higher as recommended by the
system / agent manufacturer.
 The system discharge time shall be 10 seconds or less, in accordance with NFPA
standard 2001-2012 edition.
 Sub floor and the ceiling void to be included in the protected volume, if available.
 The system to be supplied by the bidder must satisfy the and all requirements of the
Authority having Jurisdiction over the location of the protected area and must be in
accordance with the OEM’s product design criteria.

PAGE - 912
 The discharge nozzles shall be located in the protected volume in compliance to the
limitation with regard to the spacing, floor and ceiling covering etc. The nozzle
locations shall be such that the uniform design concentration will be established in
all parts of the protected volumes. The final number of the discharge nozzles shall
be according to the OEM’s patented and certified software, which shall also be
approved by third party inspectors and certifiers such as UL / FM/ULC etc.
 The Gas shall be stored in seamless storage containers complying with the SMPV
Rules set out by Chief Controller of Explosives, Nagpur, India/ relevant Govt. Body.
The Bidder shall be required to produce a NOC for the Chief Controller of Explosives,
Nagpur/ relevant Govt. Body for the storage containers against the cylinder
identification numbers punched on them.
 The Gas shall be discharged through the operation of an Electric (solenoid)
operated device or pneumatically operated device, which releases the agent through
a differential pressure valve.
 Systems that employ explosive or pyrotechnic devices for the discharge shall not be
permitted.
 AAI reserves the Exclusive Rights to unconditionally reject any and all such
components which may not be, or are suspected not to be of current manufacture
and / or on the grounds of authenticity of the system components and designs.
 The suppression agent shall be UL/FM/ULC”/VDS component recognized and the
approval agent shall be filled as certified by the OEM along with Inspection Certificate
of 3rd Party.
 The bidder shall provide all documentation such as Cylinder Manufacturing
Certificates. Test and Inspection Certificates and Fill Density Certificates.
 The Gas discharge shall be activated by an output directly from the Gas Release
control panel, which will activate the solenoid valve. The Gas agent is stored in the
container as a liquid.
 Systems containing components that have a dated life span and must be periodically
replaced shall not be acceptable.
 The releasing of Gas Cylinder(s) shall also be possible through direct mechanical
actuation, providing a means of discharge in the event of total electrical malfunction.
 The manual release device fitted on the Gas Cylinder(s) shall be of a manual lever
type and a faceplate with clear instruction of how to mechanically activate the
system. In all cases, gas cylinders shall be fitted with a manual mechanical operating
facility that requires two-action actuation to prevent accidental actuation.
 Gas storage cylinders shall be provided with a safety rupture disc. An increase in
internal pressure due to high temperature shall rupture the safety disc and allow the
content to vent before the rupture pressure of the container is reached. The contents
shall not be vented through the discharge piping and nozzles.
 Gas containers shall be equipped with a pressure gauge to display internal pressure.
The gauge shall be an integral part of the container and shall be colour-coded for fast
referencing of pressure reading.
 Gas containers shall have inbuilt low-pressure supervisory switch wherein an alarm
must be sent to the panel in case of pressure drop from the cylinder.
 Brass/Aluminium Discharge nozzles shall be used to disperse the Clean gas agent.
The nozzles shall have female threads and available in sizes as advised by the OEM
system manufacturer. Each size shall come in two styles: 180° and 360° dispersion
patterns.
 The nozzles shall be PESO / BIS / UL / VDS approved.

PAGE - 913
 All the Major components of the Gas suppression system such as the Cylinder, Valves
and releasing devices, nozzles and all accessories shall be supplied by one single
manufacturer under the same brand name.
 Gas Release Panel: The Gas release signal output shall be by a
microprocessor based Intelligent/Addressable control panel with battery charger
and stand-by batteries. The Panel shall have 2 x 40 character LCD display. The panel
should have LED indications for all zones, complete with internal sounder and
alarm/fault indications The panel shall be capable of enhanced features such inbuilt
printer and auto dialler interface, by addition of extra cards/ field modules on the
motherboard. The panel should be UL listed.
 Manual Gas Discharge stations and Manual Abort Stations, shall be provided in
conformance to the NFPA 2001 amended up-to date.
 Release of Gas agent shall be accomplished by an electrical output from the Gas
Release Panel to the solenoid valve and shall be in accordance with the requirements
set forth in the current edition of the National Fire Protection Association Standard
2001.
1.3 Acceptance Tests:
 Acceptance for the System installation, inclusive of the piping and requisite cabling
shall be strictly in accordance with the installation acceptance guidelines as put forth
in the NFPA 2001 & NBC 2016 amended up-to date.
 The bidder shall be required to carry out a simulation test [with the Electrical
Solenoid on the Gas bank (Cylinder) disenabled / disengaged so as to prevent
discharge of gas and prove the functionality of the System.

PAGE - 914
SECTION-14- VRV/ VRF BASED AC
1.0 SCOPE
 These specification covers Design, Manufacture, Assembly, Inspection, Testing and
Commissioning of the VRV/ VRF, Precision & Split/window-based HVAC system to
meeting the intents of the Tender/design requirements to make the system
completely operational i/c all accessories.
 The design specifications indicated are minimum guidelines to enable the contractor
to carry out design and execute entire HVAC works to meet the indicative design/
employer’s AAI functional requirement and EPC contractor has submit detailed
design for entire HVAC works for approval.

1.1 Codes and Standards

HVAC system with all equipment’s/accessories shall be designed to conform to the
requirements of the following Standards with up to date amendments:

S.No. Applicable Standards /Mandatory Particulars

1 National Building Code of India - 2016 (NBC)
2 Energy Conservation Building Code ECBC 2017
3 CPWD Specification 2017 with up-to date amendments.
4 Indian Society of Heating, Refrigeration, and Air Conditioning Engineers
(ISHRAE) Hand Book
5 American Society of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE)
6 Bureau of Indian Standards (BIS) relevant codes
7 Duct construction standard as per SMACNA.

1.2 Design Calculation & Drawing

 EPC agency shall submit detailed design calculations with supporting documents as
described in Design Basis Report (Page No ……. Of this tender document) for
complete HVAC System.
 All Cooling load calculations shall be done using software.
 Detailed Drawings/layouts of all proposed equipment’s.
 Detailed Drawing /layout for ducting system for complete area to be airconditioned.
 Detailed Drawing /Layout of complete refrigerant & drain piping network for
complete area to be airconditioned.
 These drawings shall contain all information required to complete the Design and
Execute the Works and shall contain details of construction, size, arrangement,
operating clearances, performance characteristics and capacity of all items of
equipment, also the details of all related items of work.
 Single Line diagram & Control diagram of HVAC system with panels
 Drawing /schematics of Power and control wiring, cable trays, supports and
terminations.
 Make of all the proposed equipment’s shall be as per AAI Approve Make List of this
Tender.
 Model of all proposed equipment’s are selected to meet the all design requirements
& applicable codes & Standards.

PAGE - 915
  O & M Manual /Catalogue /Data sheet of all equipment’s.
 All HVAC drawings shall be coordinated with all other services drawings any impact
or change due to co-ordination will be absorbed by contractor.
 All drawings shall be prepared by the EPC contractor after examining the
Architectural & design requirement & the same shall be submitted to AAI for
Approval before start of execution work.
 Scope of work.

1.3 Technical Requirements of Air Cooled VRV/VRF System

2.0 General
 The scope of this section comprises the supply, erection testing and commissioning
of inverter based Variable Refrigerant Volume System and reluctance DC
hermetically sealed Scroll Compressor conforming to applicable standards & these
specifications and in accordance with the design requirements.
 All the VRF air conditioners shall be fully factory assembled, wired, internally piped
& tested.
 The outdoor unit shall be pre-charged with first charge of refrigerant. Additional
charge shall be added as per refrigerant piping at site.
 All the units shall be suitable for operation with 415 V +/- 10%, 50 Hz + 3%, 3 Phase
power supply for outdoor units; & 220 V +/- 10%, 50 Hz +/- 3%, 1 Phase power
supply for indoor units

2.1 TYPE
 The outdoor unit shall be air cooled variable refrigerant volume air conditioner of
R410A gas-based consisting of one outdoor unit and multiple indoor units. Each
indoor unit having capability to cool or heat independently for the requirement of
the rooms.
 It shall be possible to connect multiple indoor units on one refrigerant circuit.The
indoor units on any circuit can be of different type and also controlled individually.
 Following type of indoor units shall be considered for execution however the list is
not exhaustive and can be taken up as per site requirement: -

i) AHU with DX coil

ii) 4 Way Cassette Unit
 Compressor installed in outdoor unit shall be equipped with multiple inverter
compressors above 14 HP. The system shall be capable of changing the rotating
speed of inverter compressor by inverter controller to follow variations in cooling
and heating load.
 Outdoor unit shall be suitable for mix match connection of all type of indoor units.
 The outdoor units must be suitable for up to 165 m refrigerant piping between
outdoor unit & the farthest indoor units. Allowable level difference between
outdoor unit & indoor units shall be 90 m in case of outdoor unit on top & 50 m in
case of outdoor unit at bottom.
2.2 OUTDOOR UNIT
 The outdoor unit shall be factory assembled, weather proof casing, (Material of
construction of casing shall be ap per vendors standard design) constructed from
heavy gauge GI Sheet steel panels and coated with baked enamel finish. The Unit

PAGE - 916
 should be completely factory wired tested with all necessary controls and switch
gears.
 The outdoor unit should comprise of Inverter controlled Twin Rotary Compressor /
Scroll Compressor
 All outdoor units above 14 HP rating shall have minimum two number scroll / rotary
compressors.
 Each module of outdoor unit must have at least 50 % of Variable compressor which
can work on Part load Suitable to operate at heat load proportional to indoor
requirement.
 Selected module should have minimum COP 3.10 at 100% load and minimum 7 at
50 % in cooling mode at AHRI condition.
 The above COP values as indicated are required to be furnished in Original by the
successful bidder directly from the original equipment Manufacturer (OEM) with
OEM’s seal and signature on all documents.
 The unit shall deliver the rated capacity at AHRI Conditions and work even at 50°C
ambient temperature without tripping.
 The entire operation of outdoor units shall be through independent remotes of
indoor units. No separate Start/ Stop function shall be required.
 All the details pertaining to power consumption as per ARI standards should be duly
filled and furnished.
 It should also be provided with duty cycling for D.C inverter Twin Rotary/ Scroll
compressors capable of changing the rotating speed of compressor by inverter
controller to follow variation in cooling & heating loads & switching starting
sequence for better stability and prolonging equipment life or similar features if
available in D.C Twin Rotary / Scroll will also be accepted.
 The unit shall be provided with its own microprocessor control panel with provision
for integration with the building management system.
 The machine must have a sub cool feature to use coil surface more effectively
through proper circuit/ bridge so that it prevents the flushing of refrigerant from
long piping due to this effect thereby achieving energy savings.
 The outdoor unit should be fitted with low noise level and should not be more than
65 db (A) at normal operation when measured at a point 1 mtr. In front of the unit
at a height of 1.5 mtrs.
 The outdoor unit should be fitted with low noise aero spiral design fan with aero
fitting grill for spiral discharge airflow to reduce pressure loss and should be fixed
with DC/AC fan motor for better efficiency.
 In case of trouble occurs in an indoor units (s), the continuous operation of system
should be possible after taking corrective bypass action
 The unit shall be designed in such as way that cleaning of drain Pan should be easy
& inspection/ replacement of compressor should be easy.
 The condensing unit shall be designed to operate safely when connected to multiple
fan coil units
 The outdoor unit shall have refrigerant cool PCB chamber for better operation at
high ambient temperature.
 The systems shall have free phase technology & operation shall be continuous in
case of phase reverse in supply electricity.
 The outdoor units must deliver a minimum of 100 % of nominal capacity at ARI
condition.

PAGE - 917
  The fan static pressure of the outdoor unit shall be minimum 75 Pa to avoid hot air
recirculation.

2.2.1 COMPRESSOR
 The compressor in inverter-based D.C Twin Rotary / Scroll System shall be highly
efficient. The system should response efficiently in accordance to the variation in
cooling or heating load requirement:
 All outdoor units shall have multiple steps of capacity control to meet load
fluctuation and indoor unit individual control.
 All outdoor units shall have multiple steps of capacity control to meet load
fluctuation and indoor unit individual control.

2.2.2 Oil Recovery System

 Unit shall be equipped with an oil recovery system to ensure stable operation with
long refrigeration piping lengths. The system shall have oil sensor to monitor the
level of oil in compressor.
 The system must be provided with oil balancing circuit to avoid poor lubrication.

2.2.3 REFRIGERANT CIRCUIT

 The refrigerant circuit shall include liquid & gas shut-off valves and a solenoid valves
at condenser end.
 The equipment must have inbuilt refrigerant stabilization control for proper
refrigerant distribution.

2.2.4 Heat Exchanger

 The heat exchanger shall be constructed with copper tubes mechanically bonded to
aluminium fins to form a cross fin coil.
 The aluminium fins shall be covered by anti-corrosion resin film along with
hydrophilic coating.
 The unit shall be provided with necessary number of direct driven low noise level
propeller type fans arranged for vertical discharge. Each fan shall have a safety
guard.

2.2.5 SAFETY DEVICES

 All necessary safety devices shall be provided to ensure safe operation of the system.
 Whatever safety devices are required shall be part of outdoor unit: - high pressure
switch, fuse, fan drive overload protector, fusible plug, crankcase heater, over load
relay, overload protection for inverter-based technology.

2.3 INDOOR UNITS

 Indoor ceiling mounted unit equipped with synthetic washable media prefilter, fan
section with low noise fan/dynamically balanced blower, multi speed motor, coil
section with DX Copper coil, electronic expansion valve, outer cabinet, drain pump,
grill, necessary supports, vibration isolation, cordless remote control etc. suitable for
operation on single phase 230V±10%, 50 Hz AC supply, complete, as required.
 The unit shall have automatic force shut down provision in case of fire on receiving
signal from BMS System.
 The cooling capacity of indoor unit will be at air inlet conditions of 27 DegreeDB and
19 Degree C WB temperature.

PAGE - 918
i) AHU with DX coil.
The scope of this section comprises the supply, delivery to site, erection, testing and
commissioning of double skin construction air handling units, conforming to these
specifications and in accordance with requirements of drawings and of relevant
standards.

a) TYPE
The air handling units shall be double skin construction, draw through type comprising
of various sections, pre filters (MERV-8), Space for Electronic Air Cleaner, coil section
and fan section, mixing box with volume control dampers, (wherever the return air and
fresh air are ducted).

b) CAPACITY
The air handling and coil capacities, maximum motor horse power and static pressure
shall be as per design and standard

c) CASING
 The housing/ casing of the air handling unit shall be of double skin construction.
The housing shall be so made that it can be delivered at site in total/ semi knock
down conditions depending upon the construction. The framework shall be of
extruded aluminium hollow sections. All the members shall be assembled thru
mechanical joints to make a sturdy and strong framework for various sections.

 Outer sheet of double skin panels shall be made of 0.8mm thick pre-plasticized /
pre coated Galvanized sheet steel and inner sheet of 0.8mm thick G.I. Sheet with
insulation of 50 mm thick CFC free PUF injected insulation of 40 kg/m3 density
(min.).

 The panels shall be bolted to the framework with soft rubber gasket in between to
make the joints airtight. Suitable doors with powder coated hinges and latches shall
be provided for access to various panels for maintenance

 The Fan and the motor arrangement shall be mounted on to the common
framework. The entire housing i.e. The Air Handling Unit shall be mounted on GI
Base channel framework. Drain pan shall be constructed of 18 gauge SS sheet with
closed cell nitrile/ XLPE insulation. The Kvalue shall not be more than 0.029
Kcal/hr-sq.mtr-C/M at 10C mean temperatures. The pan shall have necessary
slope to facilitate for fast removal of condensate. The coil shall be mounted on the
rollers in order to facilitate easy removal of the coil from the drain pan for cleaning

 AHU panels shall be factory fitted with pressure ports for DPT installation. The
number and size of these shall be confirmed in the AHU technical approval stage.
In case opening is to be made in AHU panel, the same shall be with C-channel all
around to prevent entry of PUF into air stream. The channels shall be cut at 45
degrees at the corners to avoid overlap. Material for the channel shall be same as
that of internal skin of AHU.

PAGE - 919
  Rubber grommets shall be provided at all entry points into AHU such as coil
connection, cable entry etc. The same shall be double lip tight fitting to prevent air
leakage

 All access doors shall be outward opening. For doors provided downstream of the
fan, especially in high static AHUs, additional clamps shall be provided along
periphery of door to maintain constant pressure and ensure proper sealing.

 Water resistance marine light with power cabling shall be included.

 Micro switch with wiring for Door shall be provided such that fan motor shall stop
upon opening the door.

THERMAL BREAK PROFILE

All AHUs shall be provided with thermal break profile. Panels and thermal break
profiles for all AHUs shall be designed and assembled in such a way that there shall not
be any condensation on AHU with conditions of 350C and 92% RH (AHU surrounding
conditions) at designed operating conditions inside the AHU.

DAMPER
Dampers shall be opposed blade type. Blades shall be made of double skinned airfoil
aluminium sections with integral gasket and assembled within a rigid extruded
aluminium alloy frame. All linkages and supporting spindles shall be made of
aluminium or nylon, turning in Teflon bushes. Manual dampers shall be provided with
a bakelite knob for locking the damper blades in position. Linkages shall be extended
wherever specified for motorized operation. Damper frames shall be sectionalized to
minimize blade warping. Air leakage through dampers when in the closed position
shall not exceed 1.5% of the maximum design air volume flow rate at the maximum
design air total pressure.

MOTOR AND DRIVE

Fan motors shall be energy efficient (IE-3) and shall be 415±10% volts, 50 cycles, three
phase, totally enclosed fan-cooled class F, with IP-55 protection. Motors shall be
especially designed for quiet operation and motor speed shall not exceed 1440 rpm for
forward curved fan and 2900 rpm for backward curved fan. Drive to fan shall be
provided through belt-drive arrangement. Belts shall be of the oil-resistant type. The
fan motor shall be suitable for VFD operation

d) FAN
 Fans shall be “AMCA certified” (For Air and Sound performance) centrifugal,
forward curved / backward curved / backward curved airfoil so as to give
maximum efficiency for given duty condition. Fans driven by variable frequency
drive shall be backward inclined irrespective of static pressure value. Fans shall be
selected for minimum efficiency of 65% for forward curved and 75% for backward
curved/ airfoil. Fan casing shall be made of galvanised steel sheet. Fan wheels shall
be made of galvanised steel. Fan shaft shall be grounded C40- 45 carbon steel and
supported in self-aligning plummer block operating less than 75% of first critical
speed, grease lubricated bearings. Fan wheels and pulleys shall be individually
tested and precision balanced dynamically. Fan motor assembly shall be statically

PAGE - 920
 and dynamically balanced to G6.3 grade as per relevant ISO/AMCA standard.
Computerized fan selection print outs shall be submitted along with the offer.
 Motors shall be mounted inside the AHU casing on slide rails for easy belt
tensioning. Motors shall drive heavy duty V-belt, constant pitch, drive selected at
minimum 110% of motor horsepower.
 Both fan and motors assemblies shall be mounted on a deep section aluminium
alloy or galvanized steel (depending on size) base frame.
 Combination spring and rubber anti vibration mounts shall be provided for
isolating the unit casing. Flame retardant, waterproof silicone rubber impregnated
flexible connection shall be provided at the fan discharge.

e) COOLING COILS
 Chilled water coils shall have 12.7mm(1/2”) dia (O.D) tubes minimum 27SWG (0.4
mm) thick with sine wave aluminium fins firmly bonded to copper tubes assembled
in stainless steel frame. Face and surface areas shall be such as to ensure rated
capacity from each unit and such that the air velocity across the coil shall not exceed
150 meters per minute (500fpm).The coil shall be pitched in the unit casing for
proper drainage. The coil shall have copper header with chilled water supply &
return connections protruding out of AHU casing by minimum 150 mm and fitted
with dielectric coupling or adapter for connection with MS pipes. Each coil shall be
factory-tested at 21 kg per sq. cm air pressure under water. Tube shall be
hydraulically / mechanically expanded for minimum thermal contact resistance
with fins. Fin spacing shall be 11 to 13 fins per inch (4 – 5 fins per cm). Water
pressure drop in coil shall not exceed 10 PSIG(0.70 kg/cm.sq.).
 Coils shall be provided with mechanical means to purge air from the coil during
commissioning by means of a purge valve or nipple. To prevent splashing,
discharge from the same shall be routed to the condensate drain pan by means of
flexible PVC tubing of suitable diameter. Purge valve / nipple shall be accessible
externally or by removal of blanking panel.
 All floor mounted AHU*s shall be provided with minimum 6 Row Cooling Coil and
ceiling suspended AHUs shall be provided with minimum 4 Row Cooling Coil. TFA
units which receive pre-cooled fresh air can be provided with 6 row deep coil upon
verification of coil selection output.
 In case AHU has multiple coil stacked one above another, intermediate drain tray
of SS 304 (18 gauge) shall be provided so that upper level of coil drains into this
drain tray. Copper / SS 304 piping shall be provided from this drain tray upto main
bottom tray.
 Computerized cooling coil selection report shall be submitted. Coil rating shall be
as per AHRI-410 / EUROVENT Certified.

f) FILTER SECTION
Pre-Filter
 Each unit shall be provided with a 50 mm thick factory assembled filter section
containing washable synthetic type air filters having anodized aluminium frame.
The media shall be supported with High Density polyethylene (HDPE) mesh on one
side and aluminium mesh on the other side. Filter banks shall be easily accessible
and designed for easy withdrawal and replacement of filter cells. Filter bank
framework shall be fully sealed and constructed from GSS. The efficiency of the
filters shall be 90% down to particle size of 10 microns(MERV-8) in AHU*s, & HR

PAGE - 921
 units(in return air stream) as per IS 7613, and ASHRAE 52.1. Filters face velocity
shall not exceed 500 Feet per Minute. Filters shall fit so as to prevent by-pass.

Electronic Air Cleaner for AHU(Fan Section), HRU

Filters - Codes and Standards

a. ASHRAE 52.1 Gravimetric and Dust spot procedures for testing Air
cleaning devices.
b. IS 7613 Methods of testing panel type Air filters for HVAC.

g) FILTER ASSEMBLY
The housing shall be made from extruded aluminium sections. All joints shall be sealed
airtight and shall be made free of all burrs and sharp edges. The filter loading
mechanism shall be sliding type or front loading type. The locking mechanism shall be
a spring loaded, toggle type mechanism with a bolt and thrust assembly which shall
thrust the filter evenly against the sealing flange of the housing when it is installed.

h) MIXING BOX
AHU*s requiring mixing boxes shall be complete with fresh and return air dampers.

i) ISOLATORS
Vibration isolators shall be provided to all air handling units. The fan and motor
framework shall be isolated from the AHU framework by means of spring type
vibration isolators. The AHU shall be mounted on 6 inch high PCC block suitable for
weight of the AHU. The platform shall be 4 inch bigger than the AHU frame size from
all sides. The framework of the AHU and the P.C.C. block shall be isolated by means of
neoprene mats of size 150mmx150mm in two layers with 16g G.S.S. sheet sandwiched
in between

j) ACCESSORIES
Each air handling unit shall be provided with manual air vent at high point in the
cooling coil and drain plug in the bottom of the coil. In addition, the following
accessories may be required at air handling units, their detailed specifications are
given in individual sections.
a. Insulated butterfly valves, balancing valves, `Y* strainer, union & condensate drain
piping with *U* trap upto sump or floor drain in air handling unit room, as
described in section “Piping”.
b. Thermometers in the thermometer wells & pressure gauge (with cocks) within
gauge ports in chilled supply and return lines as per the section “Instruments”.
c. Minimum 2 Nos nameplates (1 in etched metal and other plastic) mounted onto
AHU panel with suitable water-resistant adhesive along with relevant warning
stickers on various panels. The nameplate shall give all relevant details including
fan model selected, motor KW, Air quantity and total static pressure.

k) PAINTING

PAGE - 922
 Shop coats of paint that have become marred during shipment or erection shall be
cleaned off with mineral spirits, wire brushed and spot primed over the affected areas,
then coated with paint to match the finish over the adjoining shop painted surface.

l) NOISE CONTROL
Air Handling Units shall be selected for the lowest operating noise level of the
equipment. Fan performance rating, power consumption, and sound power data with
operating points clearly indicated shall be submitted by the tenders along with
technical submittals for approval and verified at the time of testing and commissioning
of the installation. The sound level within the AHU room shall be less than 70 dB(A) at
a distance of 1 meter from AHU.

m) CONNECTIONS
Piping installation requirements are specified in other section. The Drawings indicate
the general arrangement of piping, valves, fittings, and specialties. The following are
specific connection requirements.
 Arrange piping installations adjacent to units to allow unit servicing and
maintenance.
 Connect piping to air-handling units with flanges enabling easy removal of the coil.
 Connect condensate drain pans using 50 mm (2-0 inch) minimum, insulated G.I.
pipe and extend to nearest floor drain. Construct deep trap (depth as per detail) at
connection to drain pan and install cleanouts at changes in direction.
 Duct installations and connections are specified in other sections. Make final duct
connections with flexible connections.
 Electrical Connections: The following requirements apply:
 Electrical power wiring is specified in section Electrical.
 Temperature control wiring and interlock wiring is specified in Section "Electrical
Control systems."
 Grounding: Connect unit components to ground in accordance with the Indian
Electrical Code.

n) ADJUSTING, CLEANING, AND PROTECTING

 Adjust water coil flow, with control valves to full coil flow, to indicate lpm (gpm).
 Adjust damper linkages for proper damper operation.
 Clean unit cabinet interiors to remove foreign material and construction dirt and
dust.Vacuum clean fan wheel, fan cabinet, and coils entering air face.

o) COMMISSIONING:
Final Checks before start-up- Perform the following operations and checks before
start-up.
 Remove shipping, blocking and bracing.
 Verify unit is secure on mounting and supporting devices, connections for piping,
ductwork and electrical are complete. Verify proper overload protection is installed
in motors, starters, and disconnects.
 Perform cleaning and adjusting specified in this Section.
 Lubricate bearings and other moving parts with factory recommended lubricants.
 Set outside-air / supply air dampers to minimum outside-air setting.
 Comb coil fins for parallel orientation.

PAGE - 923
  Install temporary throw away filters for initial run and finally install clean filters.
 Verify manual and automatic volume control, and fire dampers in connected
ductwork system are in the full-open position.
 Disable automatic temperature control operators.
 Starting procedures for central-station air-handling units:
 Energize motor, verify proper operation of motor, drive system, and fan wheel.
Adjust fan to indicate RPM.
 Replace fan and motor couplings as required to achieve design conditions.
 Measure and record motor electrical values for voltage and ampere.
 Shut down and reconnect automatic temperature control operators

p) TESTING
Cooling capacity of various Air handling units shall be computed from the
measurements of air flow and dry and wet bulb temperatures of air entering and
leaving the coil. Flow measurements shall be by a calibrated rotating vane anemometer
and temperature measurements by accurately calibrated mercury-in-glass
thermometers. Computed ratings shall conform to the specified capacities and quoted
ratings. Power consumption shall be computed from measurements of incoming
voltage and input current, whereas, noise level at various locations within the
conditioned spaces shall be measured by a sound pressure level meter.

ii) 4 Way Cassette type indoor units:

a) These units shall be installed between the bottom of finished slab & top of false
ceiling.
b) Unit shall have provision of connecting fresh air without any special chamber &
without increasing the total height of the unit (320 mm maximum).
c) The unit must have in built drain pump, suitable for vertical lift of 750 mm.
d) Unit must be insulated with sound absorbing thermal insulation material,
Polyurethane foam. The sound pressure level of unit at the highest operating level
shall not exceed 46 dB (A).
e) The unit must have drain pump kit if. The drain pump must be suitable to lift drain
up to 1000 mm from the bottom of the unit.
f) The cassettes units shall have dual sensors to detect the presence of people and
floor temperature respectively to provide comfortable air-conditioning and energy
saving.

Note - Make of all outdoor, Indoor & Compressor unit shall be same.
iii) Push Button Type Central Controller
a) The contractor has to provide push button type central controller for controlling
all indoor units, monitoring of corresponding outdoor units from one central
location. Central controller should be compatible with BMS on open protocol like
BACnet, Lon works, Modbus. It must show the status of all indoor units along with
outdoor unit.
 Central Controller unit provide following minimum features-
 ON/OFF of individual & group of Indoor Units.
 Temperature setting of individual & group of Indoor Units.
 Scheduling, lock/unlock, swing control, error detection.
 Indication of operating units.

PAGE - 924
  LEC/LED display.
 BMS compatibility to control and monitor as described above through BMS.

iv) Condensate Drain Piping

a) All pipes to be used for condensate drain shall be PVC pipe conforming to IS: 4985
- Class I
b) Minimum 25mm dia. uPVC pipes used for branch circuit.
c) Minimum 32 mm dia. uPVC pipes used for Headers
d) All joints should be Gluing or solvent cementing as per manufacturer
recommendation.

v) REFRIGERANT CIRCUIT
a) All refrigerant piping shall be installed strictly as per the instructions and
recommendations of air conditioning equipment manufacturers.
b) Specification of refrigerant pipe shall be as per Item No-5 of CPWD DSR 2019
issued for VRV/VRF System.
c) Refrigerant lines shall be sized to limit pressure drop between evaporator and
condensing unit to less than 0.2 kg per Sq.cm.
d) After the refrigerant piping installation has been completed the refrigerant piping
system shall be pressure tested using, Freon mixed with nitrogen at a pressure of
20 Kg per Sq. cm. (High side) and 10 Kg per Sq. cm (Low side). Pressure shall be
maintained on the system for 24 hours.
e) The system shall then be evacuated to a minimum vacuum of 70 cm. of mercury
and held for 24 hours, during which time; change in vacuum shall not exceed 12
cm of mercury.
f) The refrigerant circuit shall include liquid & gas shut-off valves and a solenoid
valves at condenser end.
g) All necessary safety devices shall be provided to ensure the safely operation of the
system.

vi) Installation
a) The units shall be mounted on ribbed rubber pads for vibration isolation. The
contractor shall supply the required charge of refrigerant, lubricant and other
consumables, for commissioning and testing of the equipment.
b) All the equipment shall be thoroughly tested and checked for leaks. All safety
controls shall be suitably set and a record of all setting shall be furnished to the
project supervisor.
c) Providing and fixing M.S. structural support for condensing unit with vibration
isolator pad in-between support and structure and vibration isolation suspender
and pads for evaporating units shall be in scope of contractor

vii) Painting
a) Shop coats of paint that have become marred during transportation or erection
shall be cleaned off with mineral spirits, wire brushed and spot primed over the
affected areas, then coated with enamel paint to match the finish over the adjoining
shop- painted surfaces.

viii) Electrical Works-Power Supply & Control wiring

PAGE - 925
 a) Complete power supply work i/c provision of MCC/LT Panel for ODU with dual
power source from Main LT Panel.
b) Cabling work for power & control of complete HVAC system as per design
requirements.
c) Power supply near the indoor unit will be provided with suitable 6A plug point
socket & switch.
d) However, where the power requirement is of central control from ODUs, as per the
design of the system, the entire power supply & control wiring shall be done by the
Agency.
2.4 SPLIT AIR CONDITIONING UNITS
2.4.1 Scope
The scope of this section comprises the supply, erection, testing and commissioning of
Air-Cooled Split Units conforming to these specifications for Substation, Fire Station as
per design requirements.

2.4.2 Type & Capacity

 The Split Units shall be BEE 5-star rating (applicable as on date of supply of item)
consist of Inverter compressor, motor, air cooled condenser, integral refrigerant
piping and wiring, complete in all respect.
 Indoor unit to be installed for Split (Unit within building/outside building as per
design requirements) shall be housed in insulated cabinet consisting of cooling
coil, blower with motor, filter & insulated drain pan. Split unit must deliver
specified capacity after considering loses due to piping length & site conditions.
 The refrigeration capacity of split unit shall be as per actual requirement work out
by EPC Contractor.

2.4.3 Compressor and Motor

 Compressor shall be inverter type hermetic reciprocating/rotary/scroll
compressor(s), air-cooled condenser, condenser fans with motors, internal piping,
switches and internal wiring and shall be enclosed in a weather proof out door type
housing, shall have dual pressure stat, and an operating oil charge.
 The motor shall be suction gas cooled and shall be sealed against dirt and moisture.
The motor shall be suitable for 415±10% volts or 230±10 % volts, 50 Hz, A.C.
supply.

2.4.4 Refrigerant Piping and Controls

Refrigerant piping and fittings interconnecting compressor condenser shall be all
copper and valves shall be brass / gunmetal construction. The refrigerant used shall
be ozone friendly HFC R410A.
2.4.5 Casing
The indoor & outdoor units shall be sectionalized / cabinet construction. Indoor units
shall be consisting of fan section, coil section, filter section, and drain pan. Outdoor unit
shall consist of condenser coil, fan & compressor. The compressor shall be mounted
with the outdoor units. Each section shall be constructed of thick sheet steel all welded
/ bolted construction, adequately reinforced with structural members and provided
with sufficient access panels for proper lubrication and maintenance. Base panel shall

PAGE - 926
 be constructed of fabricated steel structure provided with an under frame suitably
braced. Drain pan shall extend under coil and fan sections with drain connections.
Removable panels in fan and coil sections shall provide access to all internal parts.
2.4.6 Fan Motor and Drive
Fan motor shall be suitable for 415 ± 10% volts or 230±10% volts, 50 Hz, A.C. Supply,
Single phase, motors shall be provided with permanent capacitor. Motors shall be
especially designed for quite operation.

2.4.7 Fan
 Fan wheels and housing shall be fabricated from heavy gauge steel.
 Fan wheels shall be of double-width, double inlet forward-curve, multi-blade type
enclosed in a housing and mounted on a common shaft.
 Fan housing shall be made of die-formed steel sheets with stream-lined inlets to
ensure smooth air flow into the fans, fan shaft bearing shall be oil/grease
lubricated.
 All rotating parts shall be dynamically balanced individually, and the complete
assembly shall be statically and hydraulically balanced.
2.4.8 Cooling Coil
 Cooling coils shall be of fin and tube type having aluminum fins firmly bonded to
copper tubes assembled in zinc coated steel frame. Face and surface areas shall be
such as to ensure rated capacity from each unit and air velocity across each coil
shall not exceed 100 meters per minute.
 The coil shall be pitched in the unit casing for proper drainage.
 Each coil shall be factory-tested at 21 Kg. per sq.cm air pressure under water.
 Water coils shall be designed for a maximum working pressure of 10 kg/sq.cm.
 Tube shall be mechanically / hydraulically expanded for minimum thermal
contract resistance with fins. The number of fins per cm. shall be 4 to 5.
2.4.9 Precision Air conditioner

2.5 Scope
The scope of this section comprises the supply, erection, testing and commissioning of
Precision air-conditioning Unit complete for Control Tower/UPS /Server room
/Control room as per design requirements.

2.5.1 Type & Capacity

 Precision air-conditioning Unit shall be complete with microprocessor controller
consist of hermetically sealed Scroll compressors, evaporator fan, motor, strip
heaters, integral refrigerant piping and control panel duly wired to compressor
and air-cooled condenser all mounted on a steel frame.
 Unit shall BMS Compatibility with open protocol for software integration.
 The Air-cooled condenser with fan duly mounted on a common frame shall be
installed on the Surface/wall openings / terrace with suitable angle iron / channel
frame, starters, switches, power & control cabling between Indoor unit and
outdoor unit .

PAGE - 927
  The refrigeration capacity and air quantity for the unit shall as per design
requirements.
 Agency shall submit design calculation for refrigeration capacity and air quantity
for prior approval from AAI .
2.5.2 Casing
 The indoor & outdoor units shall be sectionalized / cabinet construction.
 Indoor units shall be consisting of compressor, fan section, coil section, heater and
humidification section, pre and fine filter section, and drain pan.
 Outdoor unit shall consist of condenser coil and propeller type fan.
 Each section shall be constructed of heavy gauge Zinc-anneal corrosion resistant
sheet steel.
 The fan section shall be insulated with minimum 25 mm thick fire rated insulation.
 The cabinet shall be powder coated and have a textured finish. The Indoor cabinet
shall be with Double Skin Side Panels & front & back panels shall be with 25mm
thick acoustic mineral wool.
 Base panel shall be constructed of fabricated steel structure provided with an
under frame suitably braced.
 Each unit shall include one-piece drain pan constructed of 20-gauge galvanised
sheet steel plate. Drain pan shall extend under coil and fan sections with drain
connections. Removable panels in fan and coil sections shall provide access to all
internal parts.

2.5.3 Compressor and Motor

Compressor shall be hermetic Scroll, serviceable type and shall have dual pressure stat,
and an operating oil charge. The motor shall be suction gas cooled and shall be sealed
against dirt and moisture. The motor shall be suitable for 415±10% 50 Hz, A.C. supply.
Refrigerant shall be HFC-134a/410a.

2.5.4 Fan Motor and Drive

 Fan motor shall be suitable for 415 ± 10% volts 50 Hz, A.C. supply.
 Motors shall be especially designed for quite operation and motor speed shall not
exceed 1440 rpm.
 Motor shall be with Variable speed drive.
 Speed shall be controlled through micro-processor panel based on temperature
and humidity set points.

2.5.5 Fan
 Fan shall have minimum 650 cfm /TR. Fan wheels and housing shall be fabricated
from heavy gauge steel. Fan wheels shall be of double-width, double inlet forward-
curve, multi-blade type enclosed in a housing and mounted on a common shaft.
 Fan housing shall be made of die-formed steel sheets with stream-lined inlets to
ensure smooth air flow into the fans, fan shaft bearing shall be oil/grease
lubricated.
 All rotating parts shall be dynamically balanced individually, and the complete
assembly shall be statically and hydraulically balanced.

PAGE - 928
  Fan speed shall not exceed 1000 rpm and maximum fan outlet velocity shall be 550
meters per minute.

2.5.6 Filters
 Pleated type standard filters shall be provided with cardboard frame
 The filters shall be housed horizontally on the top of Under units and housed in
front of the coil, behind the return grille in the front panel of Over units; they shall
be easily removable.
 Filtration shall be 95% down to 5 microns.
2.5.7 Humidifier & Heater
 The unit shall be fitted with internal humidifier.
 Humidity production shall be controlled by microprocessor.
 Heater shall be provided with On-Off electronic temperature control and a safety
thermostat with manual reset.

2.5.8 Dehumidification
A specific dehumidification cycle as per manufacturer shall be provided to achieve
desired climatic condition.

2.5.9 Evaporator
 The evaporator coil shall be constructed of copper tubes and slit aluminium fins,
with G.I. frame and drip tray fabricated out of stainless steel.
 The cooling coil shall be a minimum of 4 row deep & no. of fins per cm. shall be 4
to 5.
 The distance between the fins shall not be less than 1.8 mm and face velocity shall
be less than 2.3 mts./sec.
 Aluminium fins have hydrophilic treatment on the surface to reduce water leakage.
 Evaporator surface must be designed to provide a very high level of sensible
cooling capacity, i.e. Sensible Heat Ratio (SHR) shall be > 0.9 when relative
humidity is 50%.
 The coil should have a SS drip tray to collect the condensed water. The unit shall
be floor mounted shall be designed for 24/7 operation in all respects.
 Unit shall be provided with dual cooling coils. Cooling coils shall be of fin and tube
type having aluminium fins firmly bonded to copper tubes assembled in zinc
coated steel frame.
 The coil shall be pitched in the unit casing for proper drainage.
 Each coil shall be factory-tested at 21 Kg. per sq.cm air pressure under water.
 Tube shall be mechanically / hydraulically expanded for minimum thermal
contract resistance with fins.

2.5.10 Refrigerant Piping and Controls

 Refrigerant piping and fittings interconnecting compressor condenser shall be all
copper and valves shall be brass / gunmetal construction.
 Piping thickness shall be designed based on type of refrigerant and superheated
gas pressure at full load, corresponding to ambient temperature of 52 degree C.

PAGE - 929
  The refrigerant circuit shall include the electronic expansion valve, the dryer filter,
the sight glass, liquid receiver and safety valve.

2.5.11 Painting.
Units shall be factory finished with durable alkyd spray enamel. Shop coats of paint
that have become marred during shipment or erection shall be cleaned off with mineral
spirits, then coated with enamel paint to match the finish over the adjoining shop-
painted surface.

2.5.12 Performance Rating

 The unit shall be selected for the lowest operating noise level (65dBA at 3m).
Capacity rating and power consumption with operating points clearly indicated
shall be verified at the time of testing and commissioning of the installation.
 For site verification of working of humidification / dehumidification systems, set
point RH shall be changed below / above (respectively) actual RH.
 Similar procedure shall be adopted for temperature control system. Test report
shall indicate selected set point for RH and temperature and achieved values of
these process variables after humidification / dehumidification cycles are
activated.
2.5.13 Controls
 The controller shall be of microprocessor based programmable PID logic
controller.
 The controller shall have an LCD backlit graphic display for clear visibility of text
and graphics, which shall be visible from the front of the unit without removing
any covers/external panels.
 The controller shall have programming feature for -
Temperature set point
Humidity Set point
Return temperature control
 The controller audible, visual alarm & sperate Indication for -
i) Various modes of operation (cooling, heating)
ii) Alarm conditions (temperature Low & high, Humidity Low & High wet
floor and loss of air flow)
iii) Graphical displays of set temperature and achieved temperature.
iv) Date, time and unit identification display
v) Back up battery charge status display on the controller screen
vi) Visual system alarm indication (along with mutable audio alarm as well)
vii) 48 hrs temperature graph display menu.
viii) Programmable services interval indication display

 The system shall have a menu driven interface with supporting help screens and
shall use multi-protocol data communications. Access to the controller settings
shall be protected with passwords to prevent against unauthorized access.
 The unit shall be capable of communicating through an RS-232 communication
support to link upto 99 units for monitoring and control purposes. The controller

PAGE - 930
 should also incorporate 2 additional spare alarm inputs for customer interface (e.g.
Unauthorized entry alarm, building fire alarm etc.) manual override switches &
selectable alarms. Local & remote alarms will be triggered in case of any alarm
conditions being reached.
 The unit shall also incorporate the following protections:
i) Single phasing preventers.
ii) Reverse phasing
iii) Phase im-balancing
iv) Phase failure
v) Overload tripping (MPCB) of all components

2.5.14 Thermal / Acoustic Lining and Insulation

This Section deals with supply and fixing of thermal / acoustic insulation of ducts,
pipes etc. as per the specification given.

3.0 MATERIAL OF INSULATION

3.1 Indoor Application – Piping / Ducting / Underdeck Insulation – Thermal
i) Insulation material shall be Closed Cell Elastomeric Nitrile Rubber.
ii) Thermal conductivity of insulation material shall be as per ASTM/EN standard. The
insulation material shall have fire performance such that it passes Class 1 as per
relevant BIS for surface spread of flame and also passes Fire Propagation
requirement as per relevant BIS to meet the Class ‘O’ Fire category.
iii) Density of insulation material shall be minimum 40 Kg/m3.
iv) The insulation material shall be dust and fibre free.
v) The material shall have zero ODP (Ozone Depletion Potential) and GWP (Global
Warming Potential) as per NBC requirement.
vi) The insulation material shall be installed as per manufacturer’s recommendation.
vii) Thickness of Insulation shall be as per CPWD specification.

 Accessories – Pipe Supports

Factory made Elastomeric Nitrile Rubber Insulated pipe support, single piece with self-
adhesive closure, PUR/PIR load bearing Inserts, embedded in Elastomeric Nitrile
Rubber insulation with two outer metal shells made of aluminum sheet, which also acts
as a vapour barrier for the CFC Free - PUR/PIR insert

 Insulation Covering Detail

i) Covering material is a double layer laminate of aluminium, coated with a special
UV protection and a PVC backing. Covering material shall be non-metallic.
ii) Covering material shall provide mechanical resistance with an excellent aesthetic
look.
iii) Covering material shall be glossy finish.
iv) Covering material shall have good puncture and tear resistance.
v) Covering material shall have good UV resistance as per relevant standard.

3.2 Duct Insulation

For Duct thermal insulation - Nitrile Rubber – as follows:
I. MATERIAL SPECIFICATIONS

PAGE - 931
 e) Insulation material shall be Closed Cell Elastomeric Nitrile Rubber with anti-
microbial properties and with factory laminated Aluminium Foil with reinforced
glass scrim of 12 microns’ thickness.
f) The insulation material shall give enhanced level of protection against harmful
Microbes such as bacteria, mold, mildew and fungi and should confirm to relevant
standards.

Pressure sensitive self-adhesive tape (PSA) Tape: 50 mm width (with glass cloth
only).
Type: Solvent based Acrylic Adhesive
Peel Strength: 1000 gm / 25 mm (minimum) - (Adhesive to steel)
UV Resistance: Glass Cloth shall be UV resistant for artificial weathering as per relevant
standards.
Specification for Tapes:
Glass Cloth foil-based tape with self-adhesive ability to ensure 100% leak-proof joints.
The tape shall be with a pre-coated layer of solvent based adhesive which is non-
hazardous in nature.
Width: 50 mm +/- 2 mm
GC Thickness: 180 micron
Length: 8.4 meter +/- 100 mm
3.3 Duct Acoustic Insulation:
Specifications:
 Acoustic insulation material shall be Open Cell Engineered Nitrile Rubber foam.
 The Random Incidence Sound Absorption Coefficient (RISAC) of the material - Tested
as per relevant ASTM standard.
 The acoustic insulation material shall have antimicrobial property and shall pass
Fungi / Mould Resistance as per relevant standard and tested from an independent
testing agency.

4.0 AXIAL FLOWFAN (for Fire, Smoke and Normal exhaust)

 Axial flow fan shall be of Tube Axial direct driven type with cast aluminium aerofoil
propellers and shall be suitable for mounting in duct or floor/slab as per design
requirement. Axial Flow Fan shall be AMCA certified for Air and Sound performance
in accordance to AMCA 210 and AMCA 300 and suitable for Indoor as well as outdoor
applications.
 Motors for emergency fire, smoke and heat ventilation shall have certified according
to standard BS EN 12101-3:2002 for 250oC for 2 hours,
 Fan shall be complete with motor, motor mount, direct driven and vibration isolation
type, suspension arrangement as per approved shop drawings for construction

PAGE - 932
 Casing: shall be constructed of heavy gage sheet steel and shall withstand 250°C for
2 hours as per NBC-2016. Fan casing, motor mount and straightening vane shall be of
bolted construction. Motor mounting plate shall be of structural steel suitable to
handle the weight of the motor and propeller, machined to receive motor flange.
Casing shall have flanged connection on both ends for ducted applications. Fan casing
shall be with internal punched inlet and outlet flanges to prevent air leakage, for size
upto 1600 mm dia and shall be constructed of rolled steel with a continuous seam
welded. Support brackets for ceiling suspension shall be bolted to the casing for
connection to hanger bolts. Straightening vanes shall be aerodynamically designed
for maximum efficiency by converting velocity pressure to static pressure potential
and minimizing turbulence. Casing shall be hot dip galvanized with minimum 220
GSM Zinc Coating.

 Rotor: hub and blades shall be cast aluminium alloy or cast steel construction and
shall withstand 250 °C for 2 hours. Blades shall be die-formed aerofoil shaped for
maximum efficiency and shall vary in twist and width from hub to tip to effect equal
air distribution along the blade length. Rotor shall be statically and dynamically
balanced. Motor with frame sizes above 180 shall be provided with extended grease
leads for external lubrication. The impeller and fan casing shall be carefully matched
and shall have precise running tolerances for maximum performance and operating
efficiency.

 Motor: shall be of minimum efficiency of IE2, squirrel- cage, totally-enclosed, fan

cooled, standard frame, constant speed, continuous duty, single winding, suitable for
415±10% volts, 50 cycles, 3 phase AC power supply with class F insulation. Motor
shall be specially designed for quiet operation. Fan total efficiency should not be less
than 70 % and noise level should not be more than 75 dB(A) @ 3 m distance when
measured in hemispherical reverberant room conditions. Motor conduit box shall be
mounted on exterior of fan casing, and lead wires from the motor to the conduit box
shall be protected from the air stream by enclosing in flexible metal conduit/vanes.
All the High temperature Fans should either be EN-12101-3-2002 or UL tested for
High temperature (UL Power & smoke Ventilation listed) for a minimum of 250 Deg
C for a minimum of 2 Hrs and should be UL or CE labelled. Motor conduit box shall be
mounted on exterior of fan casing, and lead wires from the motor to the conduit box
shall be protected from the air stream by enclosing in flexible metal conduit/vanes.

 Drive : Fan shall be provided through direct drive.

 Vibration Isolation: The assembly of fan and motor shall be suspended from the slab
by vibration isolation suspension of heavy duty spring isolators type.

 Accessories : The following accessories shall be provided with all fans:

i) Outlet cone for static pressure regain.
ii) Inlet cone.
 Fan silencers may be provided, as per ASHRAE/ISHRAE/CPWD standard. Complete
fan shall be factory assembled and shipped with all accessories. All high temperature
fans to be used for fire application shall bear the certification/listing of UL/CE (in
addition of being AMCA certified for Sound and Air Performance) conforming to UL-

PAGE - 933
 705 “Power Ventilator for smoke exhaust” or EN12101-3-2002 smoke and heat
control system specification for powered smoke and heat exhaust ventilator.

5.0 INLINE FANS

5.1 Circular Inline Fans
 Circular inline Centrifugal duct fan shall be energy efficient straight through radial
fan. It should be compact in design.
 The fan shall cope with high pressure and long duct runs, whilst still operating at an
acceptable sound level.
 The circular inline fans should be moisture resistant and should be approved for
installing in humid or damp environments.
 The fans should be rated IP-44 when installed in a duct system. The casing should be
manufactured from pre-galvanized steel. Automatic thermo – contact shall open up if
the temperature within the motor windings becomes excessive. Fan should be
equipped with CE certified external rotor single phase asynchronous motor.

5.2 Cabinet Inline Fans (Above 500 CFM capacity)

 The Cabinet of the cabinet inline fans should be manufactured in 20 gauge galvanized
steel complete with inlet and outlet spigots
 The cabinet of the fan shall be of double skin construction with 20-gauge GI outer skin
with 25 mm glass wool wrapped tissue paper and covered with 20-gauge perforated
GI sheet from inside.
 The Mounting brackets and access panel should be fitted as per manufacturer
standard.
 The impeller of the fans should be with high efficiency forward curved DIDW type.
 The scroll of the fans should be fabricated with galvanized sheet steel.
 The motor of the fans shall be Squirrel cage induction type with bearings swealed for
life. The motor shall be energy efficient suitable for single phase electrical supply. GI
sheet from inside.

6.0 Installation, Testing & Performance of Fans

 The Contactor shall supply all required bolts, base frame (wherever required),
vibration isolators any other accessories and shall assure that the components are
placed securely in proper position.
 Vibration isolators shall be provided with an efficiency of not less than 80%.
 All the fans shall be tested for performance at the factory and the following test results
shall be furnished:
i) CFM
ii) Static pressure at the specified flowrate
iii) KW input to motor

 Capacity of all fans shall be measured by an anemometer. Measured air flow capacities
shall conform to the specified capacities and quoted ratings. Power consumption shall
be computed from measurements of incoming voltage and input current.

7.0 AIR DISTRIBUTION

(FOR DUCTS FABRICATED IN FACTORY AS PER “SMACNA” STANDARDS)

PAGE - 934
7.1 Scope
 The scope of this section comprises design, supply, fabrication, installation and
testing of all sheet metal / aluminum ducts, grilles, registers and diffusers and
balancing of all.

7.2 Duct Raw Materials

 Galvanized steel sheets with Class - VIII Galvanizing – light coating of zinc (Zinc
coating shall be Lead free), nominal 120gm/sq.m surface area and Lock Forming
Quality prime material along with mill test certificates.
 In addition, if necessary, samples of raw material, selected at random by AAI site
representative shall be subject to approval and tested for thickness and zinc coating
at contractor expense.
 Distance of reinforcement/bracing from each joint. Bracing material to be same as
of material used for joining of duct sections.
 For Aluminum Ducts, Minimum material thickness shall 22 G

7.3 Gauges, Bracing By Size Of Ducts

 All ducts shall be factory fabricated from galvanized steel / aluminum of the
following thickness, as indicated below For Ducts with External SP upto 250 Pa
 External Pressure 250 Pa Duct Section Length 1.2 m (4 ft)

Maximum Duct Size Gauge Joint Type Bracing Spacing

1–1200 mm 24 TDF Flange Nil
1201 – 1500 mm 22 TDF Flange Nil
1501 – 1800 mm 20 TDF Flange Nil
1801 – 2100 mm 20 TDF Flange JTR or ZEE BAR
2101 – above 18 TDF Flange JTR or ZEE BAR

 For Ducts with External SP upto 500 Pa

Rectangular Ducts G. S. External Pressure 500 Pa

Duct Section Length1.2 m (4 ft)
Maximum Duct Size Gauge Joint Type Bracing Spacing
1–400 mm 24 TDF Flange Nil
401-900 mm 22 TDF Flange Nil
901-1200 mm 20 TDF Flange JTR or ZEE BAR
1201-2100 mm 18 TDF Flange JTR or ZEE BAR
2101-above 16 TDF Flange JTR or ZEE BAR

7.4 Fabrication Standards & equipment’s

 All duct construction and installation shall be in accordance with SMACNA
standards. In addition, ducts shall be factory fabricated utilizing the following
machines to provide the requisite quality of ducts:
 Coil (Sheet metal in Roll Form) lines to facilitate location of longitudinal seams at
corners/folded edges only, for required duct rigidity and leakage free
characteristics. No longitudinal seams permitted along any face side of the duct.
 All ducts, transformation pieces and fittings to be made on CNC profile cutter for

PAGE - 935
 requisite accuracy of dimensions, location and dimensions of notches at the folding
lines.
 All edges to be machine treated using lock formers, flange and rollers for turning
up edges.

7.5 DUCT CONSTRUCTION

 All ducts shall be fabricated and installed, conforming to relevant SMACNA codes.
 Ducts as per design & standard requirements, shall be acoustically lined and
insulated from outside as described in the section “Insulation”.
 All ducts shall be fabricated out of galvanized sheet steel (GSS) for long life and as
per fire norms as per National Building Code 2016 Part 4: Fire and Life Safety as
well as Part 8 Building services-Section 3 (Air- conditioning, heating and mechanical
ventilation) clause no. 7.2.7 Thermal insulation.
 Duct dimensions shall be per construction/shop drawings, are overall sheet metal
dimensions inclusive of the acoustic lining where required. The fabricated
duct dimensions should be as per approved drawings and care should be taken to
ensure that all connecting sections are dimensionally matched to avoid any gaps.
 Ducts shall be straight and smooth on the inside with longitudinal seams shall be
airtight and at corners only which shall be either Pittsburgh or snap button as
per SMACNA practice, to ensure airtightness.
 All ducts up to 75cms width within conditioned spaces shall have C &S connector.
The internal ends of slip joints shall be in the direction of airflow. Care should be
taken to ensure that Cleats are mounted on the longer side of the duct and Cleats on
the shorter side. Ducts and accessories within ceiling spaces, visible from air-
conditioned areas shall be provided with two coat of black finish paint.
 Air-turns (vanes) shall be installed in all bends and duct collars designed to permit
the air to make the turn without appreciable turbulence.
 All ducts shall be rigid and shall be adequately supported and braced where
required with standing seams, tees, or angles, of ample size to keep the ducts
true to shape and to prevent buckling, vibration or breathing.
 All sheet metal connection, partitions and plenums, required to confine the flow of
air to and through the filters and fans, shall be constructed of 18 gauge GSS/16 gauge
aluminum, thoroughly stiffened with 25mm x 25mm x 3mm galvanized steel angle
braces and fitted with all necessary inspection doors as required, to give access
to all parts of the apparatus. Access doors shall be not less than 45cm x 45cm in size.
 Plenums shall be shop/factory fabricated panel type and assembled at site. Fixing of
galvanized angle flanges on duct pieces shall be with rivets heads inside i.e. towards
GS sheet and riveting shall be done from outside.
 Self-adhesive Neoprene rubber / UV resistant PVC foam lining 5mm nominal
thickness instead of felt, shall be used between duct flanges and between duct
supports in all ducting installation.
 All fire rated duct, smoke exhaust ducts shall be quoted with flame bar BWII or
equivalent to achieve the required fire rating .
 All the related accessories gaskets shall be suitable for the required fire rating.

7.6 INSTALLATION PRACTICE

 All ducts shall be installed strictly in accordance with approved shop drawings (shop
drawings to be prepared by the Agency & prior approval shall be taken from AAI)
 All necessary allowances and provisions shall be made for beams, pipes, or

PAGE - 936
 other obstructions in the building, whether or not the same are shown on the shop
drawings.
 Where necessary to avoid beams or other structural work, plumbing or other pipes,
and conduits, the ducts shall be transformed, divided or curved to one side (the
required area being maintained) all as per the site & design requirements.
 If a duct cannot be run as shown on the shop drawings, the agency shall install the
duct between the required points by any path available in accordance with other
services and as per approval of AAI site representative.
 All ductwork shall be independently supported from building construction. All
horizontal ducts shall be rigidly and securely supported, with hangers formed of
galvanized steel wire ropes and galvanized steel angle/channel or a pair of brackets,
connected by galvanized steel wire hanger sunder ducts.Rigid supports may be
provided at certain interval, if vertical ductwork shall be supported by structural
members on each floor slab. Duct supports may be through galvanized steel insert
plates or Toggle end wire fixing left in slab at the time of slab casting.
 Galvanized steel cleat with a hole for passing the wire rope hanger shall be
welded to the plates. Trapeze hanger formed of galvanized steel wire rope
using Grapple shall be hung through these cleats.Wherever use of metal insert plates
is not feasible, duct support shall be through dash/anchor fastener driven into the
concrete slab by electrically operated gun. Wire rope supports shall hang through
the cleats or wire rope threaded studs can be screwed into the anchor fasteners.
 All horizontal ducts shall be rigidly and securely supported, , with trapeze hangers
formed of galvanized steel rods and galvanized steel angle/channel or a pair of
brackets, connected by galvanized steel rod under ducts. The spacing between
supports should be not greater than 2.0 meter . All vertical ductwork shall be
supported by structural members on each floor slab.
 Duct supports may be through galvanized steel insert plates left in slab at the time
of slab casting. Galvanized steel cleat with a hole for passing the hanger rods shall be
welded to the plates. Trapeze hanger formed of galvanized steel rods shall be hung
through these cleats. Wherever use of metal insert plates is not feasible, duct support
shall be through dash/anchor fastener driven into the concrete slab by electrically
operated gun. Hanger rods shall then hang through the cleats or fully threaded
galvanized rods can be screwed into the anchor fasteners.
 Ducting over furred ceiling shall be supported from the slab above, or from beams
after obtaining approval of AAI representative. In no case shall any duct be
supported from false ceiling hangers or be permitted to rest on false ceiling. All metal
work in dead or furred down spaces shall be erected in time to occasion no delay to
other contractor*s work in the building.
 Where ducts pass through brick or masonry openings, it shall be provided with
25mm thick TF quality expanded polystyrene around the duct and totally covered
with fire barrier mortar for complete sealing.
 All ducts shall be totally free from vibration under all conditions of operation.
 Flexible connection located at the unit discharge, shall be provided for connection of
ductwork to fans, air handling units or blower coil units that may cause vibration in
the ducts.
 Flexible connections shall be constructed of fire retarding flexible heavy canvas
sleeve at least 10cm long securely bonded and bolted on both sides. Sleeve shall be
made smooth and the connecting ductwork rigidly held by independent supports on
both sides of the flexible connection. The flexible connection shall be suitable for

PAGE - 937
 pressure at the point of installation.

8.0 DAMPERS
 Volume Control dampers shall be opposed blade type, robust in construction and
tightly fitted. The design, method of handling, and control shall be suitable for the
location and service required.
 The damper shall be of Galvanized sheet steel. The sheet thickness of blade shall be
0.8 mm and of the frame shall be 1.0mm
 Dampers shall be provided with suitable links, levers and quadrants as required for
their proper operation; control or setting devices (actuator) shall be made robust,
easily operable and accessible through suitable access doors in the ducts. Every
damper shall have an indicating device clearly showing the damper position at all
times.
 Dampers shall be placed in ducts and at every branch of supply air duct connections,
whether or not indicated on the shop drawings, for the proper volume control and
balancing of the system.
 All the dampers at grille collars shall be of extruded aluminum construction with
louver dampers of robust construction and tightly fitted.
 Pressure relief dampers: Pressure relief dampers shall be constructed with 18G
Aluminum construction with parallel blade construction. Leafs shall be 100% air
tight upon closure. Leaf’s shall be loaded with spring pressure of stiffness (k value)
or counter weight corresponding to set point pressure.
 Non return damper (Back draft damper): Non return damper shall be constructed
out of 18G GSS. Blades shall ensure 100% air leak proof performance on closure.
Design shall ensure that no rattling noise is produced at design duty.

8.1 FIRE & SMOKE DAMPERS

 All supply and return air ducts at room crossings, floor crossings or as indicated in
the approved shop drawings shall be Motor operated & at least 90 minutes Fire
rated. Electrical actuator shall be of multi-leaf type and provided with Spring Return
having its own thermal trip for ambient air temperature outside the duct and air
temperature inside the duct.
 Actuator shall have Form fit type of mounting, metal enclosure and guaranteed long
life span. The dampers shall meet the requirements of NFPA90A, 92A and 92B.
Dampers shall have a fire rating of 1.5 Hrs. in accordance with latest edition of UL555
and shall be classified as Leakage Class 1 smoke damper in accordance with latest
edition of UL555S.
 Each fire/smoke damper shall be AMCA licensed and bear the AMCA seal for air
Performance.
 Each damper shall be supplied with factory mounted sleeve of galvanized steel of
thickness as per SMACNA and of minimum 400 mm long depending up on the
approved shop drawing & wall thickness.
 The damper shall be fitted in to sleeve either using welding or self-tapping screws.
All welded joints shall be finished using heat resistance steel paint . UL listed and
approved Silicon sealant shall be applied at all corners as well as at joints between
damper frame and sleeve. Damper Frame shall be a roll formed structural top hat
channel, reinforced at corners, formed from a single piece of 1.6mm galvanized steel.
 Damper blades shall be air foil shaped (equivalent to 2.0mm thickness strength) roll
formed using 1.0mm thick single piece of galvanized sheet. Bearings shall be of

PAGE - 938
 stainless steel fitted in an extruded hole in the damper frame. Blade edge seals shall
be silicone rubber and galvanized steel mechanically locked in to the blade edge
(adhesive type seals are not acceptable). Side Jam seals of stainless steel and Top
and bottom seals of galvanized steel shall be provided.
 Bigger size Dampers shall be supplied in Multiple modules of sizes not exceeding in
dimensions of certified module, jack shafted together. Multiple actuators shall be
provided for large dampers with higher torque requirements as prescribed in UL.
 The damper shall be equipped with a device to indicate OPEN and CLOSE position
of Damper blades through a link mounted on the damper blade.
 The electric actuator shall be energized either upon receiving a signal from smoke
detector installed in supply air duct /return air duct.
 Electric Actuator of suitable Torque shall be factory mounted and tested and
approved by UL. The actuator shall be suitable for 230V AC supply. In addition
actuator shall have elevated temperature rating of 350 deg.F. Electric Actuator shall
have been energized hold open tested for a period of at least one year with no spring
return failure.
 Each fire/smoke damper shall be equipped with a heat actuated release device
which shall allow controlled closure of damper rather than instantaneous to prevent
accident (Electrical fusible link).
 Each damper shall be provided with its own control panel, mounted on the wall and
suitable for 230 VAC supply. This control panel shall be suitable for spring return
actuator and shall have at least the following features:
i) Potential free contacts for ON/Off & remote alarm indication
ii) Accept signal from external smoke / fire detection system for tripping the
electrical actuator.
iii) Test and reset facility.
iv) Indicating lights / contacts to indicate the following status:
Power Supply On
Damper open and close position.
 Actuators shall be mounted on the sleeve by the damper supplier in his shop and
shall furnish test certificate for satisfactory operation of each Motor Operated
Damper in conjunction with its control panel. Control panel shall be wall mounted
type.
 It shall be responsibility of EPC agency for correctly hooking up the Motor Operated
Damper to Fire Detection / Fire Management System. All necessary materials for
hooking up shall be supplied and installed by EPC agency under close co-ordination
with the fire protection system agency.
 EPC agency shall demonstrate the testing of all Dampers and its control panel after
necessary hook up with the fire protection / fire management system
 Testing is carried out by energizing all the smoke detectors with the help of smoke.
 Agency shall provide Fire retardant cables wherever required for satisfactory
operation and control of the Damper.
 Agency shall strictly follow the instructions of the Damper Supplier or avail his
services at site before carrying out testing and installation at site.

8.2 Supply Air Registers/Grills/Floor Grilles

8.2.1 Supply Air Registers
 Supply air registers shall be of approved make and of aluminum construction with
individually adjustable bars. Supply air registers shall be double deflection type,

PAGE - 939
 with removable key-operated volume control dampers. The outer frame shall be
made from drawn aluminum sections.
 All registers shall be selected in consultation with the Engineer.-in-charge (as
Different spaces shall require horizontal or vertical face bars, and different width of
margin frames).
 All registers shall have a soft, continuous rubber gasket between the periphery of
the register and the surface on which it has to be mounted.
 Registers shall be adjustable pattern as such grill bar shall be pivot able to provide
pattern with 0 to 100 degree horizontal arc and up to 30 degree deflection up or
down. Bars shall hold deflection settings under all conditions of velocity and
pressure.
 Bars longer than 45 cm shall be reinforced by a set back vertical member.
 Registers shall be given a rust inhibiting prime coat and factory applied powder
coated finish of approved color.

8.2.2 Air Diffusers

 Supply and return air diffusers shall be as per the approved shop drawing & meeting
the design standards.
 Mild steel diffusers/dampers shall be factory coated with rust-resistant primer.
 Aluminum diffusers shall be powder coated & made from extruded aluminum
section.
 The diffuser should be constructed with 1 mm thick frame, blade of 0.8 mm thick
and opposed blade dampers of 1 mm thick.
 Rectangular Diffusers shall be steel / extruded aluminum construction, square &
rectangular diffusers with flush fixed pattern for different spaces.
 Supply air diffusers shall be equipped with fixed air distribution grids, removable
key- operated volume control dampers, anti-smudge rings as re-required in specific
applications.
 All extruded aluminum diffusers shall be provided with removable central core and
concealed key operation for volume control damper.
 Linear Diffusers shall be extruded aluminum construction, one or two way blow
type with removable core ,. Supply air diffusers shall be provided with volume
control/ balancing dampers within the supply air collar.
 All diffusers shall have volume control dampers of extruded aluminum construction
anodized in mat black shade.
 Slot Diffuser shall be extruded aluminum construction multi-sport type with air
pattern controller provided in each slot. Supply air diffusers shall be provided with
Hit & Miss volume control dampers in each slot of the supply air diffusers. Diffusers
for different spaces shall be selected in consultation with the Architect.
 Data centres shall be provided with floor grilles. Grilles shall be of nominal size of
600mm x 600mm and shall be fitted in floor tile of false floor. Grille shall be with
dampers for flow control. Grill shall be heavy duty 16G Aluminum and shall take
care of human traffic load. Damper shall be operable in situ without requirement of
removal of grille.

Note -All diffusers shall be selected in consultation with the Architect/Engineer-In

Charge & shall be procured only after obtaining written approval for each type of
diffuser.
8.2.3 Displacement Diffusers

PAGE - 940
  The displacement diffuser shall be a rectangular unit supplying air at low velocity to
the habitable area in one direction.
 The displacement diffuser shall be suitable for supply with low inflow velocity
(Draught-free) of cooled air with a temperature difference up to 6 K compared with
room temperature (measured at 1.2 m above the floor) and can be used for constant
and variable volume installation.
 The displacement diffusers shall be designed for mounting in a corner or wall and
shall be suitable for top & bottom connection.
 The displacement diffuser shall be made of 18G Galvanized steel sheet with 50-60%
perforation (cover, mounting base, spigots and side plates) with lip seal of neoprene
rubber. The unit should be with an inserted perforated sheet steel basket to ensure
even air distribution. Nominal sizes (B× H): shall be as per the approved shop
drawing/ requirement.
 Sound power level of the air-regenerated noise shall be measured according to EN
ISO 5135.
 All components shall be manufactured as per ISO 9001:2008.

9.0 Ducting Supports:

 All ductwork shall be independently supported from building construction & shall
be rigidly and securely supported as per approved shop drawing with hangers.
 Hangers are made from galvanized steel wire ropes and galvanized steel
angle/channel or a pair of brackets, connected by galvanized steel wire hangers
under ducts,
 Rigid supports may be provided at certain interval as per design requirement
 The spacing between supports should be not greater than 2.4 meter. All vertical duct
work shall be supported by structural/strut members on each floor slab. Duct
supports may be through galvanized steel insert plates or Toggle end wire fixing left
in slab at the time of slab casting.
 Galvanized steel cleat with a hole for passing the wire rope hanger shall be welded
to the plates. Trapeze hanger formed of galvanized steel wire rope using hang fast
shall be hung through these cleats. Wherever use of metal insert plates is not
feasible, duct support shall be through dash/anchor fastener driven into the
concrete slab by electrically operated gun. Wire rope supports shall hang through
the cleats or wire rope threaded studs can be screwed into the anchor fasteners. In
case of PEB structure Loop and Catenary system can be used based on the site
conditions as per approved suspension system drawings.
 All horizontal ducts shall be adequately secured and supported as per approved
shop drawing with trapeze Hangers formed of galvanized steel wire rope in a cradle
support method,under ducts at no greater than 3000mm centre, for 3001mm- above
appropriate size angle along with neoprene pad in between the duct & MS angle
should be used with prior approval.
 All vertical duct work shall be supported by structural members on each floor slab.
Duct support shall be through dash / anchor fastener driven into the concrete slab
by electrically operated gun. Hanger wires shall then hang around the ducting. Rigid
supports shall be used in conjunction with wire rope hangers to assist with
alignment, change of direction or connection of services where recommended by the
manufacturer.
 Any other Wire for hanging arrangement solution can be used based on
manufacturers recommendation /on site conditions after prior approval from AAI.

PAGE - 941
  In cases of Spiral ducting the wire can be wrapped directly around the ducting
without the need for a spiral ducting clamp for sizes above 1100 a cradle support
should be provided refer to manufacturers recommendations.
 Ducting over furred ceiling shall be supported from the slab above or from beams
after obtaining approval of AAI.
 Catenary Supports: Refer to manufacturers recommendations on Catenary
supports with C- clip, special care should be taken with tensioning of the wire and
angles at which the installation of services are made.
 Thickness of duct shall not be less than as prescribed in ASHRAE/ ISHRAE.

Rigid Supports:
If rigid support is required as per design requirements, it should be as per following
table:
Longer size of Duct Type of Joints
Up to 750 25x25x3 mm L angle with M8 nuts & bolts

751-1000 25x25x3 mm L angle with M8 nuts & bolts

1001-1500 40x40x5 mm L angle with M8 nuts & bolts

1501-2250 50x50x5 mm L angle with M10 nuts & bolts

2251 & above 50x50x6 mm L angle with M10 nuts & bolts

10.0 Testing & Balancing

 After completion of the installation of the complete air distribution system, all ducts
shall be tested for air leaks.
 Before painting the interiors, air distribution system shall be allowed to run
continuously for 48 hours for driving away any dust or foreign material lodged
within ducts during installation.
 The entire air distribution system shall be balanced using approved anemometer.
Air quantities at the fan discharge and at various outlets shall be identical to
designed & approved CFM requirement, and shall not be less/greater than 5% of
approved value .
 Leakage in each air distribution system shall be within 3 percent so that supply
air volume at each fan shall be identical to, or no greater than 3 present in excess
of, the total air quantity measured at all supply outlets served by the fan.
 Branch duct adjustments shall be made by volume dampers/ splitter. Dampers shall
be permanently marked after air balance is complete, so that these can be restored
to their correct position if disturbed at any time.
 Complete air balance report shall be submitted to the Engineer. -in-charge. for
scrutiny and approval, and six copies of the approved report shall be provided with
completion documents.

PAGE - 942
SECTION -15 Integrated Building & Energy Management System
{IBMS/BMS/BAS}

1.0 General requirements & System Description

 This section covers Design, supply, installation, Testing and commissioning of
Integrated Building management and energy management System (IBMS) as per
design/system requirements.
 The proposed system shall be PC based Direct Distributed Digital Control (DDC)
system.
 The features shall be distributed both physically and functionally over the field
controllers.
 Microprocessor based Direct Digital Distributed Controllers (DDC) shall interface
directly with input/output card as applicable or with sensors, actuators and
environmental control systems.
 To provide maximum flexibility to respond to changes in the building use, third
party interfacing facility, shall support the use of open protocol ANSI/ASHRAE
Standard 135- 2001. BACnet, LonWorks, MODBUS, OPC, KNX Network and any other
open and proprietary communication protocols in one open, interoperable system

1.1 The system shall be capable to carry out following minimum functions-
i. Individual input/output point scanning, processing and control.
ii. Centralized operation of equipment’s. (remote control)
iii. Dynamic and Animated Graphic details of Plant and building.
iv. Alarm Detection and Early recognition of faults.
v. Faults statistics for identification.
vi. Trend register to identify discrepancies, energy consumption, etc
vii. Time, event and holiday scheduling as well as temporary scheduling.
viii. Report generation
ix. Preventive maintenance and plant servicing
x. Optimum support of personnel
xi. Energy Management, Control optimization of all connected electrical and
mechanical plant
xii. Prevention of unauthorized or unwanted access
xiii. Own error diagnosis integrated system
xiv. Auto CAD Integration/Interfacing
xv. Web based Data Visualization Tool.
xvi. Automatic Alarm Email Option.
xvii. Communication interface and control for third party integration.
1.2 The system shall be capable to carry out Control/Monitoring/Third party
integration of following MEP systems as per design requirements & I/O point
summary -

i. Electrical substation Equipment’s.

ii. LT & Hybrid APFC Panels.
iii. Energy meters.
iv. Uninterrupted Power Supply (UPS).

PAGE - 943
 v. Variable frequency drives.
vi. Elevators.
vii. Lighting Management system.
viii. Fire Alarm System.
ix. Fire Fighting System.
x. Water supply system.
xi. Plumbing System.
xii. Sewerage Treatment Plant .
xiii. VRV/VRF based HVAC System.
xiv. PAC based HVAC System .
xv. Ventilation & Exhaust system.
xvi. Smoke extraction System.
1.3 Scope of work
 The scope of work for proposed Building Management System also called Building
Automation System covered under this contract shall include but not limited to the
following:
i. Detailed designing of system as per required input/output summary.
(Input/output point summary is enclosed in this specification is only for
reference, Input/output point may increase as per detail design requirements
and shall be finalized in consultation with Engineer-In -Charge to achieve
desired result as per ECBC & GRIHA-IV rating).
ii. The contractor shall supply, install, test, commissioning and maintain the
Building Automation System (BAS) including provision of all necessary
hardware, software and relevant spares.
iii. The BAS/BMS Contractor shall provide all interface components (temperature
sensors, humidity sensors, differential pressure switches, valve actuators, fire
damper actuators etc.) & contact (Dry/potential free, SPDT type contact,
Changeover contact, Auxiliary switch packs etc.) to interface with other
mechanical & electrical equipment unless specified otherwise in this contract.
iv. All interfacing accessories & control cabling as per system design requirement,
shall be in the scope of contractor.
v. The terminations in the other services panels shall be in scope of respective
services contractors.
vi. BAS/BMS contractor perform all checks on wiring, sensor and actuator
mounting for trouble-free operation of the equipment.
vii. BAS/BMS contractor to in close coordination with other services contractor, so
that desired results are obtained along with complete monitoring of various
systems.
viii. Proper operation and maintenance of the system shall be responsibility of the
contractor and shall include debugging and calibration of each component in
the entire system. Maintenance Software package also should be included in the
scope. BAS/BMS contractor should obtain all technical details of each
equipment which are being controlled/monitored and program the
maintenance software as per the manufacturer’s recommendations.

PAGE - 944
 ix. All works for satisfactory completion & operation of the system shall be in scope
of this tender. The tenderer shall take into its scope, price for all works and
approvals in connection with installation of the BAS/BMS System from
government as well as statutory bodies.
 Besides the above, general scope of work shall also include the following:
i. Supply of all Detailed Design /Shop drawings using latest editing of Computer
Aided Design (CAD) and drafting package i/c following -
 Schematic diagram
 Layout Diagrams
 Drawings for control panels.
 Wiring diagram

ii. Supply and installation of all necessary BAS/BMS control and monitoring
outstations.
iii. Supply and installation of all BAS/BMS field controls cabling including local area
networks.
iv. Supply and installation of field interface cabling between all equipment and the
BAS System.
v. Identification of all field cabling from the motor control panels at both ends of
each core, and in junction boxes using the same ferrule numbering as used for
associated outgoing enclosure terminal.
vi. Supply and installation of controls for temperature, humidity and pressure
detectors, thermostats, flow switches and differential pressure switches, etc.
associated with the BAS/BMS.
vii. Ensure all control devices are positioned such that maximum stability of control
for each system can be achieved.
viii. Supply and fitting of necessary clips, hangers and supports for all averaging
element detectors and for serpentine them across the ducts.
ix. Installation of valves and valve actuators associated with the BAS/BMS.
x. Supply a 2-dimensional schematic at least 2D+ and information page graphic
for all systems controlled by or monitored on the BAS/Bms. Allowance shall be
made for any necessary site modifications in graphics to incorporate any
revised locations, presentation of dynamic information and Architect /
Consultants / Owner’s site representatives’ comments.
xi. Supply and fit an engraved “ traffolite ” (multi-layered phenolic plastic )label for
all controls items, equipment and plant associated with the control system,
incorporating the appropriate controller and regulator identification reference
number as detailed on the Motor Control Panel Equipment Schedules. All labels
shall be fixed with bright finish instrument head screws or plastic flat header
push-in rivets of the same Color as the label. Where no flat surfaces are available
on valves, labels shall be hung from brass chains.
xii. Fine tuning & calibration all temperature, humidity and pressure control loops
with a suitable building load. If necessary, an artificial building load shall be
generated by the Engineer.
xiii. Provide documentary evidence to the Architect / Consultant / Owner’s Site
representative prior to offering the system for testing & commissioning.

PAGE - 945
2.0 QUALITY ASSURANCE PLAN:
 The system shall be installed by specialized/trend technicians & workers in-
coordination/recommendation with the manufacturer/supplier of the control equipment.
 The complete BMS installation shall be in strict accordance with the national and local
electrical codes
 Contractor shall ensure that software used, shall carry a certificate from the supplier
and shall be original software procured for this particular project. This is to ensure
that the Owner is provided with regular updated revisions. All third-party software
shall also be the original version.
 Furnish instruments required for testing.
 Submit catalog data on all instruments for approval prior to performance of tests.
 Instrument Accuracy
 Temperature: ¼°F or 1/2% of full scale, whichever is less
 Pressure: ½% PSI or 1/2% of full scale, whichever is less
 Humidity: 2% RH
 Electrical: ¼° of full scale
2.1 CALIBRATION & COMMISSIONING
 The contractor shall indicate to the AAI his readiness for commissioning of the
system and shall commission the system only upon obtaining written approval for
the same.
 Upon completion, devices subject to manual operation shall be operated in presence
of AAI to demonstrate satisfactory operation.
 As part of Calibration & Commissioning exercise, contractor shall be required to
carry out the following:
i. Perform a three-phase commissioning procedure consisting of field I/O
calibration and commissioning, system commissioning and integrated system
program commissioning.
ii. Document all commissioning information on commissioning data sheets that
shall be submitted prior to acceptance testing. Notify the Owner in writing of
the testing schedule so that operating personnel may observe calibration and
commissioning.
iii. Field I/O Calibration and Commissioning.
iv. Prior to system program commissioning, verify that each control panel has been
installed according to the Design drawings and test, calibrate, and bring on-line
each control device. Commissioning to include but not be limited to:
 Sensor accuracy at 10, 50 and 90% of range.
 Sensor range.
 Verify analog limit and binary alarm reporting.
 Point value reporting.
 Binary alarm and switch settings.
 Actuator spring ranges.
 Failsafe position on loss of control signal or electric supply.

v. Record calibration and test data on commissioning data sheets and submit. Data
sheets shall include the device designation, the date of commissioning and the
name of person who performed commissioning.

PAGE - 946
 vi. Fan Speed Control with Out Air Flow Sensors
vii. The BMS/BAS Contractor shall work closely with the HVAC Contractor to setup
fan tracking as per the following procedure:
 With return fan at minimum speed, set supply fan to produce volume equal
to system differential. Record SF output signal.
 Increase supply fan output signal 20% and raise return fan speed until
differential is once again obtained. Record return fan output signal.
 Continue this procedure until the supply fan is at full speed. Set all values in
a look-up table so fans will track accordingly.
 Vary the speed of the supply fan and verify fans are tracking with the proper
differential.
2.1.1 System Program Commissioning
 After all control devices have been commissioned, each DDCP program shall be put
on-line and commissioned. The contractor shall confirm that the DDCP program
logic follows the approved software flow chart and sequence of operation.
 Each control loop shall be adjusted to provide stable control and control within the
specified accuracies.
 System program test results and loop adjustments shall be recorded on
commissioning data sheets and submitted.
2.1.2 Integrated System Commissioning
 After commissioning of all DDCP programs, the contractor shall verify the overall
system performs as specified. Tests shall include but not be limited to:
 Data communication, both normal and failure modes
 Fully loaded system response time
 Impact of component failures on system operation
 Time/date changes
 End of month/end of year operation
 Global application programs
 System backup and reloading
 System status displays
 Diagnostics
 Power fail/restart
 Battery backup
 Non-DDC Subsystems
 Subsystems not controlled by DDC shall also be tested and commissioned

2.1.3 Acceptance Testing /System Start-up

 BAS/BMS shall submit the detailed acceptance test procedure (startup checklist for
each task to be performed) designed to demonstrate compliance with contract
requirements at least 4 weeks before the start of testing. This procedure to be
approved prior to the start of the testing.
 Minimum Required elements of the start-up testing include:
i. Measurement of voltage sources, primary and secondary.
ii. Verification of proper controller power wiring.
iii. Verification of component inventory when compared to the submittals.
iv. Verification of labeling on components and wiring.
v. Verification of connection integrity and quality (loose strands and tight
connections).

PAGE - 947
 vi. Verification of bus topology, grounding of shields and installation of termination
devices.
vii. Verification of point checkout.
viii. Each I/O device is landed per the submittals and functions per the sequence of
control.
ix. Analog sensors are properly scaled and a value is reported.
x. Binary sensors have the correct normal position and the state is correctly
reported.
xi. Analog outputs have the correct normal position and move full stroke when so
commanded.
xii. Binary outputs have the correct normal state and respond appropriately to
energize/de-energize commands.
xiii. Documentation of analog sensor calibration (measured value, reported value
and calculated offset).
xiv. Documentation of Loop tuning (sample rate, gain and integral time constant).

2.1.4 Performance testing

 Performance verification test shall also be completed for the operator interaction
with the system. Test elements shall be written to require the verification of all
operator interaction tasks including, but not limited to the following.
i. Graphics navigation.
ii. Trend data collection and presentation.
iii. Alarm handling, acknowledgement and routing.
iv. Time schedule editing.
v. Application parameter adjustment.
vi. Manual control.
vii. Report execution.
viii. Automatic backups.
ix. Web Client access.

 Using the commissioning & test data, the Owner and/or his representative shall
select, at random, functions to be demonstrated. These functions shall be
demonstrated by the Contractor in accordance with the acceptance test procedure.
At least 15 percent of the systems functions as selected by the AAI representative
shall be demonstrated.
 At least 95% of the functions demonstrated must perform as specified and
documented on commissioning data sheets or the system must be retested.

Note -Acceptance Testing/Start-up Testing Report and a Performance Verification

Testing Report shall be provided upon test completion.

2.1.5 Training
 The BAS/BMS Contractor shall provide on-site training to the AAI representative
and maintenance personnel.
 On-site training shall consist of at the operation and maintenance of the systems.
 System Overview
 System Software and Operation

PAGE - 948
  System access
 Software features overview
 Changing setpoints and other attributes
 Scheduling
 Editing programmed variables
 Displaying color graphics
 Running reports
 Workstation maintenance
 Viewing application programming
 Operational sequences including start-up, shutdown, adjusting and balancing.
 Equipment maintenance.

3.0 SYSTEM ARCHITECTURE AND TECHNICAL REQUIREMETS (BMS/BAS)

 The intent of this specification is to provide a peer-to-peer networked, stand-alone,
distributed control system with the capability to integrate both the ANSI/ASHRAE
Standard 135- 2001. BACnet, LonWorks, MODBUS, OPC, KNX Network and any other
open and proprietary communication protocols in one open, interoperable system
 The system shall be logically structured into three distinctive levels, which are
Management Level, Automation Level and Field Level. Each level shall be
autonomous from the other. Peer to peer communication shall be possible on all
system levels and the system design shall be modular in structure to allow
straightforward extensions.
 BMS/BAS system shall consist of Network Server/Controllers (NSCs), a family of
Direct Digital Controllers (DDCs), Administration and Programming Workstations
(APWs), and Web-based Operator Workstations (WOWs).
 The system shall be designed with Ethernet network, using the BACnet /IP, Lon
Works IP, and/or Modbus TCP protocol.
 The BAS/BMS shall provide control, alarm detection, scheduling, reporting and
information management for the entire facility.
 The BAS/BMS shall be capable of supporting an unlimited number of users using a
Web browser. The Web browser software shall run on any operating system and
system configuration that is supported by the Web browser.
 The Web browser shall provide the same view of the system, in terms of graphics,
schedules, calendars, logs, etc., and provide the same interface methodology as is
provided by the Graphical User Interface. Systems that require different views or
that require different means of interacting with objects such as schedules, or logs,
shall not be permitted.

The Web browser client shall support at a minimum, the following functions:
 User log-on identification and password shall be required. If an unauthorized user
attempts access, a blank web page shall be displayed. Security using Java
authentication and encryption techniques to prevent unauthorized access shall be
implemented.

PAGE - 949
  Graphical screens developed for the GUI shall be the same screens used for the Web
browser client.
 Storage of the graphical screens (Static) shall be stored in DDC directly and should
not depend on any other hardware.
 The Web page shall get automatically refreshed without any user intervention.
 Users shall have administrator-defined access privileges. Depending on the access
privileges assigned, the user shall be able to perform the following:
 Modify common application objects, such as schedules, calendars, and set points in
a graphical manner. Schedule times will be adjusted using a graphical slider, without
requiring any keyboard entry from the operator and set holidays
 View logs and charts
 View and acknowledge alarms
 The system shall provide the capability to specify a user’s (as determined by the log-
on user identification) home page. Provide the ability to limit a specific user to
adjust their defined home page. From the home page, links to other views, or pages
in the system shall be possible, if allowed by the system administrator.
 Graphic screens on the Web Browser client shall support hypertext links to
other locations on the Internet or on Intranet sites, by specifying the Uniform
Resource Locator (URL) for the desired link

3.1 Codes and Standards:

 BACnet ANSI ASHRAE 135-2008/ISO 16484-5: BACnet A Data Communication
Protocol for Building Automation and Control Networks
 UL-916: DDCs and ancillary equipment, which are listed and labeled.
 EN 60730-1Compliant to for product safety
 Electromagnetic compatibility - 89/336/EEC
 EN 61000-6-2: Interference immunity
 EN 61000-6-3: Emitted interference
 AS/NZS 2064: Radio Emission Standard

3.2 CENTRAL STATIONS SOFTWARE AND HARDWARE

A central server, located at Control Room, shall be provided. The Control stations shall
comprise of Personal computers (PC) providing high level operator interface with the
system The terminals shall be capable of providing the operator with the facility for
remote system interrogation, control, retrieval/storage of logged data, annunciation of
alarms and reports, analysis of recorded data and the formatting of management
reports.

The control station shall consist of the following hardware with all of them suitable for
the power supply voltage of 230 V AC ± 10 % , 50 HZ + 3%.

PAGE - 950
Minimum Specifications for Workstations
FEATURES DESCRIPTION
Processor i7 ( 3.0 GHZ )
Drive controllers Integrated serial ATA controller (ICH9R) 3 Gb/s with
RAID 0, 1, 5 and 10 capability.
Cache 1 MB L2 Cache
RAM 16 GB DDR RAM
Slots 7 full length slots: 2 PCI Express (PCIe) x16 graphics, 1
PCIe x8 (x4 electrical) slot, 1 PCIe x1 slot, 3 PCI slots
Hard Disk 500 GB SATA Hard Drives x 2
Power Supply 230 V switchable/50 Hz
Video NVIDIA Quadro FX370 (256 MB,)
Ports Ports Front: 3 USB 2.0
Operating System Windows 8 or higher version & 1 No. Microsoft office
& Software software shall be provided.
Antivirus Norton
Software
Network 100 Mbps Network Interface Card with wake on LAN
support
DVD ROM Built in 52X DVD ROM with speakers

a. Key board: The central station shall be complete with detached 101-keys keyboard
which includes full upper/lower case ASCII keyset, a numeric pad, dedicated
cursor control pad, and a minimum of 10 programmable functional keys.
b. Colour Monitor LCD / TFT (Touch Screen Type): The colour LCD shall be with a
minimum 22inch diagonal non-glare screen, display resolution 1920 x 1080P,
expect ratio 16:9.
c. Mouse: For keyboard less operation, in addition to the enhanced keyboard, a mouse
shall also be provided as an alternative user interface for day to day system
operation. 1 No. mouse pads shall be provided for each mouse.
d. Printers: The contractor shall provide printers for printing alarms, operator
transactions and reports.
There shall be one printer with each Control Station. This printer shall be dedicated
for alarm printing and for printing reports, trend log, summary, totalizer logging,
recording alarms and providing system reports, overriding auto printing etc. The
printer shall have the following characteristics:
i) The printers shall be Laser color type.

PAGE - 951
 ii) Printer speed for B/W printing shall be minimum 15 pages (A3) per minute.
iii) Full toner shall be provided.
e. The available PCI slots on the PC shall be used only for communication cards and
shall not be utilized for mounting protocol converter cards.
f. Original CD of Software (Window 08 or higher version MS office software, BMS
software, Printer, Antivirus etc.) shall be furnished to AAI.
g. It shall be possible to set timers so that a timed delay may be introduced before
an action is carried out.
The following Software shall be provided besides the software for automation
system:
Operating System - Windows 08 -
Memory Manager - QEMM Version 5.11 (or higher)
Multitasking - Desqview version 2.31 (or higher)
Mouse Driver - Microsoft bus mouse 6.2
Data Base Manager - SQL SERVER 2005 OR HIGHER

3.3 Central Station Software

The BMS software shall be simple, flexible and convenient to use such that an operator
with minimal programming knowledge can use it to perform control / monitoring and
to build programs for control applications, graphics to generate management
information systems (MIS) reports. As well, on higher end it shall be possible to create
customized programs to suite the site requirement by a software programmer. All
necessary documents required to make customization possible should be available
along with the software without any additional charge.
The operating system shall be the Microsoft Windows latest version Enterprise
/Professional 32 / 64-bit multitasking environment. The networking software shall use
the TCP / IP LAN protocol. The system shall be capable of supporting unlimited users.
The following user programs must be processed by the Control Station:
i. Operating functions:
Graphic management schematics with dynamic display of actual status information,
manual control of parameters and status variables of the electrical and mechanical
plant, manual switch of programs which are not part of progress routines.
ii. Monitoring functions:
Automatic monitoring of connected plant and equipment automatic monitoring of
the system (idle or operation).
The communication techniques shall be optimized to minimize network traffic while
providing good system response and reliability. The system shall also provide
utilities to compile aggregate statistics on communication link usage.
iii. Data visualization functions:
For the individual processing of operating data for Building Management.

PAGE - 952
iv. Standardized form for:
Trend reports
Consumer statistics
Fault statistics
Maintenance management

v. Display functions:
For the representation and display of operating data and management information
in alphanumeric and graphic form.
Standard system displays
The following displays shall be included as part of the system:
Alarm summary display
Event summary display
Point detail template displays
Trend set template displays

Administrative Displays
The system shall provide the following full screen display
Master system menu
Report summary
Alarm summary
Event summary
Area assignment
Holiday assignment
History assignment
Push-button assignment
Operator definition
Operator message board
Events archive and retrieval
Time period summary
vi. Management functions:
For optimization of energy consumption.
For rational use of personnel
vii. Access control functions:
Different operating levels for all information and all data by way of code word or
user key.
Control transactions issued by the operator shall be communicated to control
devices using a write followed by read to ensure the integrity of the transaction. If
the read following the write to the device indicates that the control action has failed,

PAGE - 953
 the operator shall be informed by means of a control failure alarm. The priority of
the control failure alarm shall be configurable by the user.
viii. Commissioning functions:
For system specific software of the field stations and the management system
downloading the system specific software to the DDC units.
Testing of the software in connection with electrical and mechanical plant.
Automatic and periodic storage of all system data.
ix. Test functions:
Automatic and continuously running test functions for system tests (hardware and
operating software) and management system configuration (communication) Test
tools for individual hardware and software components which can be activated
manually. Self-test functions for individual system components which can be
activated through manually command.
3.4 Operator Interface
The operator interface provided by the system shall through an intuitive graphical user
interface and shall allow for efficient communication of operational data and abnormal
conditions. It shall provide a consistent frame work for viewing of information. Critical
areas (such as alarm icons) shall be visible all the times. A predefined area on the screen
shall provide operator messaging, and this area shall also be visible at all times.
The operator interface shall be interactive and based on graphics and / or icons.
Standard tool bar icons and drop-down menus shall be available on all standard and
custom display to allow easy access to common functions.
The system shall provide an operator interface with the following minimum capabilities:
Window re-size, zoom in, zoom out.
Dedicated icons and pull down menus to perform the following:
Associated display
Alarm summary
Alarm acknowledgement
Previous display recall
Graphic call-up
Trend call-up
Point detail
Current security level
Alarm annunciation
Communication fail annunciation
Operator message zone.

3.5 Password Access

a) None of the features of the Operators Panel shall be accessible without the user first
being required to log on by entering a password.
b) Alpha numeric passwords of up to 15 characters shall be available and definable by
individual operators.

PAGE - 954
 c) It shall be possible to grant or deny access to any terminal and/or functions for
individual user. The ability to use this feature itself shall also be definable.
d) It shall also be possible to grant or deny access to individual points or groups of points
by function or type.
e) It shall also be possible to define a timeout value for individual user. Automatic log-
off of the operator shall occur if no keyboard or mouse activity is detected during this
timeout period. It shall also be possible to allocate an infinite timeout.
f) A log of at least previous 100 users shall be available at each control station. A record
of the user’s name, the time and date of log ON and log OFF shall be available from
this file.
g) Password summary shall be available to the operators with the highest level of access.
Password shall not be displayed.
h) Password data base shall be stored in server as well as in workstation in an encrypted
form so that the failure of any one device shall not make the system inoperative.
3.6 Control Station Graphics Capabilities
The work stations shall have Graphics as the basis of operation. The software shall have
following advanced techniques for ease of operation:
a) Colour banding of screen displays shall be provided for display and differentiation
of normal and abnormal signals. This shall allow operator instant recognition and
response to critical building operation.
b) To provide instantaneous confirmation to system operator of equipment status,
graphic screen animation shall be provided. This shall allow full color animated
displays of equipment in site layouts, building floor plans, and other system
configurations. All graphic displays shall be online programmable via keyboard or
mouse selection of graphic library stored symbols and system profiles. Fully
implemented graphic displays are to be provided for all systems so identified in the
Input/ Output Summary section of this document.
c) System Shall have the capability to allow operator to observe multiple dynamic
graphic screens at the same time to enable operator to manage several separate
building operation tasks concurrently.
d) To enable operator to “find” his way in and out of the system, a stacked display of
windows shall be included to provide orderly reference. Operator option of enlarged
full screen display at any penetration level shall also be included.
e) Alarm class differentiation shall define coloration, and storage requirements for
different alarms.
f) Graphic driven point identification and selection shall be provided to allow operator
to select a point by “clicking on” the graphic symbol representing the point type.
Consequently, display will appear to enable the operator to select the desired
command.
g) The system shall be capable of running programs in both the foreground mode and
back-ground mode simultaneously. The system running only foreground “window”
while keeping the other programs dormant in the background “window” shall not
be acceptable as this slows down the availability of control and essential
information to be made available to the operator in the system.

PAGE - 955
 h) Capability of on-line graphics generation shall be a major requirement i.e. the
operator shall have the ability to create new graphics on-site from a menu of
symbols.
i) Historical system trouble, fault, false alarms shall be stored on line in the hard disk
for trouble analysis.
j) It shall be possible to define upto 12 functional categories in the plant schematic
each of which shall be removable from the screen individually. This shall allow the
operator to delete temporarily any equipment and have a better overview of the
other sections of the system.
k) Maintenance software such as inventory control, work orders shall also be on-line
with the historical data- file for proper maintenance of the system.
l) Data Base Manager shall manage all data on an integrated and non-redundant basis.
It shall allow addition and deletions to the data base without any detriment to the
existing data. Cross linkages shall be provided such that no data required by a
software program can be deleted by the operator until that data has been deleted
from its respective programs.
m) Dynamic data such as temperature and humidity values, fans and motor status,
alarm point condition, etc. shall be embedded in the graphics as the sensing location.
Points in alarm condition shall annunciate by colour changes and flashing/blinking
icon, symbol, or value.
n) Commendable points shall be uniquely identified by colour and/or discrete symbol
and shall be directly addressable and commandable from the graphic display. It
shall not be necessary for an operator to type in command request or point names.
Direct entry of commendable point address or positioning of the cursor to the point
shall cause a display of associated command states for digitals, the set point value
and valid range for analogs. Cursor positioning shall be via a “mouse”.
o) In order to allow the operators to view graphics in greater detail, zoom/pan display
feature shall be provided to return zoomed/panned graphics to their original status.
A “return to original” feature shall also be provided. The mouse shall be used to pan
in all directions in real time, and to jump, from any section of the plant schematic
directly to another section or to another level.
p) It should be possible to use touch screen monitor for viewing and control of graphic
software.
3.7 User Interface
The operator panel on a terminal shall provide the primary interface for operator access
to the BAS (Building Automation System) while also provide the annunciation of alarms
and the reporting function. The operator shall have the option of switching between a
text based and graphic based user interface at any time. In particular, following standard
functions shall be provided.
a) It shall be possible to carry out the following commands by use of dedicated function
keys on the keyboard and by the mouse:
i) ON - digital points
ii) OFF - digital points
iii) AUTO - analogue and digital points
iv) SET TO VALUE - analogue points

PAGE - 956
 v) ALARM REVIEW
vi) POINT TYPE REVIEW
vii) POINT GROUP REVIEW
viii) HOURS RUN REVIEW
ix) REVIEW CANCEL
x) GRAPHICS ENABLE
xi) HELP
xii) ALARM ACKNOWLEDGE

b) It shall be possible to add new points, and reconfigure or modify existing points
without taking any part of the system off-line. It shall be possible to change
designation of operator passwords, access levels, point segregation and auto sign
off, designation of backup consoles and printers. It shall also be possible to
add/change descriptors for points, segregation groups and access levels, and action
messages for alarms and trouble condition, system/point enable/disable, input or
output value, and assignment of alarm/warning limits. All additions and
modifications shall be on-line programmable via operators’ keyboard and then
down line loaded to distributed processing units.
c) It shall be possible to address plant, zones, points etc using clear language
descriptors. Each individual point may also be identified by a unique alpha-numeric
mnemonic address entry. Simple key names may be assigned to points to allow
direct display. These key names shall be fully operator assignable and depending on
how frequently they have to be accessed, they may be as simple as one, two or
three characters or as lengthy as 20 characters.
d) The operator shall be able to access any point on any graphic without going
through the penetration path. Graphics shall be menu-driven. Direct access to
graphics shall be menu selectable wherein the operator may select optionally by
entering the name of the graphic system desired or by selecting the desired graphic
via cursor positioning.
e) It should be possible to identify some points which are frequently addressed as
“frequent access” points. This listing shall be selectable from a screen top menu bar
drop down menu item with a user address, descriptor and value/status of each
“frequent access” point displayed.
f) The information displayed for individual points during a review shall be Its unique
mnemonic address Its current state or value (in Engineering units) Its type of point
(analog/digital, input/ output) Any secondary or tertiary value Reason for state, if
applicable
g) An Electronic message facility shall be provided on the operator station for any
operator to enter a message to another operator of the same station or different
station, by selecting the receiving operator’s ID and entering the message. When the
operator with a queued message, signs onto the operator station, a “mail message
waiting” prompt shall be issued. Upon displaying a mail message, the display shall
prompt the operator with three message options to execute, delete, print, and save.
Messages shall also include the senders personal ID and a brief title or subject
description.

PAGE - 957
 h) Dynamic data shall be automatically updated on the central station. Manual update
shall also be provided via a screen update key.
i) It shall be possible to enter any of the subroutines such as the editor functions, or
the Data Manipulation function from the central station without closing down the
terminal or the programs currently running.
j) The operator shall be provided with the facility to override the use of portable
operators terminal.
3.8 Help Facility
Software shall be provided to facilitate programming and storage of the system
operation manuals in the hard-disk. The operation manual shall be retrieved by On Line
Help mode so as to enable the operator to self -learn the system operation, command, or
function as and when needed.
This `help’ facility shall be made available to the operator by use of a dedicated key or a
single key click on the mouse. A minimum help shall be available for every menu item
and dialogue box.
The facility shall contain both text and graphics to provide information about the
selected function directly.
The information provided shall be in simple clear language and shall be capable of being
updated along with new version. Modification in help file shall not be allowed.
3.9 Alarms
Multiple priority levels of alarm shall be made available. Priority levels shall be deemed
Critical Alarms and Non- critical (general) Alarms. Normally, critical alarms shall take
precedence over non-critical alarms, and high priority over low priority.
Each analog point shall have the following limits wherever required
High priority critical alarm limit
Low priority critical alarm warning limit
Low priority warning limit
Low general alarm limit
When an analog point goes outside the low priority critical alarm limit or Low priority
warning limit, a user defined warning message shall be directed to the appropriate alarm
printers at the control station.
The Warning limits shall be used to monitor controllability, not comfort conditions. The
alarm limits shall be used to monitor comfort conditions. When a setpoint is changed,
the warning limits shall automatically change while the alarm limits shall not change.
When an analog point goes outside any of the limits defined, a user defined alarm
message for that level shall be directed to the appropriate alarm printer and to
respective operator workstation. Alarm message shall require operator
acknowledgement.

PAGE - 958
When a digital point goes into alarm, a user defined alarm message shall be output to
the appropriate alarm printer and to respective control station. Alarm messages shall
require operator acknowledgement.
When a point is overridden by operator command from an operator workstation or a
local workstation, an alarm message shall be output to the appropriate alarm printer
and to respective operator workstation. Alarm messages shall require operator
acknowledgement.
When a point returns to normal, the event shall be recorded in control stations as
‘Return to Normal’.
The Operator workstations shall be capable of displaying a list of all points in alarm for
the building in a single summary. Systems which require the operator to make a
separate summary for alarms, shall not be acceptable.
a) Annunciation: Alarms shall be annunciated at a terminal by an audible tone and
icon. Critical alarms shall be defined by a different colour than non-critical alarms.
b) Printing: Alarms shall automatically be printed on the defined alarm printer. The
printout shall contain the address, state or nature of the alarm, alarm priority, and
time and date of occurrence. It shall be possible to route alarms to any printer
on the system, in case the allotted printer fails.
c) It shall be possible to produce a user definable full text message to accompany the
annunciation of any alarm. This shall provide further information about the alarm
and any action required to be taken by the operator or indicate that action is
automatically programmed in the system. These messages shall be automatically
printed on a designated printer. There shall be no practical limit to the length of
messages created.
d) Acknowledgement: It shall be necessary for all alarms to be acknowledged by an
authorized operator. The facility shall exist for an additional message to be
appended at the time of acknowledgement to provide further information as to any
action taken.
Acknowledgement of alarms shall be automatically printed and will indicate the time,
date and any message generated by the operator.
Alarm silencing shall be by the authorized operators by pressing the silence key.
e) Alarm Clear: When alarms are cleared, then a message shall be produced to
indicate the description of the alarm point, its current state, and the time and date.
f) Disk Records: With the exception of extended text messages, all the information
produced above, alarm annunciation, acknowledgement, and clearing, shall be
automatically recorded on the fixed disk for historical purposes.

g) Alarm Inhibits: It shall be possible to inhibit the transmission of alarms in the

following ways
i) Operational Inhibits - to allow time for stabilization of power after the
normal power is restored.

PAGE - 959
 ii) Transient Inhibit - to make allowance for fluttering contacts or allow internal
responses.
It shall be possible to select time periods for inhibits (i) and (ii) and may be applied
when entering into alarm, out of alarm, or both.
h) Point lockout: It shall be possible for the operator to lockout the control for any
point, to force it to remain in its current state.
i) A summary showing locked out points shall be available. Systems which require
the operator to make a separate lockout summary shall not be acceptable.
j) Alarm Review: Points in alarm shall be displayed on the operators panel using the
alarm review function.
3.10 Logging
a) To log the status or value of system points at regular intervals or on change of state
and store this on hard-disk at any of the central station.
b) To archive this information for future reference.
c) In the case of timed interval logs, it shall be possible to specify a time interval (in
minutes) and the points which are required to be logged.
d) Storage of logged information shall be able to be carried out in any of three ways,
single-shot, roll- over, or split. These are defined as follows: -
i. Single-shot: In this type of file, logging shall be carried out only during a pre-
defined period for which the start and finish time and date shall be configurable.
ii. Roll-over: This file shall be wrap-around where oldest data shall continuously be
overwritten by new incoming data. It shall be possible to configure the number
of records to be stored or the duration in hours, days or months before wrap
around occurs.
iii. Split: Data shall be continuously stored in a series of files automatically created.
The change-over or creation of subsequent files shall be created by splits at user-
defined boundaries. The boundaries shall be able to be defined by duration
(hours, days, months) and by time and day of the first split.
e) Logging files shall be terminal based not system based, to provide true multi-
terminal capability.
f) Data produced by the logging facility must be able to be used by standard spread-
sheet package for the analysis of information and the preparation of management
report.
g) In addition to the above, the data may be presented in a simplified customized
package. The package should have the following features as minimum:

Charting of logged data on disk in line graph, bar graph or pie format.
Presentation of logged data on disk in tabular format.
Charting of dynamic data (up to 8 points) in real time.
Presentation of dynamic data in tabular format in real time.
Selection of Auto/ manual scaling of X(time) axis and Y(variable) axis.
Tailoring of charts by selection of line width and background colours.
Optional grid overlays (full and dotted lines).

PAGE - 960
 Selection of horizontal/ vertical arrangement of windows or a `cascade’
presentation.
Multiple Windows.
Printing of completed presentations.
User configurable data selections.
Optional display of point titles.
Selection of primary or secondary values for display.
Presentation of both analog and digital values (ON/OFF etc.).
3.11 Report Generation
Standard reports shall be provided, which shall be operator selectable to appear on the
operator station, any selected printer or both. A “terminate report” command shall be
available to allow the operator to stop any report in the process of being printed.
Standard pre-formatted reports to be provided shall include :
a. Point summary reports may be requested at any penetration level. Point summary
reports shall include the current value/status and condition, point descriptors and all
relevant information. Point summary reports shall be selectable for all points.
All reports shall be capable of being scheduled to run at a specific time and/or interval
via an operator function supported by necessary data entry templates and interactive
prompts.
b. As a minimum, the system shall provide the following summaries:
Point Summary
Alarm summary
Limits summary
Lockout summary
Off-line summary
Override summary
Utility summary
Point status (alarm, locked out, off-line, override)
Point name
Point status/value (automatically updating)
Engineering units.

The alarm summary shall list all points in alarm in the selected system. It shall be
possible to print on a single summary, all points in alarm in the building. As a minimum,
the alarm summary shall include :
Point name
Point status/value (when alarm occurred)
Alarm message
Date and time of alarm occurrence
The limits summary shall list all the alarm limits, and warning limits.

PAGE - 961
 The lockout summary shall display points in the selected system which have either
reporting or triggering locked out.
The off-line summary shall display points in the selected system which have lost
communication with the system.
The override summary shall display points in the selected system which have been
overridden by operator command.
The utility profile shall display the total consumption, measured peak for the current
period and the previous period.
c. Trend reports shall allow the operator to randomly select logical group of points to
be recorded at selectable time intervals. It shall be possible to assign up to ten
variables to each trend report. The format, headers, footers, and calculations shall be
selectable by the operator. The trend report shall be stored to disk and shall be
subsequently capable of being displayed, and/or printed by the operator.
d. Dynamic trends shall provide up to eight points and show real time activity of the
associated points. This information shall be printed and/or displayed in numeric, bar
chart, curve plot, pie chart, etc., as selected by the operator. Graphic plots shall allow
a unique color for each point. Sample interval of points selected for dynamic trend
shall be user selectable. 3- Dimensional dynamic trending must be provided in the
system.
e. Alarm and run time reports shall be automatically issued to assigned printers
immediately upon occurrence, and shall consist of the point with engineering unit,
the time, and the date, and the alarm message.
3.12 Data Storage
A history file capability shall be provided to allow automatic storage of certain records
plus allow the operator to selectively direct critical real time system data and activity to
a mass storage device for later recall and analysis.
a. All alarm and return to normal activity shall automatically be routed to history files.
Alarms and return-to-normal shall include warning and alarm threshold violations
with no-response, trouble, run time exceeded, demand alarms, and command
failures. It shall be possible to request a report by specifying points of interest, the
time window of interest and the type of alarms of interest. Locking out or disabling
of points shall also be historically stored and output in the all- type reports.
b. Operator shall be able to select, , those analog and digital inputs and outputs to be
stored and the interval at which samples are taken.
c. It shall be possible to access software packages, so that the operator may format
display or printouts in the form of:
i. Spread sheets.
ii. Bar charts.
iii. Curve plots.
d. History files shall be the source data for stored trend reports to be used for records
and system analysis. Operator shall be able to select specific points to be trended,
the time period of the trend, the sample interval, and time at which the report is

PAGE - 962
 printed. Trend output format shall be as specified for trend logs (shaded, un-shaded
etc.)
3.13 Time Scheduling
a. There shall be real time clock facility to help in time scheduling. The scheduling
feature shall not be dependent on a central database or an operator workstation.
b. The following commands shall be able to be time scheduled to be issued at a later
day and time from the operator workstation or portable workstation:
 Start and stop a point
 Adjust analog value
 Change setpoint

c. The following commands shall be able to be time scheduled to be issued at a later

day and time from the operator workstation:
 Change alarm limits or warning
 Lock/unlock point reporting or point control
 Demand limit target setting
 Load rolling target setting
 Reset tracking period for energy statistics
 Trend point enable/ disable for a point
 Totalization enable/ disable for a point
 Reset totalization value
d. The following summaries shall be able to time scheduled to be printed or stored in
a disk file at a later day and time from the operator workstation:
 Standard point summary
 Alarm summary
 Off-line summary
 Override summary
 Disabled summary
 Lockout summary
 Utility summary
 Alarm limits summary

e. Commands shall be able to be issued repeatedly on specified days of the week at

specified times.
f. system wide calendar shall be set up to define each day as:
 Regular day
 Special day
 Holiday

The system wide calendar shall be stored in multiple locations so that the failure of any
one device does not cause the system to fail.
The calendar shall automatically accommodate the leap year and the turn of the century.

PAGE - 963
 The calendar shall allow the days to be scheduled one year in advance from the current
system date.
g. Separate schedules shall be stored for :
 Regular days
 Special days
 Holidays
h. The system shall accept one-time schedules to accommodate overtime usage. One-
time schedules shall be automatically deleted from the system after execution.
The system shall allow one-time schedules to be programmed up to one year in
advance.

i. After recovery from a power failure, the system shall determine any time scheduled
commands which should have been issued during the period that the power was off.
These commands shall automatically be issued.
3.14 Point History
a. For every analog point in the system, a 48 hour record of the value sampled on
regular interval shall be maintained. The operator shall choose whether samples
older than 48 hours shall be discarded or archived. The most recent 48 hours of
analog point history shall be able to be displayed at the Control Station.
b. For every digital point in the system, a point history of the last 10 change of states
shall be maintained. The operator shall choose whether point history previous to
the last 10 change of states shall be discarded or archived.
The most recent 10 samples of digital point history shall be able to be displayed at the
Control Station.
c. Point history samples with time/date shall also be taken under the following
conditions:
 Point in alarm/return to normal
 Point overridden/released by operator
 Point on-line/off-line
 Point reliable/unreliable
A report shall be available showing all points for which point history is being archived.
d. The system shall provide point history graphs for analog / digital points.
3.15 Point Trend
a. The trend feature shall be able to record any of the following parameters for any
point:
 Point value
 Point alarm status
 Controlling feature
 Operator override flag
 On-line/Off-line flag

PAGE - 964
 b. The operator shall be able to select points and define any interval on which samples
may be taken.
c. For long term storage of samples, trend data shall automatically be updated.
d. A report shall be available listing all points being trended. The report shall display:
 Trend status
 Point name
 Parameter being trended
 Display units
 Sample interval
 Number of samples taken.

e. A trend for a point shall be able to be started either by operator command or

according to a time scheduled command. A trend for a point will end as a result of an
operator command, time scheduled command or when the required number of
samples have been collected.
f. Trend samples shall be displayed in either tabular or graphical format. A minimum
of eight trended points shall be able to be displayed concurrently on a graph or
report.
g. The trend graph display shall automatically scale the value and time axis to display
all samples. From the trend graph, the operator shall be able to select and read the
instantaneous value of any previous sample.
h. The trend point graphing capability shall be a built-in feature of the system and shall
not require operator set- up. Systems which require trend point data to be exported
to third party software shall not be acceptable.
3.16 Tantalization
a. For every digital point, the system shall be able to calculate:
 Cumulative on-time
 Cumulative off-time
b. For every point, analog and digital, the system shall be able to calculate:
 Cumulative time in alarm
 Cumulative time overridden by operator
 Cumulative time off-line
c. Time totalization shall have a resolution of one minute or less.
d. Time totalization shall be displayed in hours.
3.17 Data Base Manager
Control station software shall include a data base manager to allow the data to be
managed on an integral and non-redundant basis.
3.18 Site Specific Data Manipulation Software
A site specific data manipulation software feature should minimum be provided to allow
the user to modify and tailor the BAS software to the changing requirements at the site.
The modifications shall be carried out on-line.

PAGE - 965
3.19 Third Party Software Interface
 The BMS shall communicate to third party systems such as VRF Controller, Energy
meters, UPS, DG, Lifts, VFDs & HT/LT circuit breakers, access control systems, fire-
life safety systems, , Elevators System and other building management related
devices with open, interoperable communication capabilities
 The 3rd party Integration unit shall provide the interface between Ethernet LAN and
the 3rd party field control devices such as DDC or PLC or any other devices which
need to be integrated. These shall also provide supervisory capability of functions
over the devices connected to it. The purpose of using these units should be limited
to integrate devices only, not for any DDC interface with GUI, provided by others.
 The Unit must provide the following hardware features as a minimum:
a. One No. on Board RS-485 port / one no. on board RS-232 port
b. Provision to include / add additional communication card

 The Unit must communicate over TCP/IP with communication speed of

10/100MBPS.
 The Integration unit shall be selected to integrate following Protocols or as asked in
IO Summary:
a. Bacnet over MSTP
b. Bacnet over IP
c. Modbus over MSTP
d. Modbus over IP
e. Lon FTT
f. Lon IP
g. Mbus over TCP
h. Mbus Serial
i. SNMP
If the above drivers are add-on products, it shall be made available / considered while
selecting the unit & the same to be confirmed in writing.
 The Integration unit shall provide flexibility of adding communication ports (RS485)
by adding communication cards, minimum one slot, when required rather than
adding additional unit itself.
 The Integration unit shall have inbuilt JAVA/SQL/MSSQL engine and it shall be
possible to configure the IO, if required, of the 3rd party devices.
 The Integration unit should be capable of handling multiple protocol simultaneously
and should not be restricted to single protocol.
 The Integration unit should have inbuilt memory for program storage.
 The Integration unit should automatically backup its database for the user defined
interval.
 User authentication should be integral part of the unit.
 All vendors are required to provide the documentation highlighting the capabilities
mentioned above.
 All units shall have LEDs for fault / status identification

PAGE - 966
4.0 Direct Digital Controller

4.1 Direct Digital Controller

a. DDC controllers shall be BACnet IP or LON work IP 852 (Open Protocols). DDC shall
be capable of fully “stand- alone” operation i.e. In the event of loss of
communication with other DDC’s or Control Station, they shall be able to function
on their own.
b. The controllers shall consist of 32-bit microprocessors for reliable throughput,
with Electrical Erasable Program Read only Memory (EEPROM) based operating
system (OS) on BACNET/Lon work.
c. The memory available to the controller board should serve as working space and
there should not be any limitation of using particular function block other than the
memory. Each DDC shall have minimum memory as per design & I/O summary
requirement. Each Controller shall have feature to save graphics also in Memory.
d. Each DDC shall have built in Ethernet ports as per design & site requirement and
speed 10Mb/100Mb.
e. Each DDC & Module shall have LCD Display (Inbuilt or External to monitor &
control connected points from DDC itself.
f. DDC shall have embedded TCP/IP connectivity so that it can be hooked into the
Local Area Network (LAN) provided by the AAI / can be on dedicated network
created by the vendor. Each DDC can be accessed from the Graphical User Interface
(GUI) or from a standard Web browser (WBI) by connecting to the server.
g. Controller shall have capability to communicate with other controllers for any
interlock or data sharing using peer to peer technology. The Controller which route
the messages or data sharing through the system or any intermediate hard ware /
controller shall not be acceptable.
h. All controllers shall accept 24V, Uninterrupted power supply shall be provided by
end user.
i. Controller shall support DHCP addressing over Local Area Network (LAN) so that
the static IP requirements are reduced however a single static IP shall be provided
for system so that it can be hosted on to internet in consultation with end user and
approval of Engineer In charge / AAI.
j. The controllers shall have a resident real time clock for providing time of day, day
of week, date, month and year. These shall be capable of being synchronized with
system / time master clocks in the network.
k. If the controllers provided have the configurable plug in function cards, then the
following minimum specifications shall have to be met:
i) The cards shall provide for analog or digital, input or output, hardwired
connections to the installed plant.
ii) The quantity and combination of these cards shall be determined by the
requirements of the plant in that location with the concurrence of the
Engineer In charge / AAI.

l. The DDC’s shall have 20 % spare capacity for each type of point (digital/analog
input/output) to give flexibility for future expansion.
m. All DDC controllers shall have 10 / 12 bit A/D resolution and be capable of handling
voltage, milli-ampere, resistance or open and closed contacts inputs in any mix, if
required.

PAGE - 967
 Analog inputs/outputs of any of the following minimum types shall be supported:
 4-20 mA.
 0-10 volts.
 2-10 volts.
Resistance Signals (Either PTC or NTC such as PT 100, PT 1000, PT 3000, NTC20K)

Digital input/output types to be supported shall be, but not limited to the
following:
i) Potential free contact for input .
ii) Potential free, TRIAC & Transistor contact for Digital output.
Modulating outputs shall be true proportional outputs and not floating control type.
n. It shall be possible to change the analog inputs to accept any of the above depending
upon the site condition or system requirement using a jumper.
o. Controller’s packaging shall be such that, complete installation and check out of
field wiring can be done prior to the installation of electronic boards.
p. All board terminations shall be made via plug-in connectors to facilitate trouble-
shooting, repair and replacement. Soldering of connections shall not be permitted.
q. Controllers shall be equipped with diagnostic LED indicators with at least
indication for Power up Test OK, Watch dog and Bus Error. All LED’s shall be visible
without opening the DDC cover.
r. The controllers shall be housed in vandal proof boxes to protect them from
tampering by any unauthorized personnel. All DDC controllers used in plant room
spaces and external application shall be housed IP66/IP54 rating enclosures.
s. It shall be possible to add new controllers to the system without taking any part of
the system off-line.
t. All DDC should have XML web service option which can be enabled in later stage
for any higher interface with IT infrastructure or any other service.
u. Individual DDC should be BTL (Bacnet Testing Lab) tested.
v. Each DDC shall be capable of sending reports by mail once connected on IP port.

4.2 DIRECT DIGITAL CONTROLLERS CAPABILITIES:

a. Controllers shall have resident in its memory and available to the programs, a
relevant library of algorithms, intrinsic control operators, arithmetic, logic and
relational operators for implementation of control sequences & save graphics.
b. In the event of failure of communication between the controllers and/or Control
Station terminal, alarms, reports and logs shall be stored at the controllers.
c. Where information is required to be transmitted between controllers for the
sharing of data such as outside air temperature, it shall be possible for global points
to be allocated such that information may be transmitted either on change of
incremental value or at specific time intervals.
d. It shall be possible to set the parameters and structure the application programs by
using a graphic and element oriented programming language.
e. For generation of the application programs, the following function elements are
required
f. Arithmetic operations

PAGE - 968
 g. Logic Operations
h. Comparison Operation
i. Controllers function PID (Proportional control, Proportional + Integral (PI)
Control, Proportional plus Integral plus Derivative (PID) Control, Two Position
Control and Time Proportioning Control and algorithms etc)
j. Controllers must be able to perform the following energy management functions as
a minimum,
 Time & Event programs
 Holiday Scheduling
 Maximum and Distributed power demand
 Optimum start and stop program
 Run Time Totalization
 Sequencing and Optimization
 Exception scheduling

k. Run time shall be accumulated based on the status of a digital input point. It shall
be possible to total either ON time or OFF time. Run time counts shall be resident
in non-volatile memory.
l. All DDC shall have memory to store trends, Graphics, Logics etc. as per site & design
requirements.
m. Minimum communication should be 10 MBPS for each of the controller.
n. DDC should be forward compatible type so that any expansion or upgrade of the
system required in the future is easily taken care off without scrapping / removing
/ disturbing the existing working system.
o. All DDC Should be capable of sending email to specific user in the event of alarm,
identified by end user as per Engineer in-charge.

4.3 DATA COMMUNICATION

a. The communication between controllers shall be via a dedicated or customer
provided Ethernet communication network as per standards. Controller’s
microprocessor failures shall not cause loss of communication of the remainder of
any network. All networks shall support global application programs, without the
presence of a host PC.
b. Each controller shall have equal rights for data transfer. There shall be no separate
device designated as the communication’s master.
c. The communication network shall be such that:
 Every DDC must be capable of communicating with all DDC’s on its own.
 Network connected devices shall be capable of sending message after
successive retries shall constitute a communication or device failure.
 Single or multiple standalone controller failures shall not cause loss of
communication between active DDCs connected on the communication
network. Full communication shall be sustained as long as there are at least two
operational stand alone control panels active on the communication network.
 All the System Integration Units shall be linked together on a Local Area
Network.
 The communication network shall include provision for automatically
reconfiguring itself to allow all operational equipment to perform as efficiently

PAGE - 969
 as possible in the event of single or multiple failures.
 The BAS supplier shall be required to provide details of standards to which their
system conforms.

5.0 Portable Operators Terminal / Laptop (Pot)

a. POT /Laptop shall be provided to allow operator readout of system variables,
override control and adjustment of control parameters. The POT shall be portable
and plug directly into individual controllers for power and data.
b. The minimum functionality of POT /Laptop shall include:
 Set points to a fixed value or state.
 Display diagnostic results.
 Display sequentially all point summary and sequentially alarm summary.
 Display/change digital point state, analog point value.
 Display/change time and date.
 Display/change analog limits.
 Display/change time schedule.
 Display/change run time counts and run time limits.
 Display/change time and/or event initiation.
 Display/change programmable offset values.
 Access DDC initialization routines and diagnostics.
 Enable/disable points, initiators and programs.
 Display/change minimum ON/OFF and maximum OFF times.
c. The POT / Laptop shall be complete with command keys, data entry keys, cursor
control keys and a 24 character liquid crystal alphanumeric display. Access shall be
via self prompting menu selection with arrow key control of next menu/previous
menu and step forward/backward within a given menu.
d. Connection of a POT/ Laptop to a controller shall not interrupt or interfere with
normal network operation in any way, prevent alarms from being transmitted, or
interfere with Control Station commands and system modifications.
e. Connection of POT/ Laptop at any controller shall provide display access to all
controllers on that bus. In case the controller has a fixed LCD display and entry
keyboard, then the display access shall be available on each screen.
f. It should be possible to override the commands given through POT / Laptop by the
Operator Control Station.

PAGE - 970
6.0 Field Devices

6.1 Electric And Electronic Controls Related Equipment

i) General Requirements
All controls shall be capable of operating in ambient conditions varying between 0-
55 deg. C and 90% R.H. non-condensing and shall be supplied with adaptors for 25
mm conduit.
ii) Ancillary Items
When items of equipment are installed in the situations listed below. Following
ancillary items shall be supplied by contractor and nothing extra shall be paid on
this contract.

iii) Weather Protection

All devices required to be weatherproofed shall be as per manufacturer
recommendation or as detailed in the Schedule of Quantities. IP ratings required
for the equipment is mentioned in the respective section.

iv) Pipework Immersion

Corrosion resisting pockets of a length suitable for the complete active length of the
device, screwed ½” (13 mm) or ¾” (20 mm) NPT suitable for the temperature,
pressure and medium.

v) Duct Mounting (Metal or Builders Work)

Mounting flanges, clamping bushes, couplings, locknuts, gaskets, brackets, sealing
glands and any special fittings necessitated by the device.

vi) Additional features

a) Concealed Adjustment : All two position switching devices shall have
concealed adjustment unless detailed otherwise in the Technical
specifications.
b) Operating Voltage : All two position switching devices shall operate on 230 v
a.c and all accessible live parts shall be shrouded. An earth terminal shall be
provided as TNS earthing system and connected to MV & HV earth pits also.
6.2 Temperature Sensor
 Temperature sensors for space, pipes and ducts, shall be of the Resistance
Temperature detector (RTD) type or thermistor. These shall be two wire type and shall
conform to the following specifications.
a. Immersion sensors shall be high accuracy type with a high resistance versus
temperature change. The accuracy shall be at least ± .02 degrees F.
b. Immersion sensors shall be provided with separate stainless steel thermo well. These
shall be manufactured from bar stock with hydrostatic pressure rating of at least 10
kgf/cm2.

PAGE - 971
 c. The connection to the pipe shall be screwed ¾ inch NPT (M). An aluminium sleeve
shall be provided to ensure proper heat transfer from the well to the sensor.
Terminations to be provided on the head. Flying leads shall not be acceptable.
d. The sensor housing shall plug into the base so that the same can be easily removed
without disturbing the wiring connections.
e. Duct temperature sensors shall be with rigid stem and of averaging type. These shall
be suitable for duct installation.
f. Outdoor air temperature sensor shall be provided with a sun shield.
g. The sensors shall not be mounted near any heat source such as windows, electrical
appliances etc.
 The temperature sensors may be of any of the following types :
a. PT 100, PT 1000, PT 3000
b. NI 100, NI 1000
c. Balco 500.
 Thermistor
a. NTC 20
6.3 Humidity Sensor
Space and duct humidity sensors shall be of capacitance type with an effective sensing
range of 10% to 90% RH. Accuracy shall be + 3% or better. Duct mounted humidity
sensors shall be provided with a sampling chamber. Wall mounted sensors shall be
provided with a housing. The sensor housing shall plug into hte base so that the same
can be easily removed without disturbing the wiring connections. The sensors shall not
be mounted near any heat source such as windows, electrical appliances etc.
6.4 Flow Meter
Water flow meters shall be either sonic type or electromagnetic type. For
electromagnetic flow meter, teflon lining with 316 SS electrodes must be provided. The
housing shall have IP 55 protection. Vendors shall have to get their design/ selection
approved by the AAI, prior to the supply.
The exact ranges to be set shall be determined by the contractor at the time of
commissioning. It should be possible to ‘zero’ the flowmeter without any external
instruments, with the overall accuracy of atleast ± 1% full scale.
6.5 Pressure Transmitter For Water
Pressure transmitters shall be piezo-electric type or diaphragm type. (Bourdon Tube
type shall not be acceptable). Output shall be 4-20mA or 0-10V DC and the range as
specified in the data sheet depending on the line pressure. Power supply shall be either
24 V AC, 24 V DC or 110 V AC. Connection shall be as per manufacturer’s standards. The
pressure detector shall be capable of withstanding a hydraulic test pressure of twice the
working pressure. The set point shall fall within 40%-70% of the sensing range and
detector shall have sensitivity such that change of 1.5% from the stabilised condition
shall cause modulation of the corrective element. The sensor must be pressue
compensated for a medium temperature of -10 o C to 60o C with ambient ranging
between 0 o C to 55 o C. Housing for these shall be weather proof with IP 65 protection.

PAGE - 972
6.6 Differential Pressure Switch For Pipe Work
These shall be used to measure pressure differential across suction and discharge of
pumps. The range shall be as specified in the data sheet. Switch shall be ON with increase
in differential. Housing for these shall be weather proof with IP 55 protection.
The pressure switch shall be capable of withstanding a hydraulic test pressure of 1.5
times the working pressure. The set point shall fall in 40-70% of the scale range and shall
have differentials adjustable over 10%-30% of the scale range. The switches shall be
provided with site adjustable scale and with 1 NO/NC contact.
6.7 Differential Pressure Switch for Air Systems
These shall be diaphragm operated. Switches shall be supplied with air connections
permitting their use as static or differential pressure switches.
The switch shall be of differential pressure type complete with connecting tube and
metal bends for connections to the duct. The housing shall be IP 54 rated. The pressure
switches shall be available in minimum of 3 ranges suitable for applications like Air flow
proving, dirty filter, etc. The set point shall be concealed type. The contact shall be SPDT
type with 230 VAC, 1 A rating and VA rating as per design requirements.
The switch shall be supplied suitable for wall mounting on ducts in any plane. It should
be mounted in such a way that the condensation flow out of the sensing tips. Proper
adaptor shall be provided for the cables.
The set point shall fall within 40%-70% of the scale range and l have differentials
adjustable over 10%-30% of the scale range.
The switches shall be provided with site adjustable scale and with NO/NC contact.
6.8 Air Flow Switches
Air flow switches shall be selected for the correct air velocity, duct size and mounting
attitude. As per site requirements & special atmospheric conditions the parts of the
switches shall be suitably coated or made to withstand such conditions. These shall be
suitbale for mounting in any plane. Output shall be 1 NO/NC potential free. Site
adjustable scale shall also be provided.
6.9 Air Pressure Sensor
The pressure sensor shall be differential type. The construction shall be spring loaded
diaphragm type. The movement of the membrane in relation to the pressure should be
converted by an inductive coupling which would electromagnetically give an output
suitable for the controller. The pressure sensor shall be in a housing having IP 54 ratings
in accordance with IEC 529. Suitable mounting arrangement shall be available on the
sensor. The sensor shall come complete with the PVC tubes & probes.

6.10 Water Flow Switch

These shall Piezo diaphragm and suitable for the type of liquid flowing in the line. Output
shall be 1 NO/ 1NC potential free.

PAGE - 973
6.11 Transducers For Electrical Services
Electrical transducers shall be integrated electronic type and rack mounted on the field.
These shall work on 110V/ 220 V supply with the output being standard type i.e. 4-20
mA, 0- 10 Volts etc.
Power factor, Voltage, Current, Frequency and Kilowatt transducers shall have standard
output signal for measurement for the specified variable.
Kilowatt-Hour metering (if any) shall be poly-phase, three- element with current
transformer (CT) operated type. The metering shall feature high accuracy with no more
than +/- 1% error over the expected load range. The coils shall be totally encapsulated
against high impulse levels.
6.12 Level Switch
The level switches shall have to meet the following requirement :
a. Type : Float Type/Capacitance type/Conductivity type
b. Mounting : To suit application.
c. Connection : Flanged ANSI 150 lbs RF Carbon steel
d. Float material : 316 SS
e. Stem Material : 316 SS
f. Output : 2 NO, 2 NC potential free
g. Switch Enclosure : IP 55

6.13 Two Way On/Off Butterfly Valve

6.13.1 Valve
a. Type of valve : Butterfly Valve.
b. Body Material : Carbon steel ASTM A 216
c. Body seat ring (if : Gr WCB
applicable)
d. Vane : SS-316
e. Packing : Teflon
f. Mounting Stool : Required.
g. Shaft : SS-316
h. Seat : Nitrile rubber
i. Fasteners : SS-316
J. Leakage : With 100 % Leak proof

PAGE - 974
6.13.2 Actuators
Type : Electric .
Duty. : On/Off (Maximum 50 operations per
day)
Motor power supply : 230 V AC or 415 V 3-phase
Travel limit switches : 2 Nos
Torque limit switches. : 2 Nos
Hand wheel : Required
Speed : Approx 150 mm/min
Note:
a. Actuator must open/ close with one changeover contact. Control panel, if required,
must be supplied integral with the Actuator.
b. No gear box is envisaged, however if gear box is provided, the travel limit switches
must be connected directly to the valve stem.
c. Cover tube for the valve stem must be provided.
6.13.3 Current Relay
Current relay are solid state switches that operate when the AC current level sensed by
the Internal current transformer exceeds a fixed or adjustable trip points. The relay
shall be of solid or Split core.
 Switch Type Normally open solid state
 Switch Rating 1- 135 VAC/VDC
 Response Time less than 150 Sec.
 Operating Temp -40 to 50 deg C
6.13.4 Indoor Air Quality Sensor

6.13.5 CO2 Sensors (Indoor Air Quality Sensor) Duct mounted/Wall mounted
The sensor should measure and transmitCO2 level ranging from 0 to 2000 parts per
million(ppm) from return air path. These shall work on 24 vac or 24 vdc supply with
the output being standard type i.e. 4-20 mA, 0- 10 Volts etc.
 Output signal : 4 mA to 20 mA or 0 to 10 vdc
 Operating Temperature Range : 23 to 113 deg F or -5 to 45 deg C
 Operating Humidity Range : 0 to 85% non condensing
 Air Flow Range : 0 to 7500ft / min
 Power Supply : 24 VAC or 24VDC

PAGE - 975
7.0 Enclosures for Controllers and Electrical Panels
All the controllers shall be housed in pad lockable Vandal proof boxes which shall either
be floor mounted or wall mounted. These shall be free standing, totally enclosed, dust
and vermin proof and suitable for tropical climatic conditions.
The panel shall be metal enclosed 14 SWG CRCA sheet steel cubicle with gaskets between
all adjacent units and beneath all covers to render the joints dust proof. All doors and
covers shall be hinged and latched and shall be folded and braced as necessary to provide
a rigid support. Joints of any kind in sheet metal shall be seam welded with welding slag
grounded off and welding pits wiped smooth with plumber metal.
All panels and covers shall be properly fitted and secured with the frame and holes in the
panels correctly positioned. Fixing screws shall enter into holes tapped into an adequate
thickness of metal or provided with nuts. Self threading screws shall not be used in the
construction of control panels. Knockout holes of approved size and number shall be
provided in the panels in conformity with the location of incoming and outgoing
conduits/cables. lamps shall be provided to support the weight of the cables. The
dimension of the boxes shall depend on the requirement with the colour decided in
consultation with the AAI.
Note : Panel enclosures for indoor application shall have IP 42 protection and IP 65
protection for outdoor application.
8.0 Conduits and Wiring
Prior to laying and fixing of conduits, the EPC contractor shall submit drawings
indicating the layout, number and sizes of conduits, sizes and location of conduits and
other relevant details for approval by AAI.
Specifications of Conduits shall be followed as given under Internal EI Section.
9.0 Signal Cabling & Communication Cabling
The signal cable shall be of the following specifications :
a. Wire : Annealed Tinned Copper
b. Size : 1.5 sq. mm for communication & 1.0 Sqmm
for Signal
c. No. of conductors : Two (One pair)
d. Shielding : Overall beld foil Aluminium polyster shield.
e. Jacket : PVC
f. Nominal DCR : 17.6 ohm/km for conductor 57.0 ohm/km for
shield
g. Nominal OD : 8.5 mm
h. Nominal capacitance : 130 pF/m between conductors at 1 KHz 180 pF/m
between one conductor and other conductors
connected to shield.
i. Colour : Black and Red

PAGE - 976
9.1 Local Area Network Cable
Cat-6 UTP cable shall be used along with required optical fiber cable as per
manufacturer recommendation.
10.0 Electronic Metering
Digital Electronic metering (MFM-Multi Function Meter) as provided on the Electrical
panels shall be interface to BMS platform & its agency responsibility to develop all
necessary interface for downloading data in the BMS platform.
All the instantaneous measurements shall be displayed on the BMS control station and
the data shall be logged. It shall be possible to access minimum / maximum logging of
any parameter with alarm annunciation for unusual measurements. The system shall
also accept user defined “Set limit of any parameter.

PAGE - 977
 I/O SUMMARY FOR IBMS

Sr.
A D A D Field
No. Function Function By IBMS Contractor By 3rd Party Contractors
I I O O Device
Stat Alar Contr Monit
us m ol or
A Air Handling Units
1 AHU
FanEnable/Disable *
Command
2 AHU Fan Start/Stop Ptential Wiring from PFC at VFD PFC in the VFD panel to
Command * Free panel to DDC accept the ON / Off command
Contact
3 AHU Fan Run Status DPS Diff. Pressure Switch air Provision for installation of
* across AHU fan/Blower. DP switch across the blower
in AHU
4 AHU Trip Status Ptential Wiring from PFC at VFD PFC in the VFD panel to
Free panel to DDC accept the ON / Off command
* * Contact
From AHU
Panal
5 AHU Filter clean/clog Diff. Diff. Pressure Switch Provision for installation of
Status * Pressure across Filter DP switch across the filter in
Switch AHU
6 AHU Fan Auto-Manual Ptential Wiring from PFC to DDC Auto-manual switch having
Switch Status * Free PFC to be provided in the
Contact AHU starter/VFD panel.
7 AHU Return air Air Duct Temp. Sensor and Provision for installation of
temperature * Sensor+RH wiring from sensor to Temp. sensor in the return
Sensor DDC duct of AHU
8 AHU supply air Duct Temp. Duct Temp. Sensor and Provision for installation of
temperature * Sensor wiring from sensor to Temp. sensor in the supply
DDC duct of AHU

PAGE - 978
9 2 way chilled water Modulating 0-10 V DC signal from 2 Way Control Valve by HVAC
modulating valve, valve + DDC to/from 2 way vendor with acceptance of 0-
control & position Actuator control valve through 10 V DC Signal and shall have
feedback. field wiring compatibility with BMS to
* *
give feedback.

10 VFD Feedback & Third Party Integration Two way Direct Integration
Modulation Following points shall be displayedas minimum thru integration of VFD Microprocessor through Modbus
Modulation Control Panel: TRU/Bacnet/*Lonework/An
• VFD Speed Control y open Protocol
• VFD-Power (kW)
• VFD-Consumption (kWH)
• VFD- Fault Alarm
• VFD- Bypass Status
• VFD-Speed (RPM) Feedback
• CTL Address
• Frequency Output
• Speed
• Current
• Torque
• Power percentage
• Drive Temperature
• kWH
• Run Time hours
• DC Bus Voltage Percentage
• Last Fault
• First Fault
• Second Fault
• OK Fault
• Reset Fault
• Error Status
11 AHU Return Air CO2 Duct Temp. Duct CO2 Sensor Provision for installation of
Sensor * Sensor CO2 sensor in the Return duct
of AHU

PAGE - 979
12 Fresh Air Damper 0-10 V DC signal from Fresh Air Damper by HVAC
modulating control & DDC to/from Fresh Air vendor with acceptance of 0-
position feedback. Damper through field 10 V DC Signal and shall have
* *
wiring compatibility with BMS to
give feedback.

B Ventilation Fans (
Fresh Air in Fire case)
1 FanEnable/Disable
* *
Command
2 Fan Start/Stop Ptential Wiring from PFC at PFC in the starter panel to
Command * Free starter panel to DDC accept the ON / Off command
Contact
3 Fan run status DPS Diff. Pressure Switch air Provision for installation of
* across AHU fan/Blower. DP switch across the blower
in fan section.
4 Fan Trip Status Ptential Wiring from PFC at VFD PFC in the VFD panel to
Free panel to DDC accept the ON / Off command
* * Contact
From AHU
Panal
5 Fan Auto-Manual Ptential Wiring from PFC to DDC Auto-manual switch having
Switch Status * Free PFC to be provided in the fan
Contact starter panel.

C Toilet Exhaust Fans

1 Fan Start/Stop Ptential Wiring from PFC at PFC in the starter panel to
Command * Free starter panel to DDC accept the ON / Off command
Contact
2 Fan run status DPS Diff. Pressure Switch air Provision for installation of
* across AHU fan/Blower. DP switch across the blower
in fan section.
3 Fan Trip Status Ptential Wiring from PFC at VFD PFC in the VFD panel to
* * Free panel to DDC accept the ON / Off command
Contact

PAGE - 980
4 Fan Auto-Manual Ptential Wiring from PFC to DDC Auto-manual switch having
Switch Status * Free PFC to be provided in the fan
Contact starter panel.

D HT/ LT Breaker
1 Incoming breaker Ptential Wiring from PFC to DDC Potential Free Contact in
Open/Close status at * Free Panel
LT/ HT Panel Contact
2 Incoming breaker
Open/Close Command
LT/ HT Panel
3 Incoming breaker Trip Ptential Wiring from PFC to DDC Potential Free Contact in
status at LT/ HT Panel * Free Panel
Contact

E Lighting Control
(Feeders)
1 Breaker On/ Off Ptential Wiring from PFC to DDC Potential Free Contact in
Command * Free Panel
Contact
2 Breaker On/ Off Status Ptential Wiring from PFC to DDC Potential Free Contact in
* Free Panel
Contact

F DG Sets
1 DG RUN STATUS (ON /
*
OFF)
2 DG HT AMF BREAKER
*
STATUS ON/OFF
3 DG AMF BREAKER
*
TRIP STATUS
HSD SYSTEM
1 DG day oil/main tank Flame Proof Flame proof level switch Provision for installation of
storage tank low/ High * level switch and wiring level switch in the tank
level monitoring

PAGE - 981
2 DG Buffer Oil Storage Flame Proof Flame proof level switch Provision for installation of
Tank Low/ High * level switch and wiring level switch in the tank
Monitoring
DG Sets Two way Direct Integration
microprocessor panel through Modbus
integration with BMS Software Integration with DG PLC Panel Open protocol provided by the Vendor TRU/Bacnet/*Lonework/An
for intrinsic parameter y open Protocol
monitoring
G Multi Function Meter
at LT & HT
MFM meter parameters Third Party Integration Energy Meter vendor to
Current, Voltage, KWh, Following parameter shall be displayed as minimum trrough software Integration provide RS 485 MODBUS
KVA, Pf, • Voltage-Phase 1 RTU. The electrical vendor to
Frequency,Harmonics • Voltage-Phase 2 show the parameters on the
& Monitoring status • Voltage-Phase 3 MODSCAN software before
(On/Off) • Frequency integrating to IBMS. All
• PF- 3 Ph eq mapping details & the
• Current- 3 Ph eq Master/slave ID setting in the
• Current-Phase-1 meter to be done by the
• Current-Phase-2 electrical vendor
• Current-Phase-3
• PF- 3 Ph eq Active power
• PF- 3 Ph eq Reactive power
• PF- 3 Ph eq Apparent power
• Energy- 3 Ph eq Active Energy
• Energy- 3 Ph eq Apparent Energy
• THD
. Power Factor
. KWH (transformer )
. KWH ( DG)
H Elevator
Elevator ON/OFF
*
Status
Elevator Fault Status *

PAGE - 982
I TRANSFORMERS
1 Breakers status (HT) Ptential Wiring from PFC to DDC
* Free
Contact
2 Gas Alarm feedback Ptential Wiring from PFC to DDC
* Free
Contact
3 Winding temprature Ptential Wiring from PFC to DDC
alarm * Free
Contact

J Sumps & Water

pumps,STP
1 Raw Water Pump on / Ptential Relay out Put @2 PFC in the pump pannel to
off command * Free amp,230V accept the ON / Off command
Contact
2 Raw Water Pump run Ptential Wiring from Volt free Potential free contact in the
status * Free contact to DDC pump panel
Contact
3 Raw Water pump Trip Ptential Wiring from PFC at VFD PFC in the VFD panel to
Status * * Free panel to DDC accept the ON / Off command
Contact
4 Raw Water Pump auto Ptential Wiring from Volt free Volt free contact in Auto-
manual status * Free contact to DDC manual switch in the pump
Contact panel
5 Domestic Water Pump Ptential Relay out Put @2 PFC in the pump pannel to
on / off command * Free amp,230V accept the ON / Off command
Contact
6 Domestic Water Pump Ptential Wiring from Volt free Potential free contact in the
run status * Free contact to DDC pump panel
Contact
7 Domestic Water Pump Ptential Wiring from PFC at VFD PFC in the VFD panel to
Trip Status * * Free panel to DDC accept the ON / Off command
Contact

PAGE - 983
8 Domestic Water Pump Ptential Wiring from Volt free Volt free contact in Auto-
auto manual status * Free contact to DDC manual switch in the pump
Contact panel
9 Borewell pumps on / Ptential Relay out Put @2 PFC in the pump pannel to
off command * Free amp,230V accept the ON / Off command
Contact
10 Borewell pumps run Ptential Wiring from Volt free Potential free contact in the
status * Free contact to DDC pump panel
Contact
11 Borewell Pump Trip Ptential Wiring from PFC at VFD PFC in the VFD panel to
Status * * Free panel to DDC accept the ON / Off command
Contact
12 Borewell pumps auto Ptential Wiring from Volt free Volt free contact in Auto-
manual status * Free contact to DDC manual switch in the pump
Contact panel
13 Overhead/undergroun Ptential Relay out Put @2 PFC in the pump pannel to
d on / off command * Free amp,230V accept the ON / Off command
Contact
14 RO pumps run status Ptential Wiring from Volt free Potential free contact in the
* Free contact to DDC pump panel
Contact
15 RO Pump Trip Status Ptential Wiring from PFC at VFD PFC in the VFD panel to
* * Free panel to DDC accept the ON / Off command
Contact
16 RO pumps auto manual Ptential Wiring from Volt free Volt free contact in Auto-
status * Free contact to DDC manual switch in the pump
Contact panel
17 Sump Pump on / off Ptential Relay out Put @2 PFC in the pump panel to
command * Free amp,230V accept the ON / Off command
Contact
18 Sump Pump run status Ptential Wiring from Volt free Potential free contact in the
* Free contact to DDC pump panel
Contact
19 Sump Pump Trip Ptential Wiring from PFC at VFD PFC in the VFD panel to
Status * * Free panel to DDC accept the ON / Off command
Contact
PAGE - 984
20 Sump Pump auto Ptential Wiring from Volt free Volt free contact in Auto-
manual status * Free contact to DDC manual switch in the pump
Contact panel
21 High Level Monitoring Ptential Level switch & field Provision for installation of
in Sumps * Free wiring level switch in the water tank
Contact
22 Soft Water Transfer Ptential Relay out Put @2 PFC in the pump pannel to
pumps in STP on / off * Free amp,230V accept the ON / Off command
command Contact
23 Soft Water Transfer Ptential Wiring from Volt free Potential free contact in the
pumps in STP run * Free contact to DDC pump panel
status Contact
24 Soft Water Transfer Ptential Wiring from PFC at VFD PFC in the VFD panel to
pumps in STP Trip * * Free panel to DDC accept the ON / Off command
Status Contact
25 Soft Water Transfer Ptential Wiring from Volt free Volt free contact in Auto-
pumps in STP auto * Free contact to DDC manual switch in the pump
manual status Contact panel
26 Flushing Water Ptential Relay out Put @2 PFC in the pump pannel to
Transfer pumps on / off * Free amp,230V accept the ON / Off command
command Contact
27 Flushing Water Ptential Wiring from Volt free Potential free contact in the
Transfer pumps run * Free contact to DDC pump panel
status Contact
28 Flushing Water Ptential Wiring from PFC at VFD PFC in the VFD panel to
Transfer pumps Trip * * Free panel to DDC accept the ON / Off command
Status Contact
29 Flushing Water Ptential Wiring from Volt free Volt free contact in Auto-
Transfer pumps auto * Free contact to DDC manual switch in the pump
manual status Contact panel
30 Irrigation Water Ptential Relay out Put @2 PFC in the pump pannel to
pumps on / off * Free amp,230V accept the ON / Off command
command Contact
31 Irrigation Water Ptential Wiring from Volt free Potential free contact in the
pumps run status * Free contact to DDC pump panel
Contact
PAGE - 985
32 Irrigation Water Ptential Wiring from PFC at VFD PFC in the VFD panel to
pumps Trip Status 1 * Free panel to DDC accept the ON / Off command
Contact
33 Irrigation Water Ptential Wiring from Volt free Volt free contact in Auto-
pumps auto manual * Free contact to DDC manual switch in the pump
status Contact panel
K Fire Hydrant Ptential
Pumps(Electrical Free
Driven) Contact
1 Pump Run Status( Ptential Differential Switch across Suitable Insertion Provision
Alarm Point) * Free Pumps in Water Line
Contact
Pumps Trip Status Ptential Wiring from PFC at VFD PFC in the VFD panel to
* * Free panel to DDC accept the ON / Off command
Contact
2 Pump auto manual Ptential Wiring from Volt free Volt free contact in Auto-
status * Free contact to DDC manual switch in the pump
Contact panel
L Fire Hydrant Ptential
Pumps(Diesel Free
Driven) Contact
1 Pump Run Ptential Differential Switch across Suitable Insertion Provision
Status(Alarm Point) * Free Pumps in Water Line
Contact
Pumps Trip Status Ptential Wiring from PFC at VFD PFC in the VFD panel to
* * Free panel to DDC accept the ON / Off command
Contact
2 Pump auto manual Ptential Wiring from Volt free Volt free contact in Auto-
status * Free contact to DDC manual switch in the pump
Contact panel

N Third Party
Integration
1 VRV/VRF System

PAGE - 986
2 VFD's Feedback & Two way Direct
Modulation Integration through
3 UPS Modbus
4 Energy Meter / MFM TRU/Bacnet/*Lonework
5 Lifts /Any open Protocol of
5 Packaged AC all devices/detectors
6 STP
7 WTP
8 Water Meter
9 CCTV System Control
10 Fire Alarm System FAS Vendor to provide RS
485 MODBUS / Bacnet
interface in their panel. FAS
Vendor to show the
parameters on the
MODSCAN /Bacnet/IP
software before integrating
to IBMS. All mapping details
& the Master/slave ID setting
in the control panel to be
done by the FAS Contractor

Note- The above I/O summary is for reference. However, actual designing shall be based on site requirements. The I/O summary
shall be prepared by the contractor as per actual and same shall be approved by the EIC E&M prior to execution of works .

PAGE - 987
SECTION – 16 WATER SUPPLY AND DRAINAGE PUMPS
1.0 TUBE-WELLS/ BORE-WELLS & PUMPING SYSTEM
The water supply to the project shall be met from the Municipal Supply from the Local
Bodies and / or from tube wells provided in the campus. The tube wells shall be planned
for proposed development only after obtaining the required Statutory Approvals from
CGWA and shall be well spread so as to avoid effect of draw down on one and another.
The requirements for the tube wells pump shall be as under:
 The pumps shall be vertical, submersible, multistage centrifugal, stainless steel (304)
casing, stainless (304) impeller, stainless steel (316) shaft, ceramic bearings, tungsten
carbide shaft protection bushes and mechanical seal driven suitable rated motor with
1500/2900 RPM, 415±10% Volts, 50 Cycles, AC 3 –phase Each pump shall be capable
of operating within a performance pressure characteristic range sufficient below and
above the required working pressure.
 The Pump shall conform to Indian standard IS: 8034.
 Pumps and motors shall be mounts on a common MS structural base plate.
 The pump shall be water cooled coupled to induction motor of suitable H.P and R.P.M
specified in specifications and design drawings.
 Pumping set shall be provides with a Gun Metal “Bourden” type pressure gauge with
gunmetal isolation cock and connecting piping.
 The pump set shall be provided with gun metal gate valve of appropriate sizes on
delivery. & non-return valve of appropriate size and a pressure gauge with cock shall
be provided on the delivery line.
 The pumping system for tube wells shall be designed for 8-10 hours operation
(average) per day.

2.0 VERTICAL MULTISATAGE PUMP

 Pumps shall be vertical, centrifugal, multistage directly coupled to motor.

 MOC of the pumps
Pump Head : cast Iron
Pump Base : Cast Iron
Impeller : SS 316
Shaft : SS 316
 Impeller shall be hydraulically balanced and keyed to shaft. Pump shall be mounted
on a concrete foundation, projecting at least 15 CM above finished floor level. The
pumps base shall be set on a vibration elimination pad. The pump shall be lubricated
in strict accordance with the manufacturer’s instructions and shall be factory aligned
prior to shipment.
 All motors and bases shall be painted with approved finish design coat of paint. The
pump shall be selected for the lowest operating noise level and shall be complete with
flexible connections, valves, and pressure gauges. The pumps shall include cost of
foundation channel complete.
 The Contractor shall design, supply, install and commission the pumps of the type and
performance as approved by the Engineer in Charge.
 Pumps shall be so selected that the design duty point is within 5% of the maximum
efficiency point. The pump casing so selected shall have ample space to take an
impeller one size larger than that capable of performing the design duty.
 The pump shall have a speed of not more than 1500 rpm. However, pumps of 2900

PAGE - 988
 rpm with high efficiency and low noise motor can be selected and noise data
submitted for approval.
 All pumps and motors shall be of minimum vibration and noise level during
operation. Vibration isolators shall be provided for all pump sets.
 Facilities shall be provided to prevent starting of pumps when the water tank is at low
water level. An indicator for this low water level alarm shall be provided.
 Facilities to select which pump to be duty pump and standby pump shall be provided
and be interchangeable.
 Pump curves for all pumps offered shall be submitted. All curve indicating excessive
shut-off head will not be approved.
 Each pump shall be provided with a gate valve at suction and discharge, approved
check valve at discharge, approved strainer at suction, flexible connections at pump
suction and discharge, eccentric reducer at suction, concentric reducer at discharge,
pressure gauges at suction and discharge, circulation relief valve and automatic air
relief valve.
 Appropriate neoprene vibration isolation mountings shall be provided for each pump
sets.
 The shaft seal shall be easily serviceable and shall allow for correct adjustment and
loading of the seal. Pump motors above 7.5 kW shall be equipped with a spacer
coupling which allows changing of shaft seals without removing the motor. The pump
motors shall be of Class “F” insulation and IP55 rating and shall be provided with
built-in thermistors for protection against over heating.
 Pumps shall be driven by elevated in-line TEFC squirrel cage motors via extended
vertical shafted complete with universal couplings.
 The shafts shall be stainless steel. Stainless steel sleeves shall be provided to protect
the shaft in the water space and through the sealing glands. The sleeves shall be keyed
to prevent rotation and secured against axial movement.
 The bearings shall be of ball or roller type protected against ingress of water, dirt and
other matter.
 Vertical multistage pumps shall have universal flanges. Intermediate bearing, support
bearing shall be provided in the pump.

2.1 VARIABLE SPEED HYDROPNEUMATIC PUMPING SYSTEM

 Variable speed Hydro-pneumatic pumping units shall be provided for supply of
domestic water, for the project. The units shall be selected so as to provide at
minimum of 1.5 bar pressure at the highest/farthest fitting in each plumbing system
and maximum pressure at the user’s points restricted to 4.0 bar, the unit serves.
 The capacity of the Hydro-pneumatic System shall be calculated based on the Fixture
Unit calculation Table provided in National Building Code 2016 of India.
 One set of Hydro-pneumatic pumps shall be in N+1 configuration. Variable speed
drives shall be pump mounted on all the pumps.
 The system shall be provided with IE5 efficiency motors. The hydro-pneumatic
pumping units shall have the following features;

2.2 SYSTEM DESCRIPTION

 The system shall be supplied as complete sets including suction and discharge
common manifolds, non-return valves, isolating valves, pressure transmitter on the
discharge side and electrode at the suction tank.

PAGE - 989
  The system operation will be such that the initial small water demand shall be met by
the charged diaphragm pressure vessel. Should the water demand continue the
system pressure will dip to a preset pump cut-in point when the lead pump starts to
operate at reduced speed through the variable speed drive. However, should the
system pressure be still below the preset value, the controller continuously increases
pump speed to meet the system demand. When the lead pump is not able to meet the
system pressure at full speed, the second pump also starts to operate.
 At peak demand all the pumps operate, Similarly, if there is a drop-in water demand
the duty pump speed starts to reduce, then standby pumps cuts-off, followed by
stopping of the duty pump.
 The closed diaphragm pressure vessel shall be of polyethylene material with a
pressure gauge and isolating valve. The interior shall be of non-toxic lining suitable
for use with potable water. The vessel shall be manufactured to conform to ASME
pressure vessel code/standards.
 The system shall be under the control of an electronic microprocessor unit (EMU).
 A pressure transmitter shall detect the pressure at the delivery manifold and
feedback to the microprocessor control panel via control circuit.
 The system shall incorporate a frequency converter or frequency converter motors
on the pumps and the pressure transmitter shall register the actual pressure on the
discharge side.
 The variable speed drive pumping system shall maintain a constant pressure
regardless of the system demand. If there is a drop-in pressure outside the preset
point, the Variable Speed Drive (VSD) pump shall start to run until the pressure
increases to the preset limit, or it will continue to increase the pump speeds to the
upper limit of the frequency. If the water system demand still cannot be met, the
second pump shall be called in to run, the VSD will then alter the pump speed to meet
the preset pressure point. If the set point is still unable to be met, the third pump is
then activated to run (in case of 3 pumps units). All the pumps shall be installed with
variable speed drive.
 This shall be achieved by continuously varying the motor speed of the duty pump
according to the demand up to a maximum designed capacity.
 Under decreasing hydraulic demand, the reverse sequence to the above description
shall apply.
 The EMU shall ensure alternation of all the duty and standby pumps for even running
hours for all the pumps.
 The frequency converter shall be linked to the motor of the duty pump for continuous
speed adjustment and ultimately the water delivery shall be maintained at constant
pressure at the preset value.

2.3 LOCAL MOTOR CONTROL PANEL

 The motor control panel shall be equipped with all the necessary electrical
components including a microprocessor control unit and a frequency drive. The
control panel and the microprocessor shall cover the followings functions:
a. Flexibility and simplicity in allowing the necessary re-adjustment of the pumping
system pre-set delivery pressure to operate the pumps within the specified
maximum and minimum delivery ranges.
b. Built-in frictional loss compensation factor which will automatically increase the
delivery pressure setting, in collaboration with the increase in flow demand. This

PAGE - 990
 shall be able to minimize the system pressure differences and provide a more
constant pressure along the supply line and also to save the energy consumption
of the motor when running at low speed.
c. Automatic changeover of the pumps to be controlled by the microprocessor which
dictates the duty and standby pumps to run at variable speed.
d. Built-in clock functions with weekly programming and with switch on system to
operate at least 10 different pre-set pressure points as required.
e. When the system has not been operated for more than 24 hours, it shall
automatically start the pumps for a few seconds/day to ensure the pumps
readiness at all times. The standby pumps shall be activated upon failure of duty
pump(s). In event of control failure, the pumps shall be able to be start/stopped
manually at the local panel by means of pressure switches.
f. The microprocessor control panel shall be able to cut-off the pumping system
when excess pressure is registered in the discharge common manifold.
g. The system shall have the capability of receiving input signal concerning reduced
water level in suction tanks and shall have control mechanisms to prevent the
pumps form running dry.
h. Automatically starting the pumps when the water level is back to normal.
i. In case of pump failure due to motor overload, the standby pump is switched on
automatically. Alarm signal is displayed on the LCD Display unit and alarm lights
are activated.
j. Functions to limit the no. of start/stop of pumps per hour.
k. The system control panel shall incorporate at least the following components:
 LCD Display
 Pumps selections for up to 4 pumps so that system controller can control up
to 6 pumps
 Pump status button to display duty pump speed and system capacity
 Zone status button to display operating parameters for different pumping
units
 Setting button to input preset pressure, system start/stop time etc.
 ±1 button to key in numeric data such as pressure set point, etc.
 Enter button for confirmation of input into the system
 Alarm button to show location of fault - self diagnostic function display
 Hour Run measurement for each supplied pumpset
 Buttons for scrolling to select the actual display reading for system
configuration, i.e. up and down scroll concept.
 Necessary devices for programming, supervising and monitoring operation
data/system, status shall be incorporating into the control panel.

2.4 OPERATIONS
 Local control panel shall perform the operation as follows:
i. Auto mode
 The desired delivery pressure within the range specified, shall be set at the duty
local control panel. The pressure transmitter shall detect the delivery pressure
continuously within 1 second and feedback to the microprocessor which will

PAGE - 991
 control the variable speed drive frequency converter for speed control of the
duty pump.
 When demand increases, the subsequent pumps in the system will be activated
to boost up the pressure. Ultimately the duty pump set shall be operated fully
automatically to maintain the delivery pressure constantly at the desired set
value.
ii. Manual Mode
 The on/off function of the pumps shall be manually adjusted at the
microprocessor located at the local control panel.

iii. Frequency Control By-pass Mode

 All the pump sets shall be start/stop automatically with the pump output at
fixed maximum rotational speed. All the control and protection functions shall
remain active. The cut in/cut out pressure shall be internally calculated by the
microprocessor for each pump.

2.5 SYSTEM FEATURES

 The required performance features of each Hydro-pneumatic pumping unit shall be
as follows:
i. System Configuration
 Variable speed pumps with pressure vessels.
 Control panel consisting of the following components:
a. Pump Functional Unit (PFU) - control unit c/w pre-programmed
microprocessor chip. This unit shall control all pumping unit operations
through electronic controller.
b. Pumping Monitoring Unit (PMU) - monitor the operation of the pump
sets. This unit shall allow for monitoring and setting of all control
parameter.
c. Variable Speed Drive
d. Circuit Breakers
e. Fusses
f. Pressure Transmitter

ii. Set Point

 Ten separate pressure “set points” shall be able to be programmed into the
PMU, and switching between set points is timed by a real time clock when a
lower pressure is acceptable during certain periods, for instance after hours or
weekends, the set point shall be lowered to minimise power consumption.
 An external input shall also be used to switch between set points, or manually
adjust a set point at any time.

iii. Friction Loss Compensation

 It shall be possible to allow for the friction loss component of the system,
calculated at full flow and set as a percentage of the set point which will reduce
the working pressure of the pump set depending on the actual no. of pumps in
operation.

PAGE - 992
  A linear approximation of system resistance curve can therefore be allowed for,
and pressure will automatically increase as system flow and subsequent
frictional losses increase. As such power consumption shall reduce which is
required for the pumping system.

iv. Displays
 Through the PMU keypad all variable parameters shall be adjustable, current
status of settings and measured values shall be able to display on the 2-line x
24-character liquid crystal display.
 Individual menus shall be available for monitoring individual pumps, zones,
settings, alarms and ON/OFF functions.

v. Pump Status
 Running hours of each pump
 Actual pump status (running, not available, standby, allocated to zone, fault)
 Maximum head of pump at zero flow.

vi. Zone Status

 This menu shall be the main operating menu where following setting and
operating parameters can be viewed,
a. Current operating set point
b. Measured values in the system
c. Operating capacity in terms of total output
d. Mode of operation for the zone
e. Clock programs (relating to set point pressures)
f. Standby pumps
g. Pump change over time
h. Zone configuration
i. Pressure transducer scaling
j. Friction loss compensation
k. Pump priority
l. Inlet pressure measuring (if required)
m. System response times
n. Allowable number of starts per hour for the pumps
o. Minimum limit (loss of water, burst mains protection)

vii. Setting Menu (Set)

 In this menu all parameters for the operation of the pump set shall be able to be
adjusted as required.
a. Set points (up to 10)
b. On/Off function (used to prevent unnecessary cycling at low demands)
c. Displayed pressure units (Bar, PSI, mBar, kPa)
d. Real time clock programming for any time of the day, week, or weekend
e. Zone configuration
f. Friction loss compensation

viii. Alarm
 The alarm menu shall display all faults that occur during operation, logging the
time and date of when the fault occurred and when it was corrected, or whether

PAGE - 993
 it is still an actual fault, up to 10 faults can be maintained as history in the
controller. The following type of faults shall be diagnosed by the controller.
a. Mains failure
b. Frequency converter fault
c. Analogue input (pressure transducer) fault
d. High discharge pressure fault
e. Low discharge pressure fault
f. Motor thermal overload fault

2.6 Variable Frequency Drive

 Variable frequency drive shall be of a reputable make acceptable to Project Manager
and shall be complete with RFI filter and harmonic dampers.
i. Enclosure
 An IP 54 powder coated steel enclosure shall house all the electrical
components.
 The enclosure can be supplied loose for remote mounting, or mounted on a
common base with the pumps, it shall be adequately ventilated for use in
conditions up to a maximum ambient temperature of 45 degrees Celsius.

ii. Electrical Component

 All circuit breakers, thermal overloads and contactors shall be of reputable
make acceptable to the architect.
 Electrical supply to the pump controller shall be protected using an isolating
circuit breaker.

iii. Method of Starting

 The panel shall be built to start the pumps in suitable starting modes, i.e. D.O.L.,
Star/Delta, or using Soft Starters.

iv. Quality and Testing

 Manufacture of the pumps, plus design and assembly of the complete packaged
Hydro-pneumatic pumping system shall be factory assembled and the pump
station shall be fully tested hydraulically and electrically prior to dispatch to
site. Test reports etc. shall be submitted for review before dispatch.

v. Control of Duty / Standby Pumps

 Operation of the duty and standby pumps shall be carried out by the following
method:
a. Automatically by means of pressure sensor (i.e. pressure switches);
b. Manually by means of a local start/stop push buttons on pump local motor
control panel in case of emergency stop switch.

 The pressure switch shall be installed next to the manual release valve. When
the pressure drops to the pre-determined level, a signal will be sent to the pump
local motor control panel to start the pump.
 Automatic controls shall be operated by electronic, float less type level switches.

PAGE - 994
2.7 PUMP PRESSURE VESSEL
 Diaphragm type pressure vessels shall be provided as per design requirement & shall
be incorporated into the system so that during normal operation the pump shall not
need to be start within 30 seconds of it switching off in order to prevent the pump
hunting.
 The pressure vessel shall be of adequate capacity to accommodate a considerable
fluctuation in water demand by the system with minimum start/ stop cycles of the
pumps. The vessel shall be constructed of steel plate built to ASME Standards for
Unfired Pressure Vessel.
 A rubber diaphragm shall be provided in the vessel for separating the water and pre-
charge nitrogen.
 The pre-charge pressure shall be adjustable and charging port with non-return device
shall be provided.
 The adjustable cut-in and cut-off pressure unit for the pumps shall be built-in at the
vessel to suit the system.

2.8 FLOATLESS TYPE LEVEL SWITCH IN WATER TANKS

 The Contractor shall supply and install float less type switch probes in the water tanks
as indicated below and shown on the drawings.

i. Raw Water Tanks at Substation Building

a. High level alarm (over-flow)
b. Low level alarm
c. Low level cut-out for raw water pumps
d. Earthing probe.

ii. Domestic Water Tank at Substation Building

a. High level alarm (over-flow);
b. Low level alarm;
c. Low water level cut-out for the domestic hydro-pneumatic pumps;
d. Earthing probe.

 Each probe shall be of the correct length for the particular application and tank
location. Electrodes shall be of polished stainless steel 20 mm OD. Electrode holders
shall be weatherproof in all respect.
 The earthing probes shall be connected and wired to the building earth systems of the
building.
 Each set of electrodes shall be installed inside a 230 mm diameter PVC pipe acting as
a wave barrier.
 The level switch set shall operate with a stepped down voltage at 24V maximum.
Stepped down transformers shall be provided for each set of control probes and shall
be installed inside centralized control cubicles inside pump room.
 Mechanical steel stuffing boxes shall be used.

iii. Pump Indicator

 The following audible and visible indication shall be provided at the pump local
control panels as applicable:

PAGE - 995
 a. Red "overflow level" indicator with buzzer for the associated water tanks.
b. Amber "extra high-water level" indicator for the associated water tank.
c. Amber "high water level" indicator.
d. Amber "low water level" indicator.
e. Red "pump trip" indicator for each pump.
f. Green "pump on" indicator for each pump.
g. "Pump electrical supply healthy" indicator for each pump.
h. Amber "remote/local" status indicator.
3.0 SUMP PUMP
 These shall be fully submersible with a fully submersible motor. The pumps shall be
provided with an automatic level controller and all interconnecting power and
control cabling which shall cause the pumps to operate when the water level in the
sump rises to a pre-set level and stop when the pre-set low level is reached.
 The capacity of the submersible pumps shall be designed so as to empty the full
capacity of the sump within 5 minutes of the operation.
 The submersible pumps shall be installed in N+1 configuration with the option of
running both the pumps simultaneously at pre-determined level.
 Pumps for drainage and sewage shall be single stage, single entry.
 MOC of the Drainage Pumps
Body CI
Impeller CI
Shaft CI with CED Coating
Solid Handling 10-12 mm
 MOC of the Sewage Pumps
Body CI
Impeller CI
Shaft CI with CED Coating
Solid Handling 40 - 50 mm

 The vane for sewage pump will be open type, while for drainage pump, etc. it will be
of semi open type.
 Stuffing box shall be provided with mechanical seals.
 Each pump shall be provided with a suitably rated induction motor suitable for 415
volts, 3 phase, 50 Hz A.C. power supply.
 Each pump shall be provided with in built liquid level controller for operating the
pump between predetermined levels.
 The pumping set shall be for stationary application and shall be provided with pump
connector unit. The delivery pipe shall be joined to the pump through a rubber
diaphragm, and bend and guide pipe for easy installation.
 Pump shall be provided with all accessories and devices necessary and required for
the pump to make it a complete working system.
 Sump pump shall be complete with level controllers, power and control switch gear,
Auto/off/Manual switches, pumps priority selections and control and power cabling
upto motor and controller/probes etc. (Including earthing).
 Level control shall be such that one pump starts on required level, 2nd pump cuts in
at high level and alarms is given at extra high level.

PAGE - 996
  All level controllers shall be provided with remote level indications.
 The pump motor shall be a squirrel cage induction, housed in air filled water-tight
enclosure. Oil filled motors are not acceptable. The stator windings shall be Class "F"
insulation (155-degree C or 311-degree F) for general usage and class `H' insulation
(180-degree C or 317-8 grade 2) for submersible type.
 The stator shall be heat shrunk fitted into the enclosure and shall not use bolts, pins
or other fasteners that penetrate through the stator enclosure. The starter shall be
equipped with a thermal switch embedded in series in the coils of the stator windings
to protect the stator from wheel.
 The motors shall be designed for continuous running duty type at 415 volts, 3 phase,
50 Hz power supply and capable of sustaining a minimum of 20 starts/stops per hour.
 Between stator housing and pump, a tandem seal arrangement will be provided with
an oil barrier. Both seals run in oil, allowing dry running without seal damage. Both
seals shall be of the rubber bellows or metallic bellow type with positive drive
between shaft and rotating seal face.

4.0 WATER COOLER WITH PORTABLE WATER PURIFER

 Water cooler of shall be provided along water purifier as per design & architectural
requirements.
 Portable Water Purifier (RO+UV) shall be of water flow rate minimum 9-12 LPH with
storage capacity of min. 10 litres incl. RO membrane, pumps, motors, cartridge filters,
interconnecting pipes, valves, cable etc. complete in all respects as per manufacturer’s
standards & as directed by Engineer-In-Charge.
 The Portable Water Purifier shall have PP meltdown sediment filter, activated carbon
block, thin film composite spiral wound type reverse osmosis membrane, ultra violet
membranes, diaphragm type pump, suitable for maximum 500 ppm hardness, 10
NTU turbidity, TDS of max 2000 ppm inlet water quality& a reduction upto 90% in
TDS & Hardness parameters.
 The purified water flow shall be approximately 9-12 LPH on average.
 The system shall be suitable for a supply of 100-240 V AC / 50 Hz.
 The Purifier shall be supplied complete with all equipment membranes, filters and
pumps, motors, interconnecting pipes, adaptor and cable of minimum 1.8m length.

5.0 HAND DRIER

 The Stainless steel (304) hand drier shall be no touch operating type with solid state
time delay to allow user to keep hand in any position.
 The hand drier shall be fully hygienic, rated for continuous repeat use (CRU).
 The rating of hand drier shall be such that time required to dry a pair of hands up to
wrists is approximately 20 seconds.
 The hand drier shall be of wall mounting type suitable for 230V, single phase, 50 Hz,
AC power supply with 30 sec auto cut off time.
 Motor used for hand dryer shall be brush type, Dual ball bearings with a speed of
25000 RPM.

PAGE - 997
SECTION – 17- SEWERAGE TREATMENT PLANT

1.1 PREAMBLE
1.2 General Requirements
 The Contractor shall design and execute the work of MBBR based STP in compliance
with the technical specifications and requirements contained in the contract, codes of
practices as published by the Bureau of Indian Standard (BIS) or its equivalent
standard as well as Central Public Health and Engineering Organization Manual
(CPHEEO) .
 Wherever, the codes, standards and manual not provide for the design and execution
of some component i.e. required to be designed and executed, the Contractor shall
follow the standard engineering practices or as directed by EIC.
 The contractor shall be fully responsible for the final quality of treated effluent and
getting final approval from the Engineer-in-Charge as per the relevant Government &
Environmental Authorities clearances as applicable.
 The Contractor shall be fully responsible for establishing the availability,
procurement and transport of all materials, machinery, tools & plants and labourers
as required for completing the entire scope of work.
 Setting up of the testing laboratory at STP as per requirement mentioned under
relevant clause.
 Obtaining successful periodic test results from Laboratory / Agency recognized by
the relevant local Pollution Authorities of Ropar or suitable testing agency as
approved by the Engineer-in-Charge.
 STP Capacity to be designed by agency considering the building capacity and future
provision. (Present scope for electromechanical equipment)

1.3 Applicable Codes & Standards: -

1.2.1 Central Public Health and Engineering Organization Manual CPHEEO
1.2.2 National Building Code 2016.
1.2.3 Energy Conservation and Building Code (ECBC).
1.2.4 Indian Electricity Rules and Regulations 1956.
1.2.5 CPWD specification with up-to date amendments
1.2.6 Relevant BIS/IS specification for STP equipment’s with up-to date amendments.

1.4 Scope of work under this contract: -

 The proposed work consists of the complete Design, Supply, Installation, Testing &
Commissioning, handing over, and Operation & Maintenance shall be for a period of
7 years inclusive of 24 months defect liability period the period of 7 years shall be
reckoned from the date of successful commissioning of the whole plant which shall
be inclusive of 24 months defect liability period. The contractor should read the
tender document carefully and understand the scope of work to be executed under
present tender.
 The broad scope of work for STP shall be ap per Design Basis Report of this tender
document.
 The scope is not limited to as described in Design Basis Report document but any

PAGE - 998
 other related work to make STP function as per specification & relevant code
requirements.
 Operation & Maintenance: Operation and Maintenance with supply & consumption of
all consumables, chemicals, etc. for satisfactory performance of STP, including
maintenance of mechanical, electrical, pipes, fittings & other accessories for a period
as specified and handing over to the Engineer-in-Charge in working condition.

2.0 CIVIL DESIGN DATA, SPCAE & ACCESSIBILITY OF SITE

 On the basis of GFC drawings issued by the department with soft copy, the Contractor
shall prepare all their design calculations, detailed drawings for civil works, electro-
mechanical and fabrication layouts, charts etc, for the entire Sewage Treatment Plant
for approval by the Department, before proceeding with the work. The contractor
shall be responsible for the complete design, supply & installation of all
electromechanical components, design of all civil works, complete with
commissioning of sewage treatment plant, start-up and obtaining satisfactory results
from approved testing agencies, as per norms of the relevant Environmental
Authorities.
 The following provisions are presently proposed for the construction of the Sewage
Treatment Plant (s). At the time of detailing, the contractor shall get approved the
exact space and location from Engineer-in-Charge. The STP shall have to be
accommodated at the finally designated area.
 The design shall be as per final architectural approval and final architectural planning
requirements. The contractor shall provide the STP in the designated area.
 Supply of materials and Execution of the Civil Works shall be done by the main Civil
Contractor as designated by the Department.
 The STP contractor shall however be completely responsible for the design of all
components, structural details & supervision of civil works without any extra cost.
 The site for STP(s) is shown in the conceptual drawings enclosed with the tender
documents.
 The internal roads, hardscaping and chain link fencing in the STP areas shall be
provided by the client under different contract. If required, the contractor shall give
unhindered access to the agency providing the internal roads, hardscaping, chain link
fencing or any other work during construction and O/M period of STPs on the
instructions of EIC.

3.0 Influent Characteristics & Design Criteria

3.1 Type of Waste Water:
i) Soil and waste water that comes from the toilets and bathroom faucets, baths, and
showers etc.
ii) Oil, grease and food waste from kitchens & pantries etc.

 It shall be the Contractor*s sole responsibility to ensure the quality of the treated
Sewage to comply with the local Authorities requirement for the various
applications and the following characteristics, whichever is stringent.

3.2 Design Criteria -

a) Daily Flow : 0.9 x water demand
b) Peak factor : 3.0

PAGE - 999
 c) Expected peak flow : 3 times of normal
d) Duration of flow to STP : 24 hours
e) Annual mean Max. : Max. 43 0 C
f) Ph : 7.15 to 8.2
g) Colour : Mild
h) Total suspended solids (mg/l) : 250 to 350
i) BOD (mg/l) : 200 to 250
j) COD (mg/l) : 300 to 400
k) Oil & Grease : 10 - 50 mg/lit.

3.3 Effluent Characteristics

 Sewage Inlet Characteristics: -
a) PH :7.0 - 8.0
b) BOD :350 Mg/L
c) S. Solids :250 Mg/L
d) COD :450 Mg/L
e) Inlet Coliform :10 6 - 10 7 counts / 100 ml

 Desired Treated Effluent Characteristics

a) pH : 7.2 to 7.8
b) Total suspended solids : 30 mg/l
c) BOD : 20 to 30 mg/l
d) COD : 50 to 100
e) Oil & Grease : < 10 mg/l
f) NH4-N : <5
g) N total : <10

 It may clearly be understood that the Client intends to make re-use of treated
effluent. The filtered water after above treatment shall be used for flushing in water
closets/ urinals and irrigation purposes.

4.0 MBBR BASED STP TREATMENT PROCESS

 MBBR based STP shall be implanted in this project.
 The treatment process is aimed to convert the influent quality as mentioned above,
into the required quality standards so that the treated effluent can be re-used as
specified above.
 It is proposed to perform the treatment of the effluent by the biological aerobic
process. The process is designed to induce the growth of bacteria, which by physical
and physio-chemical action retain the organic pollution and live on it.
 This growth is obtained by putting a bacterial culture disposal as a flock in the
aeration tank.

5.0 PROCESS DESCRIPTION

 Incoming Wastewater from Last Manhole should be collected through gravity pipes
into the screen chamber. This manually cleaned screen should be provided to remove
floating and big size particles.
 Manual cleaned bar screens will be installed to screen any large pieces. After
screening, the waste water should be allowed to pass through an oil & grease trap to

PAGE - 1000
 remove the grit material. The screens and grit chambers shall be accessible so that
they may be manually cleaned from time to time.
 The waste water from the OGT should then pass into the Equalization Tank.
 The design of Equalization tank should cater for the condition that the waste water
generation may not be uniform and higher quantity may come out during peak hours.
There may be very low flow condition for few hours. To optimize the size of the plant,
the plant design should cater for continuous operation and hence a buffer should be
provided to store the waste water during its peak hour generation and supply the
same during lean or no flow hours.
 The equalization tank is provided to homogenize the waste water quality and also
even out flow fluctuations and feed waste water of uniform quality at constant rate to
subsequent treatment units.
 Air mixing should be provided to mix the contents of the equalization tank. An
aeration grid should be provided to mix the contents of the equalization tank and also
to avoid septic conditions in the tank.
 From the equalization tank the wastewater will be pumped into anoxic tank for
removal of nitrogen & phosphorous through denitrification process in the absence of
oxygen.
 Bypass line shall be provided from the pumping system which shall only be
provisional for disposal of sewage to mobile sewage tanker for emergency purposes.
From the anoxic tank the wastewater will be overflowed into MBBR Tank.
 The MBBR process uses small plastic carrier elements to provide growth sites for
bacteria attachment in a suspended growth medium. The carrier elements shall allow
higher biomass concentration to be maintained in the reactor. This shall increase the
biological treatment capacity for the given reactor volume.
 The carrier elements shall be continuously kept in suspension by the aeration system.
The agitation pattern in the reactor shall be designed to provide an upward
movement of the carriers across the surface of the retention screen which creates a
scrubbing effect to prevent clogging. Combination of fine & coarse bubbles may be
provided to provide oxygen as per detailing.
 From the MBBR tank mixed liquor shall flow by gravity into the secondary settling
tank. The solids will settle in the tank. The sludge that settles down shall be
transferred to sludge holding tank via sludge loading pumps, with provision of sludge
return to the bioreactor if necessary.
 From the settling tank, treated wastewater will flow into clarified water tank.
 Treated water after CWT(clarified water tank) shall be clear, odourless, low BOD, low
suspended solids, which shall be of quality which is acceptable as per standards
prescribed by CPCB/Environmental norms for disposal directly into public/natural
drain.
 The treated water from Clarified water tank is fed by means of filter feed pump sets
to pass through dual media filters, activated carbon filters and stored in the treated
water tanks.
 The activated carbon filters shall ensure removal of all coloration and odours present
in the treated effluent. Backwash of Filters and shall be done intermittently as per
requirements. The filtered water being stored in the filtered water tank shall again be
dosed with chlorine by a suitable chlorinator/Dosing system and a residual Chlorine
level of 1 PPM shall be maintained.
 The filtered, clean and odourless water from treated water tank is then fed through a
variable frequency drive hydro-pneumatic system to the external treated effluent

PAGE - 1001
 rings as per the masterplan, for flushing & irrigation system as per
detailing/architectural design.
 According to the guide lines of Ministry of Environment and Forest the UV system will
be provided on the discharge point of treated effluent supply lines to ensure 100%
pathogen free treated water for recycling and re-use. The UV system shall be provided
as online installation on the treated water supply line being supplied to the external
distribution ring.
 Excess sludge from the settling tank will be taken periodically into sludge holding
tank. In this tank sludge will be aerated for self-stabilization.
 Air will be shut off periodically and superannuate water will be transferred to the
aeration tank creating stabilized sludge.
 The final sludge shall be de-watered through a centrifuge mechanism. Sludge loading
arrangements shall also be provided for direct disposal of sludge to sludge tankers /
trolleys.

PAGE - 1002
  Process flow diagram.

Raw Sewage Screen Oil & Grease Equalization

Chamber Trap Tank

Raw Sewage Pumps

MBBR Tank 1 Air Blowers

MBBR Tank 2

Chlorine
Tube Settler
Doser

Chlorine Contact
Tank Filter Press
Feed Screw Pump

Multi Grade
Filter
Filter Press

Activated Carbon
Filter

Sump
Irrigation/Flushi
ng(Treatted)
Water Tank

Irrigation/Flush Sump Pumps

ing (Treated)
Water Transfer
Sludge Cake for
Disposal

For Flushing

6.0 MAIN ELECTRO-MECHANICAL COMPONENTS OF THE PLANT

 The scope of work shall consist of design, supply, erection, testing, commissioning
and satisfactory handing over of all Electro-mechanical equipment’s and works for
the satisfactory performance of the plant as per attached specification & relevant
codes, generally comprising of but not limited to:-
a) Bar Screen (coarse & Fine) with frame.
b) Air Blowers with motor and related accessories
c) Air diffusers.

PAGE - 1003
 d) Bio media for MBBR & secondary settling tank.
e) Submersible type Raw Sewage Relift pumps
f) Sludge Return / Relift pumps
g) Filter feed pump
h) Sludge Loading pump
i) Treated effluent pump such as for Flushing water, Garden hydrants water
j) Dual Media filter, Activated Carbon Filter.
k) PH dosing system.
l) Ozonator.
m) Centrifuge / Sludge handling Mechanism.
n) Submersible type Drainage sump pumps with SS 304 guide rail and SS 304 chain
for STP plant room area.
o) UV for supply for treated water line.
p) All pipelines with necessary accessories and valves.
q) Motor control center complete with all internal wiring and accessories, Electrical
cables from M.C.C panel to all electric motors and units, level indicators/switches
for low- and high-level alarm for all tanks, sumps as well as for dry run protection
of pumps.
r) Instrumentation Equipment’s and Laboratory apparatus.
s) Agitator for Anoxic tank.

 The contractor shall own responsibility for the specified characteristics of the final
effluent and shall make appropriate addition/alterations to the equipment or plant, if
the same fails to meet the required standards, without any extra cost. These
additions/alterations shall be made after obtaining approval of EIC.
 Construction of all elements of the plant unless otherwise specified including, internal
& external lighting, and finishing work as per requirement, within the battery limits
as per the site plan / master plan.
 Interconnecting piping between all units, valves, gates and all other appurtenances
and devices as required.
 All mechanical / fabricated equipment shall be duly protected against corros

7.0 TECHNICAL REQUIREMENT OF SEWERAGE TREATMENT

7.1 SUMP PUMPS (RAW SEWAGE RELIFT PUMP FOR EQUALIZATION TANK, DRAINAGE
SUMP FOR PLANT ROOM)
 Sump pump set shall be dry motor submersible type with SS304 Guide Rail, &
SS304 Chain with level float switches & suitable for auto / manual operation with
class “F” insulation of suitable capacity & RPM operating on 415volt ± 10%, 3
phase, 50Hz AC supply, with non-clog free flow open CI impellers, CI casing (Pump
& Motor) and having solid handling capacity of required size for lifting domestic
sewage or muddy water/drainage.
 Pump shall inclusive of all necessary accessories like valves, piping, Control Panel
and Cabling, Level Controllers, Test and/or air vent etc. as required. The Contractor
has to ensure for smooth and trouble-free operation after the commissioning of the
entire system.
 The pump having dry run protection & high-level alarm with audio and visual
function / indication shall automatically operate with high water level and stop at low

PAGE - 1004
 water level in the sump by means of “Electronic Level Controller”, with necessary
control cabling up to control panel.
 The pump shall have the facility to cycle through the total number of pumps provided
and in case of High Level shall be capable of cumulative operation.
 The sump pumps shall be complete in all respect and shall be installed as per
manufacturer*s recommendations. All accessories shall be In-Built as per
manufacturer*s specification.
 Contractor shall provide Electrical control panel having all necessary accessories,
safety devices, Indication Lamp, Ammeter & voltmeter and shall be suitable for
receiving incomer armoured cable to connect complete. Control panel shall be
function as follows:

i) All the working and standby pumps shall start/stop automatically and alternatively.
ii) Each pump shall start/stop automatically at pre-set levels and work alternatively
in cyclic operation.
iii) In case of pump getting overloaded, indication shall come on the panel and hooter
will give sound non-operation of pump.
iv) In case of emergency due to high volume flow of incoming sewer all pumps shall
start operating simultaneously.

 The entire system along with pumps & control panel must be sourced from single
manufacturer only for unit responsibility.

8.0 AIR BLOWERS

 The treatment plant shall be provided with rotary positive displacement roots type
blowers with a common base TEFC electric motors with necessary valves &
accessories
 Air blower shall have a pressure release valve and suitable filter and silencing
mechanism.
 All piping and related accessories necessary to connect the blowers to the plant air
header shall be provided.
 Flexible reinforced rubber connecting/coupling sleeves shall be provided wherever
required.
 Standby arrangements shall be provided for blowers to enable cyclic operations.
 The Air blower shall have min. requirements as mentioned below:

Casing CI
Fluid Handled AIR
Installation INDOOR
Sealing LIP SEAL
Recommended Suitable H.P. Motor WITH 1500 RPM of efficiency class IE-3,
Operated on 415 Volts ±10%, 3 phase, 50 Hz A.C. supply.
Motor
Drive DIRECT
Shafts EN18/19 (BS970:1955)/SG Iron

PAGE - 1005
9.0 AIR DIFFUSERS
 The air diffusion devices shall be designed to distribute air to cover the entire length
of the tanks and to have efficiency such that an adequate supply of oxygen is
maintained in the tanks to treat the effluent load for which the plant is designed.
 The aeration grid is provided in the tanks to mix the content of sewer to avoid any
septic condition in the tank.
 Diffuser shall be non-clog type diffuser.
 Supply pipes shall be of sufficient size to keep pressure loss through the drop-pipe
assembly to a minimum.

10.0 SLUDGE RETURN / RE-LIFT PUMPS

 Sludge return pumps shall be horizontal non-clog centrifugal pumps for the required
discharge and head and of required specifications.
 Pump shall be directly connected to an electric motor by means of a flexible coupling
and mounted on a common G.I. base plate.
 Each sludge return pump shall have a capacity suitable for re-circulating 100% sludge
 Standby pump shall be provided for cyclic operation.
 Sludge return pumps shall have CI Impeller, Cast Steel Shaft, CI delivery casing,
bronze sleeve & Mechanical Seal fitted coupled with suitable motor of efficiency class
IE-3 with required HP & RPM operated on 415 Volts ±10%, 3 phase, 50 Hz A.C. supply.

11.0 SLUDGE LOADING / DISPOSAL PUMPS

 Sludge loading/ disposal pumps shall be horizontal non-clog screw type pumps for
the required discharge and head and of required specifications.
 The pump shall have following operating parameters:
Pump Type Screw Pump
Pumping Fluid Sludge
Suction Head Flooded
Motor Suitable Motor of required HP & RPM of
efficiency class IE3, operated on 415 Volts
±10%,3 Phase, 50 Hz A.C. supply.
Flow Suction on Gland
Suction & delivery position Top/End
Type of drive O/H Drive, V-Belt Driven
Mounting M.S. Fabricated Common Base Plate

12.0 CLEAR WATER PUMP

 Water supply pumps shall be multistage, Inline vertical, centrifugal pumps with SS
casing, stainless steel impeller, stainless steel shaft, CI base with CED coating and
directly coupled with TEFC induction motor of class "F" insulation & efficiency class
IE-3, 2900 RPM, IP 55 enclosure, suitable for operation on 415 volts ±10%, 3 phase,
50 Hz, A.C. supply. Each pump should operate at maximum efficiency duty point at
specified head. Bidders shall select their drives within 10% to 15% in excess of the
maximum B.H.P of the pump plus transmission losses, if any & shall be suitable for
clean water.
 Pump and motor shall be mounted on a common G.I. structural base frame.

PAGE - 1006
  Each pumping set shall be provided with a 150mm dia or of suitable size gunmetal
“Bourden” type pressure gauge with gunmetal isolation cock and connecting piping.
 Pump shall be equipped with Anti vibration mounting pads, Lubrication fittings and
seal piping, Test and/or air vent cocks,25mm GI gland drain appropriate for each
pump.
 Vibration eliminators/expansion joints on suction and Discharge side of the Pump
and wherever required shall be provided.
 All water supply pumps shall be provided with mechanical seals (cartridge type), of
required specifications.
13.0 CENTRIFUGE (SLUDGE HOLDING MECHANISM)
 The Centrifuge shall comprise of a rotating bowl, consisting of a feed pipe, a
cylindrical section where the separation of the suspension takes place and a conical
section where the scroll removes the dewatered sludge.
 The Centrifuge shall be high efficiency type system for de-watering of sludge. The
separation of the solid-liquid sludge suspension shall be accomplished using high
bowl speeds and low scroll differential speeds at high scroll torques.
 Provision shall be made for the feed suspension to enter the rotating feed
compartment through the feed pipe. There it shall accelerate in the direction of
rotation and enter the rotating bowl via feed ports. The settled solids shall be moved
by the scroll to and through the conical section, at the end of which shall be discharged
through the discharge ports of the bowl as dewatered solids.
 The liquid effluent shall be discharged from the bowl over adjustable weir plates at
the feed end.
 The rotating bowl shall be supported by the main bearings, mounted in pillow blocks,
pinned to the base frame. The base frame shall be mounted on hollow rubber buffers.
Lubrication of the main bearings and the scroll bearing shall be done by grease
lubrication.
 The dried sludge from centrifuge shall be made available as a fertilizer for utilizing
for horticultural purposes within the site and excess, if any, to be carted away from
the site premises by Contractor at his own cost until Operation & Maintenance period
end. Output Filtrate from centrifuge may be disposed back into the equalization tank.
 The centrifuge completes with VFD Control panel in all respects.

14.0 MATERIAL
Parts in contact with process – product Stainless Steel
Bowl material Stainless Steel
Screw conveyor material Stainless Steel
Housing material Stainless Steel, Epoxy Painted
Parts not in contact with process-product Carbon Steel / Cast Steel
Solid and Liquid Chutes MS (Epoxy Painted) / FRP
Construction
Speed of Motor 3000 rpm
(3 phase)

PAGE - 1007
15.0 UV SPECIFICATIONS
Flow As per design
UV Dose 60,000 uW•sec/cm2
UV Transmission 65 %
Basic 220-240V / 50-60Hz
Maximum Power Consumption 1956W
Number of Lamps 5
Electrical Rating IP54
MOC of lamp housing M.S. (optionally SS304)
Max. Lamp Cable Length 4.5 m
Control Panel MOC Stainless Steel 316L
End Connections (ASA 150 RF 3"
Max. Operating Pressure 120
Max. Operating Temperature 45 degrees
Max. Sanitization Temperature 125 degrees C (lamps turned off)

Quartz Jacket MOC High Purity Quartz (UVT > 95%)

Output Signal 4-20 mA
Interface RS485 / MODBUS

16.0 SPECIFICATION OF BIO- MEDIA FOR MBBR AND SECONDARY SETTLING TANK
 The Bio-Media shall be in PVC/PP/ suitable plastic media, having shape and design
such that there is uniform and continuous distribution of air and water throughout
with self-supporting shape.
 The surface area shall be for effective attached growth of bacteria & shall increases
the contact time of waste water within media, providing high efficiency with
minimum recirculation.
 The media shall have low resistance to air flow to provide better aeration & shall have
excellent wetting so that there should be zero fly nuisance.
 Specifications for MBBR tank Media:
Length 19.80 mm
Average diametre 24.525 mm
Shape Conical frustum
Type Semi clog
PSA/TSA ratio 0.7
Void ratio 78.43
Material PP
Surface area by 61760 pieces 400 m2 (0.00648 m2 per piece)
Media fill range, % fill of V 15-67
Specific gravity 0.92 to 0.945
Membrane forming time 7-15 days

 Specifications for Secondary settling tank Media/ Tube settler media:

Distance b/w adjacent tubes Horizontal 120mm, vertical 44 mm
MOC of media PVC
Shape of tube Hexagonal chevron
Tube fitting Tongue and groove

PAGE - 1008
 Thickness 1.1 mm
Maximum continuous working 55 deg celcius
temperat
Colour re Black
Plan settling area 11 m2/m3 at 60 degree slope and 13
m2/m3
Height of media 750 mm

17.0 PIPING
 G.I. Pipes confirming to I.S:1239 upto 150mm nominal bore and as per I.S:3589 for
200mm nominal bore and above to be used in the STP. Galvanizing shall conform to
IS 4736 and IS 2629.
 Pipes and fittings shall be jointed with screwed/flanged joints, flanges shall be either
screwed or welded complete and jointed with 3mm thick rubber gasket as per
requirements complete with nuts, bolts and washers etc. All Fittings shall be new and
from approved manufacturers, Fittings shall be of malleable iron galvanized of
pressure ratings suitable for the piping system. Fitting for G.I. pipes shall include
couplings, bends, tees, reducers, nipples, unions, bushes etc.
 U-PVC (un-plasticized Polyvinyl chloride) pipes being used for the air distribution
lines, confirming to IS: 4985.
 All metal pipes should have high corrosion resistance and should be immune to
chemical, electrolytic and galvanic action. These pipes should be long lasting as it
would be corrosion prone.
 Pipes should be kept on an even surface while storing. They should be properly
supported and should not be stacked for heights more than 1.5 meters for longer
duration.
 For the connection of PVC pipe to metal pipes, a piece of special thick wall PVC
connecting tube threaded at one end shall be used. The other end shall be connected
to the normal PVC pipe by means of glued spigot and socket joint.
 All piping shall be tested to hydrostatic test pressure of minimum 10 kg/cm² or 1.5
times the design pressure whichever is higher for a period of not less than 24 hours.
All leaks and defects in joints revealed during the testing shall be rectified to the
satisfaction of the Engineer-in-charge.
 The direction of flow of all fluids in the pipes shall be visibly marked in white arrows
or as directed by the Engineer-in-charge.

18.0 VALVES
i) Sluice / Gate Valves
 Sluice Valves above 50 mm (inside screw and non-raising screw type) shall be of Cast
Iron body and Gunmetal seat with double flanged ends and valve wheel. They shall
conform to type PN 1.6 of IS:14846.
 Sluice valves upto 50mm (outside screw raising spindle type) shall be of Gunmetal
Full way Valve with wheel tested to 20 Kg./cm2 class-II as per I.S: 778 with female
screwed ends.

PAGE - 1009
  Valve wheels shall be of right hand type and have an arrow head engraved or cast
thereon showing the direction for turning open and close. Wherever necessary,
suitable chamber of required depth shall be provided, and in case of deep location of
sluice valve, necessary key/level/extension rod shall be provided for operation.

ii) Butterfly Valves

 The Butterfly Valve shall be suitable for wastewater / waterworks & conforming to
IS: 13095.
 All valves shall be suitable to withstand the pressure in the system and rating shall
be PN 1.6.
 All valves shall be right handed (i.e. handle or key shall be rotated clock wise to close
the valve).The direction of opening and closing shall be marked and an open / shut
indicator fitted.
 The material of valves shall be as under:
a) Body - Cast iron
b) Style of disk - Wafer end type
c) Disc - Ductile Iron
d) Seat - EPDM / nitrile rubber
e) Shaft - Stainless Steel
 The Valve shall be fitted between two flanges on either side of pipe flanges. The
Valve edge rubber shall be projected outside such that they are wedged within the
pipe flanges to prevent leakages.

iii) Non-Return Valve

 Non-return valves shall be of Cast Iron body ball type and Stainless Steel seat for
Sewage water handling up to clarified water tank & shall conform to IS 3512 and have
companion flanges.
 Valve shall be Stainless steel Dual Plate Type for Clear water suitable for both
horizontal and vertical installation. An arrow mark in the direction of flow shall be
marked on the body of the valve.

iv) Ball Valve

 The Ball Valve of size below 50 mm dia shall be made from forged brass and tested to
16Kg/ cm² pressure. The valve shall be internally threaded to receive pipe
connections.
 The Ball shall be made from brass and machined to perfect round shape and
subsequently chrome plated. The seat of the valve body bonnet gasket and gland
packing shall be of Teflon.
 The handle shall be of chrome plated steel with PVC jacket. The handle shall also
indicate the direction of *open* and *closed* situations. The gap between the ball and
the Teflon packing shall be sealed to prevent water seeping upto 14 Kg / cm²

PAGE - 1010
 pressure.
 The handle shall also be provided with a lug to keep the movement of the ball valve
within 90 degree.

v) Strainer
 Strainers shall be of the approved type with SS body with SS304 Strainer Basket
designed to the test pressure of 16 Kg/ cm².
 Strainers shall be fabricated with minimum 1.2mm thick stainless-steel sheet with 3
mm dia. perforation holes.
 Strainers shall be provided with flanges or threaded sockets as required & shall be
designed so as to enable blowing out accumulated dirt and facilitate removal and
replacement of screen without disconnection of the main pipe.

vi) Pressure Gauges

 15.6.1 Pressure gauges shall be of 150mm dia. dial and of pressure range from 0 to
15 Kgs / Sq. cm. and be complete with shut off gauge valve etc., duly calibrated before
installation.
 Diaphragm seal type Pressure Gauges shall be provided with proper isolation valves.
 Flow meters shall also be provided with isolation valves and by-pass arrangement to
enable of maintenance of the flow meter as and when required Care shall be taken to
protect pressure gauges during pressure testing.

vii) Flexible Connection for Pumps

 All suction and delivery lines shall be provided with double flanged reinforced
neoprene flexible pipe connectors. Connectors should be suitable for a working
pressure 0 to 10 Kgs/ Sq. cm. of each pump. Length of the connector shall be as per
manufacturer*s details.

19.0 ELECTRICAL AND INSTRUMENTATION WORKS

 The components of ELECTRICAL AND INSTRUMENTATION works of the Sewage
treatment Plant are as follows.
a) MCC and PLC Panel
b) Electrification of the MCC Room and Area lighting
c) Instruments
d) Earthing
e) Fresh Air and Exhaust System of the STP area.

 Cabling from main point to termination point shall be drawn through flexible steel
conduit with lead coating on steel surface to corrosion resistant as per IS 3480 & BS
731, air tight, water proof, heat resistant, high mechanical strength suitable for
protection and laying of electric and signal cables (PLICA or equivalent make)

PAGE - 1011
20.0 INSTALLATION
 STP shall be installed as per manufacturer*s recommendations.
 Pump sets shall be mounted on machinery isolation cork or any other equivalent
vibration isolation fitting. The vibration isolation pads, foundation bolts etc. shall be
supplied by the Contractor.
 Contractor shall ensure that the foundation bolts are correctly embedded and
providing1:2:4 cement concrete foundation.
 Pump-sets shall preferably be factory aligned, wherever necessary, site alignment
shall be done by competent persons.

21.0 TESTING
 The contractor shall submit the performance curves of the pumps supplied by them.
They shall also check the capacity and total head requirements of each pump to match
his own piping and equipment layout.
 On completion of the entire installation, pumps shall be tested, wherever possible, for
their discharge, head, flow rate, B.H.P. Where it is not possible at least the discharge,
head and B.H.P. (as measured on the input side) shall be field tested. Test results shall
correspond to the performance curves.

22.0 PAINTING
 After the piping has been installed, tested and run for at least ten days. The piping
shall be given two finish coats of approved color. The direction of flow of fluid in the
pipes shall be visibly marked in white arrows or as directed by the Engineer in charge.

23.0 INSTRUMENTATION & LABORATORY EQUIPMENT

 Work under this section shall consist of providing detailed design, materials, labour
and equipment for all Instrumentation and testing apparatus for laboratory.
 Contractor shall provide, install and commission instrumentation system /
equipments for the proper and efficient functioning of the Sewage Treatment Plant.
 Contractor shall be fully responsible for design, sizing and selection of the proper
instruments for the system.
 All equipments supplied shall be approved both with respect to design and materials.
No prototype instrument or instrument of an experimental nature shall be offered or
supplied.
 No instrument requiring special maintenance or operating facilities shall be offered or
supplied as far as possible.
 Contractor shall prepare and submit a P & I (Process & Instrumentation) Diagram for
the system within the scope of his supply, showing all the instruments and
interlock/trip operations. Each instrument shall be given individual tag numbers from
blocks of numbers allotted by the purchaser.
 All instrument design shall be intrinsically safe wherever applicable.
 All instruments and equipment shall be suitable for use in a hot, humid and tropical
industrial climate (in which corrosive gases and/or chemicals may be present).

PAGE - 1012
  All the panel-mounted instruments i.e. indicators, recorders, controllers etc shall be
provided as per approved technical data sheets to be submitted by the Contractor.
 All the controllers shall be single loop dedicated controllers. All the recorders shall be
3- pin type.
 The contractor shall submit to the Engineer-in-Charge the Technical Specifications for
all instruments supplied giving manufacturers name, model number etc. Instrument
specification must include process data, minimum/normal/maximum values or
variable and all information required to define instrument specification and
application.
 Electronic instruments shall generally operate on 220v, 50 Hz and shall have
transmission and output signal generally of 4 to 20 mA DC. Transmitters shall be two
wire and shall be capable of delivering rated current into external load of at least 600
ohms when powered with 24v DC.
 All receivers shall be suitable for voltage input of 1 to 5 V or 0.25 to 1.25 V DC.
 All electronic instruments shall be immune to Radio interference.

24.0 TESTING & MONITORING SYSTEM

 The scope of work includes establishing fully equipped in-house Testing Laboratory
at the STP so as to perform regular testing and monitoring of the quality of the
incoming raw effluent, as well as the treated effluent from the various main
components/stages of the sewage treatment plants. The monitoring system shall
ensure that a strict vigilance may be kept on the functioning of the plant and to
enable smooth operation & maintenance of the plant.
 Parameters to be Monitored
i) Physical:
a) pH
b) Colour & Odour
c) Turbidity
d) Total Suspended Solids

ii) Chemical:
a) Chemical Oxygen Demand
b) Oil & Grease
c) MLSS
d) MLVSS
e) F/M Ratio

iii) Biological:
a) Biochemical Oxygen Demand
iv) Microbiological:
a) Coliform
b) E. Coli
c) Total Plate Count
d) Faecal Coliforms

PAGE - 1013
25.0 EQUIPMENT GUARANTEE / DEFECTS LIABILITY PERIOD
 All equipment supplied and installed by the contractor under this tender (whether
manufactured by him or not) shall be guaranteed for a defect liability period (DLP) of
02 year from the date of successful commissioning of the respective Sewage
Treatment Plants, and the DLP shall be applicable for all components of the plant
against defective materials, workmanship and installation.
 The DLP shall include warrantee to cover replacement of all defective parts with new
ones. Replaced parts shall also be covered by a similar warrantee.
 The replaced parts shall be of approved make as per approval by the Engineer-In-
charge.

PAGE - 1014
SECTION-18 SOLAR POWER SYSTEM

1.0 Design Objective

 The Solar Plant shall be installed in order to achieve GRIHA compliance rating.
 The Solar plant shall be On-line(On-grid)with net metering facility or off Grid as per
site requirements.
 The Solar power is harnessed by connecting the solar photovoltaic panels through a
Grid tie inverter and feeding the solar energy to the internal electrical circuitry at the
building / premises.

1.1 SYSTEM COMPONENTS AND DESIGN CONDITION

1.2 Basic Components of a Solar PV System

 Solar panels - The solar panels (photovoltaic or PV modules) convert sunlight to
electricity. A number of modules are connected together to increase the electrical
power output. The entire bank of modules may be referred to as the solar array.
 DC Isolator - The DC isolator provides a safe means of disconnecting the solar array
from the inverter, for example for periodic maintenance. Some inverters have
integrated DC isolators.
 Inverter - The inverter converts the Direct Current (DC) electricity produced by the
solar panels to the Alternating Current (AC) form that is required for connecting to
the Grid and for the operation of household electrical appliances.
 Also, the inverter provides a fail-safe link between the solar generator and the mains
electricity network. If there were a problem with the PV system or (more usually) a
fault on the electricity network, the inverter would make the system safe.
 As the electrical output of Solar PV generators is nonlinear due its dependency on
solar irradiation and temperature, inverters are equipped with a controller to get the
maximum possible power from the solar PV array.
 Generation meter - The generation meter accurately counts the number of units of
electricity generated by the PV system.
 AC isolator - A main isolator is included to provide a means of disconnecting the solar
PV system from the building electricity supply. This may be important if there is an
emergency, but (more usually) is needed when maintenance has to be done on the
building supply.
 Existing supply meter - When you need more electricity than your solar PV system
is generating (for example during the night), you will draw power from the mains
supply. Any electricity that you draw from the grid will be registered on your supply
meter as normal. If our installer has installed an import / export meter (Net Metering)
then this will also register the amount of excess production that is fed back into the
grid.
 The Grid - The mains electricity network which supplies power to you may now also
supply excess solar PV production to other consumers.
 Use of electricity - At times you will be using solar PV electricity, at other times you
will be drawing from the mains supply as normal. You will not notice any difference.

PAGE - 1015
  Battery – Optional, connected to the charge conditioning unit.
 General Layout for Solar power plant

1.3 DESGIN CONDITION

Bidders will seek from relevant database / source, all the data pertaining to the ambient
conditions like temperature, humidity, wind load, rain, weather condition and
historical solar radiation etc., pertaining to the site location Indore and optimize the
design accordingly. All design calculations and installation details shall be submitted
after the award of work.

2.0 LOCATION OF THE SOLAR EQUIPMENT

The solar PV modules shall be installed as per design requirement and architectural
layout.
3.0 EQUIPMENT SPECIFICATION

3.1 Solar PV Module (Electrical Features)

 Solar PV module array will be made by utilizing mono/poly Crystalline high
efficiency Silicon Solar PV cells. Minimum power output guarantee offered for the SPV
Module shall not be less than 25 years. Individual solar module rating will not be less
than 300 Wp at Standard test conditions. Each Solar PV module offered shall meet
following min. requirement.
 Efficiency of cell, Ef,c - >21%
 Efficiency of module, Ef,m - >19%

 I-V curve of each PV module with Sl. Nos. should be submitted along with modules.
 Solar PV modules shall conform to IEC-61215 standards. Documentary evidence

PAGE - 1016
 towards IEC- 61215 certification shall be submitted for approval before
procurement:-
 Maximum Power, Pmax
 Minimum Power, Pmin
 Open Circuit Voltage, Voc
 Short Circuit Current, Isc
 Voltage at Max Power Vmp
 Current at Max power lmp
 Fill Factor, FF
 Efficiency of cell, Ef,c
 Efficiency of module, Ef,m
3.2 Solar PV Module (Mechanical Features)
 Solar PV Module design will conform to following Mechanical requirement:-
 Toughened, anti-reflective, low iron content, high transmissivity front glass.
 Anodized Aluminium Frame
 Ethyl Vinyl Acetate (EVA) encapsulant
 Silicon edge sealant around laminate
 Tedlar / Polyester trilaminate back surface
 ABS plastic terminal box for the module output termination with gasket to
prevent water moisture.
 Resistant to water, abrasion, hail impact, humidity & other environment factor
for the worst situation at site.
 Bypass diode.

3.3 Module mounting structure

 The array structure shall be made of hot dip galvanized MS angles of size not less than
50mm x 50mm x 6mm size. The minimum thickness of galvanized shall be at least
70microns. All nuts & bolts shall be made of good quality steel.
 The work should be completed with supply, fitting fixing of clamps, saddles, nut &
bolts etc. While quoting the rate, the bidder may mention the design & type of
structure offered. All nuts & bolts shall be made of very good quality steel.
 The structure shall be designed to allow easy replacement of any module and shall be
in line with site requirements.
 The structure shall be designed for simple mechanical and electrical installation. It
shall support SPV modules at a given orientation, absorb and transfer the mechanical
loads to the ground properly. There shall be no requirement of welding or complex
machinery at site.
 The array structure shall be so designed that it will occupy minimum space without
sacrificing the output from SPV panels & shall withstand heavy winds.
 The supplier / manufacturer shall specify installation details of the PV modules and
the support structures with appropriate diagrams and drawings.

3.4 Junction Boxes

 The junction boxes shall be dust, vermin and waterproof and made of FRP/ Thermo

PAGE - 1017
 Plastic. The terminals shall be connected to copper bus bar arrangement of proper
size.
 The junction boxes shall have suitable cable entry points fitted with cable glands of
appropriate sizes for both incoming and outgoing cables.
 Suitable marking shall be provided on the bus bar for easy identification and cable
ferrules shall be fitted at the cable termination points for identification.
 The junction boxes shall have suitable arrangement for the following:-
 Combine groups of modules into independent charging sub-arrays that shall be
wired to the controller.
 Provide arrangement for disconnection for each of the groups.
 Provide a test point for each sub-group for quick fault location.
 To provide group array isolation.
 The rating of the JB*s shall be suitable with adequate safety factor to inter
connect the Solar PV array.
 Metal oxide varistors shall be provided inside the Array Junction Boxes.

3.5 Power Conditioning Unit (PCU):

 The PCU is a combination of Solar Charger (MPPT), Inverter, AC Charger and data
logger all housed in a single unit.
 Maximum power point tracker (MPPT) shall be integrated into the PCU to maximize
energy drawn from the solar PV array.
 MPPT shall be microprocessor/micro controller based to minimize power losses and
maximize energy utilization.
 The efficiency of MPPT shall not be less than 94%. PCU shall include self-protective
and self-diagnostic features to protect itself and the PV array from damage in the
event of PCU component failure.
 Power conditioning unit will comply the following requirements.
 415V AC + 5% 50Hz, 3 Phase
 Overload capacity – 150% for 60sec.
 Output wave shape: sine wave with <3% total harmonic distortion (THD).

 Provide all safeguard needed for power transfer to GRID . The situation case of supply
GRID failure shall also be taken into account. If required necessary modifications shall
be made in Transformer Marshalling Box also.

3.6 MODES OF PCU

3.6.1 STANDBY MODE:
The control system shall continuously monitor the output of the solar power plant until
pre-set value is exceeded and that value to be indicated.
3.6.2 BASIC SYSTEM OPERATION (FULL AUTO MODE):
The system shall automatically *wake up* in the morning and begin to export power
provided there is sufficient solar energy and the grid voltage and frequency is in range.

PAGE - 1018
3.6.3 SYSTEM OPERATION WHEN GRID supply not available: it shall switch off outgoing
breaker to transformer and switch on outgoing breaker to LT main LT panel, of
main solar collector AC panel in Substation, in case of HT grid failure. So that solar
power is used in house along with dg sets supply in case of supply company power
failure.in such case synchronisation shall also be done accordingly.

3.6.4 MAXIMUM POWER POINT TRACKER (MPPT):

MPPT control algorithm shall adjust the voltage of the SPV array to optimise solar
energy fed into the grid.
3.6.5 SLEEP MODE:
Automatic *sleep* mode shall be provided so that unnecessary losses are minimized
at night. The power conditioner must also automatically re-enter standby mode when
threshold of standby mode reached.
3.6.6 INVERTER
 The inverter output shall always follow the take reference of grid in terms of voltage
and frequency. This shall be achieved by sensing the grid voltage phase and feeding
this information to the feedback loop of the inverter. Thus control variable then
controls the output voltage and frequency of the inverter, so that inverter is always
synchronized with the grid.
Efficiency > 98.3%

Output frequency 50Hz inverter to follow grid frequency upto +/-2 Hz

of the nominal output frequency during normal
Output voltage 433 ±20% to be synchronizing automatically for
stepping upto 33/11 KV and then fed to supply
company grid

THD (at point of connection) Less than 3 % (of rated power)

Ambient temperature -20 to 50 deg C without any derating in nominal

inverter Rating and 60 deg C with derating
Humidity 100 % non- condensing

Input DC Range 360 to 800 volt

Reactive Power Capability 0.8 (leading) and 0.8 (legging)

Maximum Permissible 1000 V

Voltage
Enclosure IP 65 (Outdoor rated)

 The Inverter shall have following features:

 Auxiliary power consumption shall be < 0.5% of rated power and maximum loss
in sleep mode shall be less than 0.02%

PAGE - 1019
  Sinusoidal current modulation with excellent dynamic response.
 Unit wise & integrated Data logging.
 Dedicated Ethernet for networking
 Protection against
a) over-under current
b) Over voltage & under voltage,
c) Over and under frequency
d) Sync loss
e) Over temp
f) Line to line fault
g) Short circuit
h) Protection against lightning
i) Surge voltage induced at output due to external source
 Set point pre-selection for VAR control
 Remote control via telephone modem or mini web server
 Integrated protection in the DC and three phase system
 Insulation monitoring of the PV array
 Ground fault detector – which is essential for large PV generators in view of
appreciable discharge current with respect to ground.
 Over voltage protection against atmospheric lightning discharge to the PV array
is required.
 The power conditioner must be entirely self-managing and stable in operation.
 A self diagnostic system check should occur on start up. Functions should
include a test of key parameters on start up.

3.7 Cable and accessories

 All the cables shall be supplied conforming to IS 694 & shall be of 650 V/ 1.1 kV grade
as per requirement. Only FRLSH PVC copper cables shall be used.
 The size of the cables between array interconnections, array to junction boxes,
junction boxes to DCDB, DCDB to PCU etc shall be so selected to keep the voltage drop
and losses to the minimum.
 Agency shall submit the design calculation for each size of cables used & shall
consider necessary derating factors for optimization of cable as per manufacturer
cable catalogue.
 The Agency shall supply all installation accessories, which are required to install and
successfully commission the power plant.

3.8 Earthing protection

 The array structure of the PV yard shall be grounded properly using adequate number
of earthing kits.
 All metal casing / shielding of the plant shall be thoroughly grounded to ensure safety
of the power plant.

3.9 Space for Solar Array and Control /battery room

 The bidder shall give the details of array layout and control / battery room layout
before execution for approval.

PAGE - 1020
  Bidders are advised to visit the site and conduct a survey with prior notice to the
Department for deciding the most suitable location from the installation &
maintenance point of view.

3.10 Spare parts

 Bidder shall arrange /supply recommended spares required for day to day operation
for next 2 years free of cost. They are also required to furnish the availability of
essential spares at their nearest service centre.

3.11 Type tests

 Type test reports of all major equipment’s (Solar module, battery & PCU) shall be
submitted to the AAI.
 The type test report shall be within 5 years from bid opening date, in absence of which
fresh type test shall be done without any cost to owner.

3.12 Installation and commissioning

 Detailed project execution program shall be submitted along with the offer. The
contractor will be responsible for arranging all tools & plants for installation and
commissioning the complete system.
 The contractor will also submit the erection, testing & commissioning procedure for
approval to the AAI. These procedures will form integral part of the acceptance report
for successful erection and commissioning the system. These reports will be prepared
and signed by contractor*s representative & the owner concerned with project.

3.13 Packing, shipping and marking

 The bidder shall be responsible for assuring that all commodities shipped are
properly packed and protected to prevent damage or deterioration during
shipment, packaging and shipping costs shall be borne by the supplier.
3.14 Insurance
 The bidder shall provide insurance coverage ex-factory until commissioning and
acceptance for replacement of repair of any part of the consignment due to damage
or loss.

4.0 WARRANTY
4.1 Warranty for PV module
 Performance guarantee At-least 90% of rated performance after 10 years
 Performance guarantee At least 80% of rated performance after 20 years

4.2 SYSTEM WARRANTY

 Inverter Warranty – 5 years
 Balance of System – 5 years

PAGE - 1021
SECTION -19 LIFTS
SCOPE OF WORK
 The work shall be strictly carried out as per the scope listed in this document and in
accordance with the specifications. The equipment & material supplied at site will also be
selected out of the list of approved makes. Specifications provided with the document is for
EPC contractor guidance. It is expected that after award of work, EPC contractor shall prepare
design drawings for approval by the Client representative and also submit Technical
documentation duly identifying shortlisted make of material/equipment along with its data
sheets. Actual ordering shall be based on approved design drawings & documents.
 The work at site shall comply with the approved design drawings and will meet the
satisfaction of Client representative. The EPC contractor shall be required to demonstrate
satisfactory operation of entire system and furnish the required labour, material & tools to
install & commission the system.
 The broad scope of work for proposed Electrical system covered under this contract shall
include supply, installation, testing & commissioning of the following but not limited to :

 Elevator

 Besides above, EPC contractor shall also be required to undertake following:

 All Coordination for submission of required documents & demonstration of systems for Local
Authorities shall be done by the EPC contractor.
 Commissioning of the plant including test reports to demonstrate satisfactory working prior
to handing over.
 Provide as-built drawings and handing over document comprising of list of recommended
spares, catalogues and service schedule for each equipment/material.
 Training of Client’s staff.

PAGE - 1022
TECHNICAL DESIGN AND SPECIFICATIONS FOR TRACTION ELEVATORS / LIFTS:

This section provides the technical requirement of Electric Traction Type Machine Room Less
Glass (Scenic) / Stainless steel Passenger Elevators with glass door, Service Elevators and
Goods Elevators, their components, safety devices, etc. All features shall be according to the
standards/ codes listed below. The contractor shall be responsible to check and ensure
dimensions of hoist ways before manufacturing, the requirements of statutory laws and local
codes of Electrical / Elevators inspector and the equipment offered are suitable for the space
available. Elevator door opening shall meet minimum requirement of NBC-2016 for handicap
operation.
1.0 STANDARDS / CODES
 The following Standard Specifications and Codes of Practice, currently applicable
and updated as of date irrespective of dates given below, shall apply to the Elevators
and the work covered by this contract.
National Building Code of India NBC - 2016
Code of Practice for installation, operation and IS-14665 (Part 2) Sec-1 :
maintenance of electric passenger & goods lifts. 2000
Code of practice for installation, operation and IS-14665 (Part 2) Sec-2 :
maintenance of electric service lifts. 2000
MRL Code of Practice IS-15785:-2007
Safety Rules Section-1 Passenger and Good lifts IS-14665 (Part 3) Sec-1 :
2000
Safety Rules Section-2 – Service lifts IS-14665 (Part 3) Sec-2 :
2000
Outline dimension for electric lifts. IS-14665 (Part-1) : 2000
Inspection Manual for Electric lifts IS-14665 (Part 5) : 1999
Electric Traction lifts – Components IS-14665 (Part 4) Sec-1 to 9 :
2001
Installation and Maintenance of lifts For IS 15330 :2003
Handicapped Persons (Code of Practice)
Specification for lifts cables. IS-4289 (Par-1) : 1984
Reaffirmed 1991
Specification for hot rolled and slit steel tee bars. IS-1173-1978 Reaffirmed
1987
Method of loading rating of worm gear. IS-7443-1974 Reaffirmed
1991
Code of practice for selection of standard worm IS-7403-1974 Reaffirmed
and helical gear box. 1991
Isometrics screw threads. IS-4218-(Part-II)1976
Reaffirmed 1996
Degree of protection provided by enclosure for IS-2147-1962
low voltage switchgear and control gear.
Classification of insulating materials for electrical IS-1271-1985 Reaffirmed
machinery and apparatus in relation to their 1990
thermal stability in service.
Code of practice for earthing. IS-3043-1987

PAGE - 1023
Electrical installation Fire Safety of Building. IS-1646-1997
PVC insulated electric cable for working voltage IS-694-1990
up to and including 1100 volts.
Code of practice for electrical wiring and IS-732-1989
installation
PVC insulated (Heavy Duty) electric cables for IS-1554-1988 (Part-1)
working voltage up to and including 1100 volts.
Flexible steel conduits IS-3480-1966
Accessories for rigid steel conduit for electrical IS-3837-1976
wiring
Boxes for the enclosure of electrical accessories IS-5133-1969 (Part 1)
Guide for safety procedures and practices in IS-5216-1982 (Part-1)
electrical work
Conductors for insulated electric cables and IS-8130-1984
flexible cords
Miniature Circuit Breakers IS-8828-1996
Rigid steel conduits for electrical wiring (Second IS-9537-1981
revisions)
Methods of test for cables IS-10810-1998
Earth Leakage Circuit Breakers. IS-12640-1988
Molded Case Circuit Breakers IS-13947-1993
General requirement for switchgear and control IS-13947-1993
gear for voltage not exceeding 1000 volts.
1100 volt grade XLPE insulated armored cables IS 7098
Specifications for hoist way door-locks IS 7754-1975
Rules for design, installation, testing and IS 1735-1975
operation of lifts, escalators and moving parts.
Seismic Zone: Comply with code requirements IS: 1893-Part 1 & 2 -2002
for seismic risk zone-III
Safety rules for the construction and installation EN 81-20
of lifts - Lifts for the transport of persons and
goods - Passenger and goods passenger lifts
Safety rules for the construction and installation EN 81-50
of lifts. Examinations and tests. Design rules,
calculations, examinations and tests of lifts
components
Remote alarm on passenger and goods lifts EN 81-28
Accessibility to lifts for persons including EN 81-70
persons with disabilities
Fire fighters lifts EN 81-72
Behavior of lifts in the event of fire EN 81-73
Safety Code for lifts and Escalators EN 81-80
Electromagnetic Compatibility EN 12015 & EN 12016
Maintenance Instructions for lifts and Escalators EN 13015
Life Safety Code NFPA 101

 In addition, the relevant clauses of the following, as amended up to date shall also
apply:

PAGE - 1024
  The Indian Electricity Rules 1956
 The Indian Electricity Act 1910
 Local Fire safety regulations
 Building Bye-Laws
 CPWD specification for Lifts and Escalators work
 Any applicable local lift / elevators act / rule for design and installation of the
elevators

1.1 DESIGN
 The design of the equipment shall match the design & performance requirements as
specified below.

1.1.1 PROVED DESIGN

 The elevators specialized agency shall develop the design based on the below
specifications and on proven and reliable engineering practices. All sub systems &
equipment shall be of proven design.

1.1.2 DESIGN CRITERIA

 THE DESIGN OF THE EQUIPMENT OFFERED SHOULD MEET THE FOLLOWING
CRITERIA:-
 Usage of the latest state of the art technology.
 Design enhancements should not reduce the life cycle of equipment /
components
 Design life of at least 20 years
 Highest levels of reliability& equipment availability
 Lowest maintenance cost
 Modular design
 Minimum life cycle cost
 High traceability of components through unique bar coding / serial nos. / tagging
 Lowest energy consumption
 Highest levels of safety
 Environment friendly
 Code compliance

1.1.3 DESIGN INTENT

 The intent of this document is to make sure that the design of the MRL glass door
elevators must follow the design criteria per above & to ensure the performance
parameters to be met not only at the stage of handover but consistently year over
year during the service life cycle.
 The elevators shall be provided with built in diagnostics to enable maintenance staff
to reduce down times & also to demonstrate performance requirements to
ENGINEER IN CHARGE.

1.2 SIZE & SPEED

 The capacity of the elevators shall be as specified.
 Elevators Speed shall be as per NBC-2016.

1.3 TRAVEL
 The travel of elevators shall be as per design requirements.

PAGE - 1025
2.0 DRIVING MECHANISM& ACCESSORIES
2.1 ELEVATORS MACHINE
 The elevators machine shall be suitable for 415 volts, 3 phase, 50 Hz AC supply with
a voltage variation of ±10% and frequency variation of ±5% and shall be placed
inside the top of hoist way either on the steel beams or self-supported on the rails
as per the manufacturer’s design.
 The elevators machine shall have high efficiency equivalent to IE3 or above, high
power factor and low power consumption and shall be designed to withstand peak
currents in elevators duties. Resilient anti-vibration mountings of suitable design
shall be provided to minimize vibration transmission to the building structure.
 The assembly is to be designed & tested to sustain contract load plus 25% overload.
 The elevators shall have a gearless machine with permanent magnet consisting of
motor traction sheave completely aligned on a single shaft. Gearless machine shall
be AC PMSM (Permanent Magnet Synchronous Motor) gearless with VVVF drive.
The sheave should have groves/wedges for PVC coated traction belts/ ropes as
specified in MRL code of Practice IS-15785:2007.The machine shall be placed at the
top inside of the hoist way on steel beams / rails. Requirements for permanent lifting
hooks, hoisting beams and access hatches shall be indicated on the drawings by the
elevators system, supplier/ installer.
2.2 A C MOTOR
 The AC self-lubricating motor shall be suitable for elevators use with high starting
torque and low starting current. Thermistors shall be embedded in the stator
windings to indicate the temperature rise in the motor. The A C motor shall have
Class F insulation and shall be designed for not less than 240 starts per hour with a
maximum temperature rise of 50 degree Cover the ambient when run continuously
for an hour without any additional or assisted cooling.
 The elevators shall be provided with AC variable voltage variable frequency (VVVF),
microprocessor controlled motion and drive control system. The model No., name
of manufacturer and country of origin shall be provided by the elevators system,
supplier/ installer.

2.3 ANTI-VIBRATION SUPPORTS

 The whole traction machine shall be mounted on appropriate anti-vibration
supports to minimize noise &vibration and to meet the ride quality parameters
desired in this document.

2.4 BRAKE
 The electromagnetic brake or permanent magnet brake shall be spring applied and
electrically released. It shall come into action after the elevators has come to a
complete halt to hold the car in position. The brake shall operate automatically with
the safety devices and failure of the mains. It shall be released electrically. It shall be
possible to release the brake manually – such release requiring the action of manual
force to move the elevators in short stops for machine above equipment. In case of

PAGE - 1026
 machine room less elevators, elevators contractor shall provide suitable means to
hand wind or lower the elevators from a remote point.
 The brake shall be capable of stopping and holding the Elevators car in its
downward travel to rest with 125% of its rated load from the maximum governor
tripping speed. In this condition the retardation of the Car shall not exceed that
resulting from the operation of the Safety gear or stopping on the buffer.
 Springs used to apply the brake shoes shall be in compression and adequately
supported.
 Brake linings shall be of renewable incombustible materials and shall be secured to
the brake shoes such that normal wear shall not weaken their fixings. Band brakes
shall not be used.
 No earth fault, short circuit or residual magnetism shall prevent the brake from
being applied in the event of loss of power supply to the Elevators motor and control
circuit.
 A means of adjusting the brake plunger stroke and releasing the brake in emergency
shall be provided.
 The Elevators machine shall be fitted with a manual emergency device capable of
having the brake released by hand and requiring a constant effort to keep the brake
open.
 The fail safe break shall incorporate an approved design of brake switch i.e. pick up,
hold, discharge. Brake coil shall be wired in series & their respective switches in
parallel. The operation of brake shall be thyristor controlled from solid state drive
in order to affect minimum pick up time and synchronized start.
 The fail-safe brake shall be tested and adjusted at the manufacturer’s works to
provide a braking torque of at least 1.5 times the motor torque output required to
elevators full load + 10 % in the up direction. The resultant final length of brake
springs shall be stamped on a suitable nameplate adjacent to the fail-safe brake.
Solenoid air gap dimension, if used, will also be stamped on the nameplate.
 The Elevators machine shall be fitted with a manual electrical emergency device
with battery backup capable of having the brake released by hand and requiring a
constant effort to keep the brake open. In case of MRL elevators, the motor brake
shall be able to be remotely released outside the elevators well.

2.5 SUSPENSIONROPES / BELTS

 Suspension Ropes / Hoist Ropes shall be self-lubricated; round stranded steel wire
ropes manufactured from high grade steel and special flexible material and shall
conform to the IS-2365 / EN81-20. The minimum tensile strength of the ropes shall
not be less than 1230 N/ sq.mm. Suitable no. of hoist ropes and size of the hoist ropes
shall be so selected that it has the combined breaking strength calculated with a
minimum factor of safety of 12 times the combined weight of car with full load and
also have adequate traction for the elevators. The governor ropes shall also be wire
ropes.

PAGE - 1027
  Elevators using belts as suspension / traction media shall confirm to factor of safety
mentioned above and shall be designed based on the relevant European Norms.

2.6 COMPENSATINGCHAINS / ROPES

 Compensating chains or ropes shall be installed for the elevators if required to
compensate the shifting mass of the suspension ropes. In case compensating ropes
are used, a tension pulley with weight shall be provided with suitable guides
mounted in the pit to ensure proper tensioning of the ropes.
 These Chains or Ropes shall not be a cause for any noise and suitable flame resistant
casing or jacketed shall be provided.

2.7 ALIGNMENT
 The brake plunger, collar, sleeve, motor, sheaves and all bearings shall be mounted
and assembled so that proper alignment of these parts is maintained.
 The assembly shall be reviewed and rectified when excessive noise is emitted during
operation.

2.8 CAR SAFETY, COUNTERWEIGHT SAFETY AND GOVERNOR:

 Car and Counterweight safety shall be provided to stop the car or counterweight
whenever excessive descending speed is attained.
 Mechanical safety gear shall be mounted on and securely fastened to car /
counterweight frame and actuated by a governor mounted in machine/ shaft.
Governor shall be directly driven by steel wire ropes.
 In machine room less applications, the governor shall be mounted in the overhead
area of the hoist way. The manual tripping and resetting of the over speed governor
shall be remotely controlled from outside the elevators well at the top-serving floor.
 Safety gear shall hold car securely under maximum load and governor tripping
speed conditions. Jaws of gear shall engage guide rails through self-aligning shoes
with surfaces carefully machined parallel to guide rail face. Pressure of jaws on the
two guides shall be equal. Safety gear shall bring car to stop from governor tripping
speed. Method of stopping shall be progressive as specified in Elevators Schedule.
Deceleration shall be less than gravity.
 Governor shall be accurately adjusted and sealed to electrically trip safety gear at a
speed at least equal to 115% of car’s specified speed. The maximum allowable
tripping speed shall be as specified in EN 81-20 / IS-14665. Operation of governor
on over speed is also to open a switch disconnecting power from motor and break
control circuits, which are to be open before safety gear is applied. Restoration of
power shall not be possible until safety gear has been manually re-set. Electrical
tripping & Mechanical tripping will appear at about 1.1 to 1.25 times the rated speed.
Double trip (downward and upward) protection shall be in accordance with EN 81-
20 / IS-14665. The elevators system supplier/ installer shall submit required
related type tests certificates to the Contractor.

PAGE - 1028
  A similar safety needs to be provided for counterweight as well in case of elevators
with hanging pit/s and as a means for ascending car over speed protection. The
governor tension weight shall be provided with a built-in switch to detect broken
rope/belt.

2.9 DRIVING SHEAVES

 The sheaves shall be manufactured in steel or SG iron and fitted with sealed for life
lubricated bearings.
 The sheaves shall have machined rope grooves that can be reworked for future
wear.
 Adequate provision shall be made to prevent any suspension ropes leaving groove
due to rope slack or introduction of foreign objects.
 All traction & diverter sheaves shall be enclosed with a suitable & removable
guarding for eliminating moving equipment pinching hazards.

3.0 CONTROL SYSTEM

3.1 CONTROLLER
 The elevators shall have state of art microprocessor/PLC based AC variable voltage
variable frequency (ACVVVF) drive.
 The elevators controller shall be wall/guiderail mounted, vertical, totally enclosed
cubicle type with hinged doors on the front and/or the rear to provide easy access
to all components in the controller. The cubicle shall be well ventilated such that the
temperature inside never exceeds the safe limits of the components at ambient
room conditions in the hoist way.
 The controller shall operate within the supply voltage variation of ±10% and
frequency variation of ±5% of the nominal voltage. An inbuilt voltage stabilizer shall
be provided in the controller for the purpose.
 The controller shall be complete with relay protection against the following:
 Over current
 Under voltage
 Single phasing
 Phase reversal
 Earth leakage
 Over voltage
 Under voltage
 Spikes & Surges
 Heat Sink Over temperature
 Stall prevention (During acceleration, deceleration and constant speed operation)
Control panels & drive systems shall be designed to meet the requirements laid
down by the EN12015 standards relevant to Electro-Magnetic Compatibility (EMC).
 Elevators motor control system shall be electronic closed-loop control to ensure fail
safe motor over speed controls and stopping accuracy of ±3 mm. Load compensation

PAGE - 1029
 circuits shall also be included to further improve upon the levelling accuracy. The
levelling shall be ensured within +5 mm.
 An Automatic Phase reversal device shall be provided on the controller which shall
be designed to protect the elevators equipment against phase reversal and phase
failure.
 The controller shall be designed to cut off the power supply, apply the brake and
bring the car to a rest in the event of any of the above failures occurring. System
should automatically restart when power is restored.
 System memory should be retained in the event of power failure or disturbance.
Elevators should not go in to correction mode or correction run to the lowest floor
/ highest floor to update its position & memory.
 The acceleration and deceleration shall be adjustable at site using a service tool.

3.2 VVVF DRIVE UNIT

 Elevators drive controls shall be A.C. Variable Voltage Variable Frequency (ACVVVF)
Drive System with microprocessor based site programmable controls.
 In normal operation, the electromagnetic brake shall only be applied when the
elevators have come to a complete standstill. The brake shall hold the elevators in
position at every landing, and shall provide stopping without any jerking effect.
 The VVVF Drive shall employ Sine wave PWM control & shall be designed to run at
an ambient temperature of 50 °C and maximum relative humidity of 90%.
 The VVVF drive shall be vector with flow closed loop control always.
 Shielded cables to be used to cover the path from inverter output terminal box to
motor terminal box; this is required to reduce EMI or radio disturbances. Input
filters to be used at inverter input to reduce disturbance to power supply.
 To safe guard motor against these voltage spikes, VVVF drive shall consist of
appropriate protection device at output of the inverter.
 Following protections shall be built in with the inverter: -
 Motor overload / over torque
 Instantaneous over current
 Ground fault
 Under voltage
 Over voltage
 Output & Input phase loss
 Output short circuit
 Over speed
 Spikes & Surges
 Heat Sink Over temperature
 Stall prevention (During acceleration, deceleration and constant speed operation)
On fault occurrence, the VVVF drive shall store the status of all parameters
prevailing at the time of fault occurrence etc. & the same shall be available to the
user to assist him in the fault diagnosis.

3.3 UP/DOWN SELECTIVE COLLECTIVE AUTOMATIC OPERATION WITH OR

WITHOUT ATTENDANT (SIMPLEX CONTROL SYSTEM)
 Individual elevators cars shall be provided with Simplex Control. The Elevators shall
respond to all registered hall calls and car calls automatically with the help of one
button per Elevators stop inside car and UP & DOWN buttons in each landing except
the terminal landings where only UP or DOWN buttons are provided. It shall

PAGE - 1030
 respond to all registered hall calls and car calls in the direction of service. When no
call is registered then after a pre-set adjustable period Elevators car shall come to
designated floor and open the door for 30 seconds (adjustable time) and then park
the car there with doors closed.
 Apart from above, a two position key-operated switch marked to indicate “ATT”
(Attendant Operation) and “AUTO” (Automatic Mode) shall be provided. When the
switch is in the position of “ATT” mode, the Elevators shall be in attendant mode. It
will connect the hall button pushes to the annunciator provided in the car, to register
the calls.

3.4 ENERGY EFFICIENCY

 The control systems should incorporate energy control features to reduce the power
consumption when the elevators are not in use or there is low demand; these include
but not limited to: -
 Auto Fan / Car light Cutoff: Auto switch off feature to be provided for switching of
the ventilation fan & car lights after 90 seconds of elevators being idle. This should
be programmable at site to increase or decrease the timing. These have to switch
ON automatically at the time of first landing call.
 In low demand times (Off Peak Hours), number of service cars to be reduced without
impacting passenger waiting times.

3.5 FIRE MANOPERATION

 All the elevators in the building shall be equipped with a control system to recall and
operate cars in the event of fire any other emergency situations. This shall always
be in line with the latest IS codes / EN codes / NFPA standards amended up to date
even if the below description is found as different from the latest amended codes
mentioned here.
 Operation Requirement of elevators(s): -
All elevators(s) shall be provided with the following as a minimum: -
 A two position ON/OFF fireman’s switch which may be common to all elevators in a
group control at evacuation floor (normally the main entrance floor) protected in a
box with glass in front with suitable label indicating that it is the fireman switch and
 Audio & visual signal in car for Fire or any other emergency
 Sequence of operation: -
Return to Evacuation floor (Phase1): -
 Shall start when the switch at the evacuation floor is turned to the ‘ON’ position or
the signal indicating a fire received from the automatic fire detection and alarm
system (if provided by the BMS) is on. The elevators(s) controlled by this switch
shall cancel car calls and separate from landing calls and no landing or car calls shall
be registered. The audio and visual signal in car shall be turned on. All heat and
smoke sensitive door re-opening devices shall be rendered inoperative.
 If the elevators are travelling towards evacuation floor, it shall continue driving to
that floor.
 If the elevators are travelling away from the evacuation floor, it shall reverse its
direction at the nearest possible floor without opening its door and return non-stop
to the evacuation floor.
 If the elevators are standing at a floor other than the evacuation floor, it shall close
the doors & start travelling non-stop to the evacuation floor.
 When at the evacuation floor, the elevators will park with doors open.

PAGE - 1031
  The audio signal is turned off after this drive.
 Fireman’s Service (Phase2): -
 The Phase 2 is started after Phase 1 if the fireman’s switch is on.
 The elevators do not respond to landing calls. All heat and smoke sensitive door re
opening devices shall be rendered inoperative.
 When the car call button is pressed the doors start closing. If the button is released
before the doors are fully closed, they reopen. The car call is registered only after
the doors are fully closed.
 After registering a car call the elevators start driving to a call. If more than one car
calls are registered, only the nearest call is answered & the remaining car calls will
be cancelled at the first stop.
 At the floors the doors are opened by pushing the door open button. If the button is
released before the doors are fully open, they reclose.
 The elevators return to normal service when it stands at the evacuation floor with
door open & the fireman’s switch is off or by an electric signal from the automatic
fire detection system when it is reset.

 The breakdown or shut down of a elevators in a group of interconnected elevators

shall not affect the return of the other elevators to the evacuation landing.
 The elevators will automatically be reset to normal operation by:
 An electrical signal from the automatic fire detection system when it is reset; or
 The reset of the manual grounding switch.
 The fireman’s switch shall be located adjacent to the elevators opening at the
evacuation floor and shall be at a height of approximately 1.8 m above the floor level.
 Electrical components/switchgears within the elevators hoist way and on the car,
located within 1.0 m of any wall containing landing doors shall be protected from
dripping and splashing water and shall have ingress protection class not less than
IPX3

3.6 AUTOMATIC RESCUE DEVICE

 The ARD shall have the following specifications:-
 ARD should move the elevators to the nearest landing in case of power failure
during normal operation of elevators.
 ARD should monitor the normal power supply in the main controller and shall
activate rescue operation within 10 seconds of normal power supply failure. It
should bring the elevators to the nearest floor at a slower speed than the normal
run. While proceeding to the nearest floor the elevators will detect the zone and
stop. After the elevators has stopped, it automatically opens the doors and parks
with door open. After the operation is completed by the ARD the elevatorsare
automatically switched over to normal operation as soon as normal power supply
resumes.
 In case the normal supply resumes during ARD in operation the elevators will
continue to run in ARD mode until it reaches the nearest landing and the doors
are fully opened. If normal power supply resumes when the elevators are at the
landing, it will automatically be switched to normal power operation and start
from there instead of getting into correction mode and going to lowest floor.
 All the elevators safeties shall remain active during the ARD mode of operation

PAGE - 1032
  Audio / Visual alarm to be provided in car to announce ARD operation; voice
synthesizer to make an announcement that elevators is running to floor level on
emergency power and to exit upon arrival.
 The battery capacity should be adequate so as to operate the ARD at least six
times without recharging of battery.
 The ARD battery shall be dry and sealed maintenance free rechargeable type.

3.7 SEISMIC OPERATION AND SAFETY DEVICES

 Seismic operation Control system with primary wave sensors for all the elevators
needs to be provided. It could be one control device installed in each isolated zone
of the buildings (separated by expansion joints) which shall be integrated with all
elevators units in that particular zone.
 Upon detecting such wave& sensing the limit exceeding the programmed limit, the
equipment shall direct the control system to bring the cars to the nearest floor and
immediately open doors for safe exit. The electronic sensor should sense & measure
acceleration across all three axis.
 The elevators shall only be reset manually after the signals clear and the
maintenance personnel have inspected the elevators.
 Upon Detection of a Seismic wave the control system shall provide for a signal to be
sent to the BMS system.
 Adequate protection such as protection wires, etc. as suggested in NBC-2016 shall
be provided for Suspension ropes, governor ropes, travelling cables, compensating
chains and ropes from swaying in the elevators hoist way and getting entangled with
the fixed brackets, sill, equipment, etc. inside the hoist way.
 Car and Counterweight retaining devices as per NBC-2016 shall be provided for all
the elevators to hold the Car and Counterweight frames within the guiderails during
seismic movement.
 A “counterweight derailment” device or “displacement switch” shall be installed
on counterweight guide rails which are to be activated in case counterweight
sections are dislodged from original position between the guiderails due to seismic
movements.
 An automatic reset shall not be possible in such case and the elevators shall remain
inoperable until the counterweight sections and guiderails are inspected thoroughly
and defects are rectified by the maintenance personnel.

4.0 STANDARD FEATURES TO BE INCLUDED

4.1 AUTOMATIC BY-PASS
 Load weighing devices located either on car top or under the car cage shall be
provided for all elevators. Whenever the load exceeds 80% of the capacity load of
the elevators, the elevators shall ignore all landing calls and only respond to car calls.
Landing calls which are bypassed shall not be canceled. The automatic load bypass
device shall be field adjusted for 50%-80% of rated load.

4.2 OVER LOAD DEVICE

 A load weighing devices shall operate when the load in the car exceeds the rated
capacity. The operation of the device shall activate buzzer sound and flashing
‘overload’ signals. At the same time the car doors shall be prevented from closing.
When the excess load has been removed from the car, the buzzer alarm shall stop

PAGE - 1033
 automatically and the car shall function normally. The sensitivity shall be 30 kg for
Passenger elevators and 5% of the contract load for service elevators. The load
sensing shall be achieved either by way of load sensors placed under car platform
or rope/ belt tension device as per manufacturers standard design. The load sensing
device should be site- programmable/adjustment type.

4.3 AUTOMATIC SELF-LEVELING

 All elevators shall be provided with automatic self-leveling feature that shall bring
the elevators car level to within ±3 mm for passenger/service elevators and + 5mm
for freight elevators of the landing floor regardless of load or direction of travel. The
automatic self-leveling feature shall take carefor over / under travel.
4.4 ALARM BELL/BUZZER
 An Emergency alarm bell/ Buzzer, including wiring to be provided and connected to
a properly marked push button in the car operating panel. The alarm bell shall be
located at the Main Landing floor, at the floor landing outside and adjacent to hoist
way or as desired by ENGINEER IN CHARGE.
 The alarm sound shall be siren type audible from at least 50 meters from the Main
landing, operated by Rechargeable Nickel/Cadmium maintenance free batteries to
give a warning siren when the alarm button in the car is pressed momentarily.

4.5 SAFE LANDING FEATURE

 If a car has stopped between floors due to some equipment malfunction, the
controller checks the cause, and if it is considered safe to move the car, the car will
move to the nearest floor at low speed and the doors will open.

4.6 AUTOMATIC DOOR OPEN TIME ADJUSTMENT

 The time the doors are open will automatically be adjusted depending upon whether
the stop was called from a hall call or a car call.

4.7 NEXT LANDING

 If the elevators doors do not open fully at the destination floor, then the doors will
close and the elevators will automatically move to its next destination.

4.8 INDEPENDENT SERVICE

 Under this operation the car is withdrawn from the group control operation for
independent use, such as transporting goods, carrying large number of people
between floors or maintenance & at such times only responds to car calls. The
elevators will remain parked on a floor with its doors open until a floor is selected
and the door close button is held until the elevators starts to travel. The switch for
this service shall be located inside the lockable service box in Car operating panel.

4.9 RETURN OPERATION

 Using a key switch on the face plate at main lobby floor, an elevator can be taken out
of the group control operation & brought to the main lobby floor (orother
designated floor). The car will park on that floor with the doors open till
independent operation begins.

PAGE - 1034
4.10 CAR CALL CANCELLATION
 This function allows passenger to cancel the selection of a floor which is accidentally
pressed by pressing the button again.

5.0 CAR ENCLOSURE

5.1 CAR FRAME
 The car frame/sling shall be fabricated from steel angle or channel section and be
separate from the elevators car. The safety gear positioned below the sling shall be
of gradually applied type, which can be released by lifting the car. This safety gear
shall be operated by an over speed governor located in the top of hoist way. The
governor tension weight shall be provided with a built-in switch to detect broken
rope/belt.
 Sheet steel thickness for Car shall be at least 1.5 mm. Joints in all surfaces shall be
coordinated. All fixings to be of the hidden secret type (cover strips at joints are not
acceptable).
 Platform shall be isolated type, constructed of steel, or steel and wood which is
fireproofed on underside. Design and construct to accommodate load classification
requirements. Protect underside of platform with sheet steel covering at least 2.0
mm thick. Sill shall be anti-slip, with provision for car doors. Sill shall be of the type
reducing the number of call backs related to entrance problems.
 Every elevators car body shall be carried in a steel car frame assembly that shall
have sufficient mechanical strength to resist the forces applied by the safety gear or
impact of the car on the buffers. The deflection of the steel members carrying the
platform shall not exceed 1/1000 of their span under static conditions when the
rated load is evenly distributed on the platform.
 Every elevator shall be provided with an apron of at least 750 mm below car door.
This apron should extend up to full width of the car door plus 150 mm on the either
side. This apron must be rigidly braced with only countersunk screws & any fixings
/ mountings used shall be of steel.
 The car roof shall be provided with a car top rail / balustrade in accordance with the
requirements of EN 81-20 including a mid-rail& toe guard where applicable. A
suitable warning notice for the fall hazard shall be placed.
 At least four renewable guide shoes or shoes with renewable linings or sets of guide
rollers shall be provided two at the top and two at the bottom of the car frame
assembly.

5.2 CAR ENCLOSURE FINISHES

 Car enclosures shall be stainless steel (SS 304) hairline finish or Clear Tempered
Glass (for Scenic Elevators) or as per design and technical specifications.
 All finishing materials shall be fireproof or fire resistant conforming to applicable
codes.

5.3 CAR CABIN CONSTRUCTION

 Height of the enclosures shall be 2700 mm. The enclosure shall have recessed by
25mm to enable civil contractor to provide floor finish as approved by engineer in
charge.
 The weight to be allowed for flooring shall be as specified in annexure-1. Enclosure
shall have stainless steel false ceiling with led cluster lights or as approved by

PAGE - 1035
 Engineer in Charge. The enclosure shall have fixtures and fittings including
provision of car ventilation as detailed in annexure-1.
 The material chosen for car walls, floors and ceiling must meet fire resistance
classification requirement in accordance to en81-20 and as specified in en 13501-1.

5.4 CABIN FAN

 At least two numbers Noiseless pressure fan or blower shall be provided in each
elevators cabin with supply grill matching with the interior of the car. The required
no. of cabin fans shall be adequate for 20 air changes per hour with Car doors closed.
 Airflow in the car should be such that adequate amount of airflow reaches all parts
of cabin. One of the blowers shall be connected through a rechargeable UPS to
ensure continuous blower operation for at least 15 minutes in event of power
failure.

5.5 EMERGENCY LIGHTS

 In addition to normal lighting an emergency light unit using sealed Nickel/Cadmium
Maintenance free battery power pack with charger and fluorescent lamp to operate
automatically and to illuminate the car for minimum 30 minutes in case of power
failure shall be provided in each elevators car.
 An “Emergency light test” button to verify the proper functioning of car emergency
lights shall be provided inside the service cabinet in the Car operating panel. When
this button is pressed, the main car lighting should be disconnected and emergency
car light should get illuminated thus verifying the proper functioning of emergency
lights including rechargeable batteries.

5.6 GUIDE SHOES

 Two number of guide shoes at the top and bottom shall be provided on the elevators
car & counterweight. Guide shoes shall have non-metallic renewable lining’s, which
requires minimum lubrication.
 Sliding guide shoes for car & counterweight shall always be of spring loaded
adjustable type.

6.0 CAR SIGNALS & OPERATION DEVICES:

6.1 FOR CARS WITH SIMPLEX / DUPLEX CONTROL
 A flush type Stainless Steel "Car Operating Panel (COP)" with the following devices
shall be fitted:-
 Bank of call buttons corresponding to landings served. Tactile braille LED
illuminated Buttons.
 The push buttons should be tonal contrast to the COP & car panels finish
 Each push of any COP button shall provide a soft audible signal to confirm
operation.
 Alarm button shall be provided with a yellow pictogram to indicate the alarm
button provision.
 Fan /Blower switch.
 Door open button.
 Door close button.
 "Up" & "Down" direction indicators indicating travel direction
 Key operated switch for "Attendant" and "Automatic" operation.

PAGE - 1036
  Provision in car to be connected with P.A. System, Fire Control Room, CCTV and
BMS Control Room.
 Overload panel along with audio /visual indication.
 In case of service elevators& bed cum passenger elevators, provide door hold
button, which extends normal door open period by up to 30 seconds. The extended
time can be cancelled by actuation of door close button.
 Adequate space provision for access control card reader, if required.
 A load weighing device shall be provided to by-pass landing calls, should the load of
the elevators reach 80% of the full contract load.
 The Fan /Blower switch shall be a tactile push type switch located inside the service
cabinet of Car operating panel. Fan / Blowers shall be isolated with vibration
isolators from the car and the sling. The "up" and "down" reversal buttons and key
operated inspection switch shall be provided on a maintenance control device on
top of the elevators car.
 In case of "Attendant" operation of the car indicator on the car station shall be
provided for the attendant to know on which landing the call has been registered to
answer that call.
 If the sole control of the elevators is to be retained on the car station, a car
preference switch shall be provided to ignore all landing calls.
 ALCD / LED based / scrolling digital car position indicator with LED/LCD
illumination shall be provided in each elevators car indicating the landing at which
the car is stopped or passing.
 Car enclosure will be provided with arrangement for fixing of Internal Telephone.
Car shall have a provision for communication with main control room / fire control
room.

6.2 EMERGENCY INTERCOM

 Each elevator shall be fitted with an intercom system to allow atleast3-way, hands
free, conversation between the elevators car, Maintenance access panel and two
remote stations.
 The microphone & speaker unit has to be concealed behind the COP in the elevators
car & is activated by pressing the button which has an indication glowing when
intercom is in operation.
 The master unit in the remote stations has to have an indicator for each elevator.

6.3 VOICE SYNTHESIZER

This shall be provided & needs to be of the digital type capable of site programming.
 Besides giving a choice of background music (with option at site to choose or reject)
it should be capable of providing following messages in at least two languages per
choice of the owner:-
 Arrival at the floor & its designation.
 Door closing initiated.
 Elevators failed to start, please press the door open button
 ARD operation
 Final messages list & wording to specified / approved by ENGINEER IN CHARGE.

7.0 CAR & LANDING DOORS

7.1 DOOR OPERATOR& LOCKS

PAGE - 1037
  Door operator shall be positive acting and powered by an A.C motor rigidly
connected to the door and controlled by a VVVF unit. Operator shall simultaneously
open the car and hoist way doors and maintain the doors fully open or closed at each
door step. Door operators shall be suitable for Attendant/Automatic operation. The
door operation shall ensure smooth opening of door without any jerk and closing of
door without any banging noise.
 The operator and closed loop VVVF control panel and its associated devices should
be mounted on steel members forming part of the car sling & in no way shall the
operator be fitted to the car enclosure.
 Direct door drives through PMSM motors driven through closed loop VVVF drive
shall be the preferred method.
 The equipment shall consist of a door operator unit on the elevators car operating
the car door when the car is stopping at a landing. The car door and hoist way door
shall be mechanically coupled and shall move simultaneously during opening and
closing.
 The car door and the hoist way door shall be power opened and power closed and
shall be checked in opening and closing with an oil cushioning mechanism built into
the gear unit if any; nylon / plastic gears will not be acceptable.
 Each hoist way door shall be provided with an interlock, which will prevent
movement of the car away from the landing until the doors are locked in the closed
position.
 An electric contact for the door shall be provided which shall prevent car movement
away from the landing unless the door is in fully closed position.
 The car door and the hoist way shall open automatically as the car is stopping at a
landing. The closing of the car door must occur before the car can be started. Doors
can be stopped and reversed during their closing motion.

7.2 DOOR HANGERS AND TRACKS:

 The car and the landing doors shall be provided with two-point suspension sheave
type hangers complete with tracks. Sheaves and rollers shall be steel with molded
nylon collar and shall include shielded ball bearings. Tracks shall be of suitable steel
section with smooth surface. The landing doors shall be complete with headers, sills,
frames etc. as required.

7.3 CAR &HOIST WAY DOOR PROTECTION:

 A multiple beam full height infrared electronic door detector shall be provided to
regulate the closing motion of the doors for entry of the passengers. When a person
is entering the car while the doors are closing the detector shall sense the same and
reverses the door closing to permit entry. The operation of detector shall be of non-
contact type.

7.4 CAR & LANDING DOORS:

 The car & landing entrances for elevators shall be protected by automatic power
operated, center opening/2 Speed side opening, horizontal sliding doors with size
and glass finish .
 Car entrance shall be protected by steel doors of the same size as landing doors.
 Elevators shall be provided with automatic doors
 The door shall be provided with Multi beam Infra-red sensors, high speed door
operators, sheave type two point hangers, and tracks as specified.

PAGE - 1038
  The thickness of the door panels shall be at least 1.5 mm and shall be of single skin
construction.
 The face of the door panels shall maintain a fixed running clearance with respect to
the architrave and / or door frame.
 Every landing door shall be provided with an emergency landing door unlocking
device. When operated by an authorized person with the aid of a key to fit the
unlocking triangle, the landing door shall be unlocked irrespective of the position of
the elevators car for rescue purpose. When there is no “unlocking” action, the key
shall only be able to stay in the locked position.
 In the case of coupled car and landing doors, the landing doors shall be automatically
closed by means of weight or springs when the car is outside the unlocking zone.
 A potential cause of accidents could be the attempt to open the landing door locks
of lower floor in case car stops away from floor level. This attempt in panic may
result in an accidental fall in to the elevators pit. In order to ensure that the trapped
passengers do not attempt the above, the electromechanical latch should be so
designed that it is inaccessible or invisible to the passenger in car. In addition to
above, a car door lock mechanism shall be provided in accordance to EN81-20 to
prevent opening of the car door from inside the elevators car when it is not in close
proximity to the landing doors.
 Each landing door shall be complete with locks, headers, sills, frames, rims, hanger
supports with cover plates, etc. The finished work shall be strong, rigid & neat in
appearance. Plain surface will be smooth & free from warp or buckle. Molded
surfaces shall clean out, straight & true. Fastenings shall be concealed from the fascia
side of the material.
 For all elevators in buildings the landing doors will need to have a minimum fire
resistance rating of 01(One) hours for integrity. Necessary certification from a
nationally recognized testing laboratory approved within the governing jurisdiction
shall be submitted to the Contractor before shipment.

8.0 LANDING SIGNALS AND OPERATION CONTROLS

8.1 SIMPLEX / DUPLEX CONTROL
a) Terminal Landings
 LED illuminated type single push buttons with travel indication arrow in hairline
finish stainless steel facia plate.
 Color LCD / LED Dot Matrix type Digital car position indicator in hairline stainless
steel fascia plate or as specified in the Annexure 1 or as approved by ENGINEER
IN CHARGE.
 Direction & position indicators requirement is mutually exclusive and both
displays have to work simultaneously.
b) Intermediate Landings
 Two LED illuminated type push buttons with travel indication arrow in hairline
finish stainless steel fascia plate.
 Color LCD / LED Dot Matrix type Digital car position indicator in hairline stainless
steel fascia or as approved by ENGINEER IN CHARGE.
 Direction & position indicators requirement is mutually exclusive and both
displays have to work simultaneously.
 The number of risers shall be as specified / approved by ENGINEER IN CHARGE.

PAGE - 1039
  Surface mounted face plates will be preferred though the final approval on
faceplate design shall be provided by ENGINEER IN CHARGE. The cover plates
should be secured by semisecret fixings such as recessed captive grub or socket
headed screws but not by visible screw heads.
 Options of faceplates / buttons / indicators / hall lanterns to be submitted by
elevators system supplier / installer for approval by ENGINEER IN CHARGE.
 The indicators should provide an angle of view of 140 degree.

8.2 ELEVATORS IDENTIFICATION PLATES:

 Elevators identification numbers stating e.g.“ELEVATORS 15” shall be provided in
the following locations for each elevators by the elevators contractor: -
 All landing entrance headers
 Top of the COP in car
 On each elevators control panel
 Each Car top control station
 Each Machine
 Each safety governor
 Each pit switch
 These may be painted except for the ones required for first two items above, which
will need to be engraved on matching material to each item as approved by the
architect.

9.0 ELEVATORS SHAFT & PIT

9.1 LANDING FASCIA
 Fascia panels of minimum 1.6mm zinc coated mild sheet steel shall be fitted between
the header of each entrance & the sill of the floor above.
 These fascia plates must be rigidly braced & any fixings / mountings used shall be of
steel.
 Each fascia should be full width of entrance plus 150mm atleast on either side and
only counter sunk screws will be accepted on the surface.
 Fascia panels post fitting have to be site painted to match all other site steel work.

9.2 GUIDE RAILS

 The Car and Counterweight guide rails shall be solid ‘T’ section, duly machined,
tongued and grooved. The guide rails shall have sections, the properties of which
shall comply with the requirement of the relevant IS / EN codes. The guides shall be
capable of withstanding forces resulting from the application of the car or counter
weight safety devices.
 The guide rails should be continuous throughout the entire travel and shall
withstand without any deformation the action of safety gear with a fully loaded car.
 Guide Rail brackets shall be fixed to the wall by anchor fasteners. Adequate steel
brackets of suitable design and spacing shall be provided, so that guides shall not
deflect more than 5 mm. under normal operation.
 When rail lengths exceed 30m, means shall be provided to absorb rail expansion and
structural settlement.

9.3 BUFFERS
 Suitable heavy duty spring or oil buffers (depending on speed of the elevators) shall
be placed below the car and counterweight in the pit and arranged to sustain any

PAGE - 1040
 shock, should the elevators over travel past the terminal limits. Buffers shall be
mounted on RCC foundation blocks. Dowels for the purpose shall be left while
casting the pit floor. Clearance from underside of the car resting on a fully
compressed buffer shall not be less than 1.20 mtr. Buffers shall be designed for a
design speed + 15%.
 The normal operation of the elevators shall depend on the return of the buffers to
their normal extended position after operation. The device for checking this shall be
an electric safety device mounted on the buffers.

9.4 SILLS
 The sills to be provided should be Stainless Steel grooved / Slot less, with self-
supporting sill M.S. angle of adequate size.

9.5 COUNTER WEIGHT

 The counter weight shall be made of cast iron firmly fixed using 2 numbers tie rods
and consist of structural steel frame which shall travel between rigid guides and also
shall be capable of withstanding buffer impacts. The counter weight shall have
weight equal to that of the complete elevators car and approximately 45-50% of the
contract load. Suitable metallic counter weight guard of not less than 1.80 m shall be
provided in the pit to avoid accidental contact.

9.6 HITCH PLATES

 The end of the elevators ropes shall be properly secured to the car and counter
weight hitch plates as the case may be with adjustable rope shackles having
individual tapers babbit sockets, or any other suitable arrangement. Each elevators
rope shackle shall be fitted with a suitable shackle spring, seat washer, shackle nut
& lock & shackle nut split pin.

9.7 PAINTING
 All elevators metal work shall be given one design coat of rust inhibiting paint in the
factory and painted with finishing coats on site. Factory finished powder coated
paint of desired shade is acceptable. Any damage caused during erection of the
equipment shall be repaired to restore it to required finish.

10.0 SAFETY DEVICES

 All safety devices statutorily required by IS / EN / NBC standards, including but not
restricted to the following shall be provided:-

10.1 TERMINAL AND FINAL LIMITS

 Terminal limit switches shall be provided to slow down and stop the car
automatically at the terminal landings, and final limit switches shall be furnished to
automatically cut off power should the car travel beyond the terminal landings.

10.2 INTERLOCKING
 Each Hoist way gate / Landing doors shall be provided with an approved interlock
and which shall prevent the movement of the car away from the landing unless all
gates are closed and locked. The interlock shall also prevent opening of gate except
at the landing where the car is stopping or has stopped. Adequate interlocking is to

PAGE - 1041
 be provided so that the car shall not move if the landing doors are even partially
open and also the elevators is overloaded.
 A car door lock mechanism shall also be provided in accordance to EN81-20 to
prevent opening of the car door from inside the elevators car when it is not in close
proximity to the landing doors.

10.3 SELF LEVELING

 The elevators shall be provided with self-leveling features of ±3 mm for
passenger/service elevators and + 5mm for freight elevators.

10.4 ASCENDING CAR OVER SPEED PROTECTION

 The elevators shall be provided with an ascending car over speed protection device
conforming to EN 81-20. This device shall comprise a speed monitoring and
reducing element which shall detect uncontrolled movement of the ascending car at
a minimum of 115% of the rated speed and a maximum of 125% of the rated speed.
This shall cause the car to stop, or at least reduce its speed to that for which the
counterweight buffer is designed.
 The device shall not allow a retardation of the empty car in excess of 1gn during the
stopping phase. The device shall act to the car or the counterweight or on the rope
system or on the traction sheave.
 The device shall operate an electrical safety switch to switch off the power supply to
the elevators motor. This safety switch shall not be of auto resetting type.

10.5 UNINTENDED CAR MOVEMENT PROTECTION

 The elevators shall be provided with a device to stop the unintended car movement
away from the landing with the landing door not in the locked position and the car
door not in the closed position, as a result of failure in any single component of the
elevators machine or drive control system upon which the safe movement of the car
depends.
 The design and operation of such device shall conform to EN 81-20.

10.6 PIT LADDER &SWITCH

 The elevators contractor shall provide fixed pit ladders between the bottom landing
and the pit floor. These will be safe from all falling hazards.
 Two pit stop switches, one at bottom landing level in the shaft & the other on the pit
shall be provided, which, when in the STOP position, shall prevent any movement of
the elevators car including movement during inspection operation, until both the
switches are set in the run POSITION. The switch shall have a mushroom red head.
It shall be locked off when pushed and reset manually.
 First stop switch shall be accessible from the lower landing on opening of the landing
door and the second switch from the pit floor.
 Any switchgear or electrical equipment placed less than 1 m from the elevators pit
floor shall be protected to IP 67 and any switch socket & lamp / light shall start from
at least 0.5 m above the highest permissible water level in pit.
 A permanent inspection control device in accordance to EN 81-20 shall be provided
in the pit and accessible from the safety refuge space required in pit as per EN 81-
20.

PAGE - 1042
10.7 SAFETY ITEMS
 Following safety items shall be provided in for each elevators; Contractor to cover
the cost of these items in his quoted rates, nothing extra shall be paid on this account.
 Safety item that may be required by authorities.

11.0 ELECTRICAL EQUIPMENT AND WIRING

11.1 SCOPE
 The scope of this section comprises supply, installation and wiring of all electrical
equipment including control wiring. Power supply at 415 V, 3-phase, 50 Hz, 4 wire
with double earthing shall be supplied by designated system Contractor and
terminating in MCB (TPN) in sheet steel enclosure for each elevator. All further
wiring to motors and controllers, hall buttons, alarm bell, car position indicators etc.
shall be provided by the elevators system supplier / installer. All electrical
installation shall be carried out as per standard practices of IS.

11.2 WIRING
 All wires and cables shall be insulated with polyvinyl chloride base insulation
rendered flame retardant low smoke halogen free (FRLSHF) armored and rated for
1100-volt service and suitable for use in dry and wet locations. Makes of wires and
cables shall be as per attached list of approved makes in tender document and
subject to the approval of ENGINEER IN CHARGE before delivery. Colour coding,
numbering and ferruling to be in accordance with the requirements of standard
specification.
 All control wiring shall be of copper. All electrical wires and cables shall be fire
retardant low smoke emission and halogen free type (FRLSHF).
 The control wiring shall be laid out neatly and clearly in cable sleeves and all
terminals and cables shall be labeled or marked for identification.
 Wires and cables subject to movement and abrasion shall be protected by flexible
galvanized steel conduit.
 A travelling cable for lighting control and signal circuit is permitted, if all the
conductors of these travelling cables are insulated for maximum voltage running
through any one conductor of this cable.
 The lengths of the travelling cable shall be adequate to prevent any strain due to
movement of car. All cables shall be properly tagged by metallic / plastic tags for
identification.
 Travelling cables shall be of flat type and shall run from a junction box on the top of
the car to a junction box located in the shaft bear mid-point of travel and from these
junction boxes conductors shall be run to the various locations.
 Travelling Cables shall have fire retardant low smoke halogen free type (FRLSHF)
and moisture resistant outer covering with a steel-supporting strand. Travelling
cables shall be suitably suspended to relieve strains in individual conductors.
 Travelling cables shall be provided for telephone, signals, controls, lights, fans, alarm
bell, emergency circuit, music and communication with control room etc.
 Provide 10% of the total capacity subject to a minimum of 5 wire pair sun utilized
in the Travelling cable everywhere suitably distributed between various functions.
 Metal frames and all metal work of the elevators controller frame etc. shall be
earthed with double earth leads taken to the earth bar. Looping shall be permitted
if such routing is feasible. All other individual metallic framework of components

PAGE - 1043
 etc. shall be loop earthed. All the elevators shall be provided with earthing
arrangements as per IS 1860.

12.0 BMS COMPATIBILITY

 All the elevators shall be provided with necessary interfacing circuits for the BMS
system in each Elevators controller, in order to achieve an integrated ‘view’ of the
Elevators being monitored.
 Ethernet Interfaces shall be provided for any Elevators signal outputs, in order to
directly interface with the BMS system. Similarly, necessary Ethernet Interfaces
points shall be provided for any BMS signal inputs to the elevators controllers. These
signals shall be collectively referred to as the interfacing I/O points.
 All field controllers shall connect to the Airport’s Local Area Network via an RJ45
port which will be supplied by designated system contractor at a location to be
defined by elevators system supplier / installer.
 The designated system contractor for IT cabling shall supply a Cat 6 UTP patch cord.
 Controller network communications shall comply with the TCP/IP standard IEEE
802.3i
 Control and monitoring data which passes between the BMS and the elevators
controller shall use a protocol which complies with one of the four standards listed
below:
a) BACNet (BTL) certified
b) OPC Data Access Version 2.0
c) OPC Alarm & Events Version 1.02
d) OPC Historical Data Access
e) OPC XML-DA
f) MODBUS

 These I/O points shall include, but not limited to, the following:
a) Run / Stop Status
b) Fire emergency mode
c) Digital car position and direction indicator
d) Attendant / Independent Operation Status
e) Emergency Stop Operation Status
f) Safety switch tripped
g) Under Maintenance Mode Status

 I/O points interface shall be provided near the Elevators controller for BMS. An
Ethernet /IP network interface & gateways needed to interface between Elevators
controller equipment & Airport’s backbone network shall be provided in order to
integrate the respective elevators controllers.
 The Controller shall send the necessary information via the Ethernet /IP.

13.0 INTERFACE MANAGEMENT

 The elevators system supplier / installer shall initiate and manage the design,
development, installation and testing of the interface between the elevators and the
BMS system; the CCTV system; the Access Control systems; the Fire alarm systems;
the Public Address systems and the wireless communication system.

PAGE - 1044
14.0 RIDE QUALITY
14.1 BACKGROUND
 According to ISO 18738:2003 the elevators ride quality is defined as the noise level
in the car and vibration on the car floor, which is relevant to the user perception and
associated with elevators motion.
 The following set of parameters is integral to the evaluation of the ride quality: -
 Airborne noise level inside the car
 Horizontal car vibration
 Vertical car vibration
 Car acceleration
 Jerk

14.2 APPLICABLE STANDARDS

a) Airborne noise:
 L (Aeq) – A-weighted equivalent sound pressure level: can be interpreted as a mean
level and measured directly with an integrating sound level meter.
 L (p) – Maximum A-weighted sound pressure level measured over the same time as
the equivalent level.
 All sound pressure level measurements requiring setting “FAST” of the sound level
meter.

b) Vibrations:
 a (xmaxPtP), a (ymaxPtP), a (zmaxPtP): ISO-weighted maximum peak to peak
vibration value, according to ISO 18738:2003
 a (xA95), a (yA95), a (zA95): ISO-weighted A95 vibration value according to ISO
18738:2003. 95% of all peaks of the ISO-weighted signal are below this value.
 VDI 2566 Part 1: 2001: acoustical design for elevators with machine room ISO
18738:2003:elevators – measurements of elevators ride quality

14.3 RIDE QUALITY PERFORMANCE VALUES

 It is expected from the elevators contractor that his design of equipment will
consequently lead to not only a very reliable, energy efficient, state of the art
technology, high traffic handling efficient system but should also be able to achieve
ride quality performance values as provided in the details below.
 Elevators system supplier / installer shall arrange for the tools at the time of
handover to show the results which are equal to or better than the value specified
below.
Speed – As per NBC -2016

Top Most Landing

Airborne Noise Max 58 dB(A)

Car (ISO 18738:2003)

Airborne noise

L(Aeq) Max 48 dB(A)

PAGE - 1045
 L(P) Max 57 dB(A)

Horizontal vibrations

a(xmaxPtP) & a(ymaxPtP) Max 20 mg

a(xA95) & a(yA95) Max 15 mg

Vertical vibrations

a(zmaxPtP) Max 20 mg

a(zA95) Max 15 mg

Airborne noise at landing floor

Door movement noise L(p_door) Max 52 dB(A)

Pass by noise L(p_landing) Max 48 dB(A)

14.4 OTHER PERFORMANCE PARAMETERS

Some of the other performance parameters required are innumerate below: -
 Starting Current - 1.2 – 1.5-time full load running
current
 Leveling accuracy and - ±3 mm for Passenger/service
elevators
+ 5mm for freight elevators
 Stopping accuracy - ± 3 mm
 Acceptable Voltage Fluctuation - + 10 to - 10%
 Acceptable Frequency Fluctuation - +5 to -5%
 Rate of acceleration/deceleration (M/S2)- 0.6 – 1.5 (Adjustable at site)
 Maximum jerk (M/S3) - 0.7 – 1.5 (Adjustable at site)
14.5 ASUREMENT OF ELEVATORS RIDE QUALITY
 The Elevators system supplier / installer shall at no additional cost measure
elevators car ride quality during the handing over of elevators for public usage and
then annually for all elevators indicated, with specified ride quality parameters and
forward printed results to ENGINEER IN CHARGE.
 The ride quality measurement shall be taken with a recently calibrated Performance
measuring tool, capable of displaying the test measurements on site, supplied by the
Elevators system supplier / installer.

15.0 PROVISIONS FOR SPECIALLY-ABLED PASSENGERS

All the Elevators shall have accessible friendly features including but not limited to the
following:
 Elevators control buttons in the COP at locations and height specified in IS 15330 –
2003 / EN 81-70
 Hall call buttons at locations and height specified in IS 15330 – 2003 / EN 81-70

PAGE - 1046
  Hand rails shall be provided on the side walls of the Elevators at height & locations
specified in IS: 15330 – 2003 / EN 81-70.
 An international symbol of access of the disabled shall be permanently and
conspicuously displayed at each and every Elevators landing next to the Elevators
entrance (to be provided by signage contractor).
 Braille notations indicating the floor levels shall be incorporated next to each button
at the COP and hall call buttons.
 A digital voice system for announcing the car position, opening/closing of doors,
direction of travel and messages shall be provided as per IS:15330 – 2003 / EN 81-
70
 A laminated safety glass type mirror of at least half of the size shall be installed on
rear panel at appropriate position as per IS: 15330 – 2003 / EN 81-70
 In the event of a conflict between any of the above applicable or reference standards,
the more stringent requirements shall take precedence.

16.0 TESTING
 ENGINEER IN CHARGE reserve the right to inspect the elevators and its components
during manufacturing, installation & post installation.

16.1 TESTS DURING MANUFACTURING

 Testing for the various items of equipment shall be performed by the elevators
system supplier / installer. Test certificates for various components including but
not limited to the following shall be furnished as per IS-14665 / EN81-20:
 Hoist ropes
 Governor ropes
 Over speed governor
 Buffers
 Main motor & Door drive motor
 Safety gear
 Fire rating for doors
 Controller

(a) PROTOTYPETESTS
(i) One complete Elevators shall be available for the commencement of witness
testing after Contract Award. The selected Elevators shall be representative of
their various types.
(ii) A complete Elevators system including traction drive system, in addition to the
controller, Elevators car enclosure, landing and car doors, protection devices and
call fixtures shall be assembled on a test rig or inside a test tower to undergo a
comprehensive running and functional testing in accordance with the accepted
test specification to verify compliance with the Specification.
(iii) The tests shall include the following minimum requirements.
 Verification of the suitability of the traction drive system;
 Verification of the car operation and response to call fixtures, door operation
including the safety edges, all indications and signaling features, and car top
control features;
 Weight tests on safety gear and measurement of electrical readings and
verification of the operating speed under various loading conditions;

PAGE - 1047
  Verification of riding comfort and leveling accuracy under various load
conditions.
 Verification of the fault indication and fault diagnosis features.
 Verification of the construction of the various control panels to the
specification shall be done. Insulation resistance and high voltage tests shall
be conducted in accordance with the test specification.
 Any additional testing as required by BS 5655 Part 10.
 A 12-hour duty cycle test, during which the Elevators shall run continuously
with the contract load for 12 hours and shall travel up and down with
intermediate stops such that the number of starts per hour as specified.
 Complete functional tests on the isolating transformer and ripple filter.
 Operation of the battery back-up device and the battery operated power
supply.
 Simulation of the emergency homing sequence during fire and power failure.

(b) Factory Inspection

(i) ENGINEER IN CHARGE’s authorized representative shall have full powers to
examine the material and workmanship at the contractor’s work or at any other
place where the material or equipment is manufactured. Acceptance of any
material or equipment shall in no way absolve the contractor of his responsibility
for meeting the required specifications.
(ii) Routine tests for the various items of equipment shall be performed at the
contractor’s manufacturing works and test certificates shall be furnished. The
contractor shall permit ENGINEER IN CHARGE’s authorized representative to be
present during any of or all the acceptance test in respect of the equipment/work.
(iii) Contractor shall give sufficient time notice for ENGINEER IN CHARGE’s authorized
representative for inspection at the original equipment manufacturers’ factory in
India or abroad. All the expenditures in connection with deputing of Officials would
be borne by ENGINEER IN CHARGE. However, in case inspection results are not
satisfactory or all materials are not offered for inspection by the contractor, the
cost of second inspection incurred by ENGINEER IN CHARGE shall be recovered
from the bill of the contractor.
(iv) The Elevators to be supplied under this contract shall be offered separately for
factory inspection.

16.2 TESTS DURING INSTALLATION

 Tests & inspections – in stage – may be always / randomly conducted for at least
each of the following critical phases of work. This list is not inclusive but indicative.
48 hours’ notice is required prior to completing these phases to enable ENGINEER
IN CHARGE to carry out any checks deemed necessary. The following are the
minimum requirements: -
 Setting out the plum lines
 Erection and alignment of guide rails & rail brackets
 Erection & alignment of landing doors, sills, header, jambs etc.
 Positioning of hoist way equipment & controller etc.
 Erection / Fixing of landing fixtures

PAGE - 1048
16.3 1POST INSTALLATIONTESTSAT SITE
 Post installation test at site shall be conducted by the elevators system
supplier/installed in the presence of ENGINEER IN CHARGE as per IS 14665 PART
3 and PART 5 and the below is not an inclusive list. Also the elevators system
supplier/installer shall have to perform tests to confirm the performance
parameters in the presence of ENGINEER IN CHARGE post installation and
commissioning.
 The tools & tackles required for such tests will have to be brought in by the
elevators system supplier/installer. All test instruments shall be calibrated not
more than one year prior to their use. The contractor may be asked to submit
calibration certificates or other documents for proof of compliance.

(a) Leveling Test

 Accuracy of the floor leveling shall be tested with the elevators empty, fully
loaded.
 The elevators shall be run to each floor while travelling both in upward and
downward directions and the actual distance of car floor above/ below landing
floor shall be measured. In each case there shall not be any appreciable
difference in these measurements for leveling at the floors when the car is empty
and when it is fully loaded. The tolerances for leveling shall be as ±3 mm for
passenger/service elevators and + 5mm for freight elevators.

(b) Safety Gear Test

 Safety gear controlled by a governor should be tested with contract load and a
contract speed, governor being operated by hand. Two tests should be made,
however, with wedge clamps or flexible clamp safeties, one with contract load in
the car and the other with 68 kg (equivalent to one person) in the car. The
stopping distance obtained should be compared with specified figures and the
guides, car platform, and safety gear should be carefully examined afterwards for
signs of permanent distortion.
 Counterweight safety gear should be tripped by the counterweight governor and
the stopping distance noted. In this case, however the governor tripping speed
should exceed that of the car safety governor but by no more than 10 %.
 During the safety gear test, car speed (from the governor or the main sheave)
should be determined at the instant or tripping speed with that stated in IS / EN.
The governor jaws and rope should be examined for any undue wear.

(c) Contract Speed

 This should be measured with contract load in the car, with half load & with no
load and should not vary from the contract speed by more than 3%. The
convenient method is by counting the number of revolutions, made by the sheave
or drum in a known time. Chalk mark on the sheave or drum and a stop switch
will facilitate timing but care must be exercised to ensure that no acceleration or
retardation periods are included. If the roping is 2 to 1 the sheave speed is twice
the car speed. Alternatively, the speed can be measured by a tachometer applied
directly to shaft or a contact free tachometer immediately below the sheave.

PAGE - 1049
(d) Elevators Balance
 After the above test, some of the weight shall be removed until the remaining
weights represent the figures specified by the bidder. With this condition car at
half way travel the effort required to move the elevators car in either direction
with the help of winding wheel shall be as nearly as can be judge by the same.

(e) Car and landing doors interlocks

 The elevators shall not move with any door open. The car door relay contact and
the retiring release cam must be tested. The working of the door operation and
the safety edges and light equipment if any provided shall also be examined.

(f) Controllers
 The operation of the contactors and interlocks shall be examined and it shall be
ascertained whether all requirements laid down in the specifications have been
met.

(g) Normal Terminal Stopping Switches

 This shall be tested by letting the car run to each terminal landing in turn, first
with no load and then with contract load and by taking measurements, top and
bottom over travels can be ascertained.

(h) Final Terminal Stopping Switches

 The normal terminal stopping switches shall be disconnected for this test. It shall
be ensured that these switches operate before the buffers are engaged.

(i) Insulation Resistance

 This shall be measured (after removing the electronic PCB’s and their
connection) between power and control lines and earth and shall not be less than
5 mega-ohms when measured with D.C. voltage of 500 volts. Test certificates thus
conducted in the controlled factory environment shall be submitted.

(j) Earthing
 All conduits, switches, casing and similar metal work shall have earthing
continuity.

(k) Ropes
 The size, number construction and fastenings of the ropes should be carefully
examined and recorded.

(l) Buffers
 The car should be run on to its buffers at contract speed and with contract load
in the car to test whether there is any permanent distortion of the car or buffers.
The counterweight buffers should be tested similarly.

(m) Integrated System Test

 The elevators system supplier/installer shall co-ordinate and carry out
interfacing and integrated testing together with other System-wide Contractors
to ensure that the all integrated systems function as desired.

PAGE - 1050
PAGE - 1051
DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   

DBR & Technical Specifications

for IT Works at ATC cum
Technical Block, Indore

Page 1 of 23 
 
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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   

1. Introduction
1.1 The following details specify the scope of work, design & technical specification for all the IT Works
in the building as mentioned in the scope. It comprises the systems listed out in this document and
defines a turnkey solution.

2. Scope of Work
2.1 Set up of LAN, WLAN & WAN by providing Passive and Active Networking Components.

(A) Passive Cabling Works:-

I. At the ATC Tower cum Technical Block Integrated Local Area Network shall be
provided for all the Data requirement for the AAI users working at the ATC block.
II. The Contractor has to provide Integrated LAN Points for WLAN, Access Control
System, Internet or any other application that require internet or AAI Intranet for all
users in redundant mode.
III. The Contractor shall be responsible to provide connectivity (existing AAI Link) in
the new ATC Tower cum Technical Block. OFC & its accessories shall be provided
to connect with existing AAI link.
IV. The ATC Tower cum Technical Block will be having passive works like laying of
OFC backbone, UTP cabling and their associated components, installation of racks,
conduit, covered cable trays and Raceways.

(B) Active Networking Equipment:-

I. Active Networking Equipment (Core cum Distribution Switch, Wireless Controller /
Manager etc.) shall be provided by the Contractor in HA Mode.
II. Edge Switches, PoE+/ Non-PoE shall be provided for end node connectivity. PoE+
switches are required for Wireless Access Points etc.
III. Active Networking Equipment’s are required to establish WAN, LAN, WLAN at the
ATC Tower cum Technical Block for All Applications including Bio-Metric Access
Control system and other applications for all users. Users of these applications are
distributed across various floors of the ATC Tower cum Technical Block

2.2 Setup of Server Room

(A) Server Room:- Required space for Central Server Room and the locations of Edge switches and
Distribution switches shall be marked in the drawing. Requisite no. of Integrated Modular Data
Centre Rack (Servers & Network Racks) alongwith PDU, Networking and Other Security
Devices, Modular UPS with half an Hour Battery Back up, Precision Air Conditioning System,
Access Control, CCTV for Data Center, FSAS, Gas Supresson System, Anti Rodent, WLD,
Dedicated Earthing shall be provisioned by the vendor. Dual Power Sources etc shall be
provided in the Server Room by the vendor.

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2.3 Cabling for Access Control System as per BCAS guidelines: Count of Data points shall be
considered for locations where data node is required for Biometric Access Control system to be install
and only cabling shall be laid for the same accordingly.
Provision of access control system equipments and software is not in scope of this tender.

2.4 AMC/Warranty: All products should be offered with 2 Years OEM Warranty from the date of
completion of SAT (Site Acceptance Test). After 2 Years, products shall be under 5 Years AMC with
OEM Support/Service for all items.

3. Design Recommendations
3.1 Active Networking Components:- The key requirement is to design the LAN network for the
building which is redundant, robust, scalable & secure. The building LAN would also be connected
via redundant 10G OFC cables with the Distribution Switch placed at server room. The requirements
mentioned above also require critical applications to deliver information and data in real time.

3.2 The key features of network may be briefly outlined as:

(A) Guaranteed Application Response: The network backbone shall ensure that there is no delay
in the flow of information and data, irrespective of file size or amount of network traffic at any
given point in time.

(B) Scalability: The network shall be scalable as well as flexible so that future expansions can be
made.

(C) Energy efficient network hardware with small network footprint for ensuring lower cost of
operation and Green technology that reduced carbon footprint.

3.3 The 2-tier Network Architecture has been recommended for simplifying the design, implementation
and management operations:

3.3.1 Access Network Zone / Access Layer:

(A) The Access Layer consists of 24 port and 48 port POE+ / Non-PoE switches as per requirement,
which will give 1G connectivity to the end-points in the building eg. PC, Laptops, Network
Printers/Plotters, Access Points etc.
(B) The Ethernet switches shall have interconnection to the Core cum DS switches which are located
in the Data Centre/Switch Room in HA mode through 6 Core Single mode/ Multimode 10G Fibre
Connectivity.

(C) The access switches will have min 2 nos. 10G SFP+ uplink ports which will be used to connect
the switches to the core/distribution network. The Connectivity between Edge switches shall be
through stacking module or 10 G SFP+ Modules.

3.3.2 Core cum Distribution Network Zone :

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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   
(A) The Core cum Distribution layer comprises of a set of two Layer-3 Ethernet switches (HA mode)
configured to operate in a redundant cluster to which all the uplinks from Access/Edge switches,
Security Gateway and Server zone switches, Storage connect.

(B) Core cum Distribution Switches interconnection shall be through stacking/10G/40G fibre
connectivity.

3.4 Wireless Controller / Manager in HA mode:- used for centralized control, provisioning and
management of the Wireless network shall be located in the Core cum Distribution layer and will be
connected to the Core cum Distribution switches through Gigabit links.

Note:-
a. All Edge Switches shall be provided with Redundant Power Supply as per the requirement.

b. Ethernet (UTP/Copper) cable shall not be used between switch to switch connectivity. Only fiber
connectivity shall be provisioned for connectivity. Stacking modules along with stacking cables can
be used for switch to switch connectivity if these are installed in one rack. SFP modules can also be
used for switch to switch connectivity if these are installed in one rack. Switch to Switch
interconnection can be through Stacking Modules along with Stacking Cables or through SFP
modules.

c. Min. 8 Port PoE+ Managed Industrial Grade Access Switch with 2x10G SFP & IPV6 Logo ready/
Certified can be used for remote location connectivity as per site requirement.

d. VLANs need to be created,as per the site requirement and on the basis of user group / application
based and access between VLANs shall be provided as per the security of the data and systems.

e. All switches shall be installed in closed and secure environment. No Open Rack should be provided.

f.
Quantity and Capacity of the Racks, shall be as per site requirement however minimum two 42U Smart
Rack shall be provided for server room in addition to racks requested for specific application server,
storage & field networking rack .
3.5 Setup of Server Room :

3.5.1 Central Server Room & Hub Room at field locations (if required) shall be setup. Central Server Room
shall be provisioned with Integrated Modular Data Rack Solution having UPS with half an hour battery
backup, Precision Air Conditioning, Access Control, CCTV for monitoring etc.

3.6 Passive Cabling Components –

3.6.1 Fiber Cable (6 Core SM/MM) laying in redundant mode (through different route and mesh topology)
and laying of UTP Components (Min. CAT6A Cabling U/UTP Solution) is required.

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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   
3.6.2 Contractor shall provide an “end to end connected I/O Node” per 15 Sq. Meter (in effective &
operational areas of the building) covered space area of the buildings. Contractor shall be
responsible to provide all the data node for all requisite application as per the site requirement.

3.6.3 LAN points redundancy shall be applicable for important LAN Devices.

3.6.4 The LAN Structured cabling should be of CAT 6A UTP or latest. All user nodes of passive cabling
should be on CAT 6A (10G) networks
3.6.5 Third party test should be done for certification of Copper and Fiber nodes. Fiber cable should support
10G or higher transmission. The IT network backbone shall have redundancy in fiber optic cable
topology. All the structured cabling should be ANSI/IEIA/TIA approved for appropriate work. The
passive cabling shall be laid as per BICSI standard.

3.6.6 Count of Data points shall be considered for locations where data node is required for Biometric
Access Control system to be install and only cabling shall be laid for the same accordingly.

3.6.7 Fiber route markers with arrow showing the route as per site requirement are required.

3.6.8 Cables should be appropriately labeled. The labeling scheme must identify the associated physical
locations (building, room, cabinet, rack, port, etc.). cables and connecting hardware should be labeled.

3.7 AMC/Warranty– All products should be offered with 2 Years OEM Warranty from the date of
completion of SAT (Site Acceptance Test). After 2 Years, products shall be under 5 Years AMC with
OEM Support/Service for all items. All Inclusive Comprehensive Maintenance of ITC for 5 years after
DLP including trouble shooting, preventive maintenance and breakdown maintenance, supply of all
spares and accessories and replacement of batteires of UPS as required etc. as required as per good
engineering practice, recommendation of the manufacturer, instructions of Engineer-in-Charge/ as per
terms and conditions specified.

4 General Guidelines
A. Terms & conditions

 Payment against AMC shall be made quarterly after successful completion of services in the
quarter.

 GoI orders regarding Preference to Make in India / MSEs shall be followed.

B. General Guidelines regarding Offered Products

1) The capacity given in the specification is minimum and Contractor has to provide as per requirement.

2) All Electrical / Power Requirement shall be designed accordingly. UPS power supply for 24x7 to all
Active Networking Equipments is mandatory.

3) UPS supply should be provided to all Active Networking Components installed at Field/Remote Racks
for uninterrupted service during power down.

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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   

4) OEM of all offered products should have Technical Support Center presence in India.

5) There should be compatibility of network with existing equipments at the airport (if applicable).

6) All Covered Cable Trays, concealed Conduit and other accessories like HDPE/GI Pipe/Channel
Conduit shall be provided for the passive cabling works by Engg-Electrical Contractor as per site
requirement.

7) CableTray/ HDPE/ GI Pipe/ Conduit/ Channel conduit shall be confirming to the specifications similar
to respective engineering items.

8) The offered equipment by the Contractor shall be fully complied with the specifications to full fill the
requirements. Higher specifications suitable to requirement can be accepted. The offered products
should be complied by the standards given in the specifications or its equivalent standards in respective
category.

9) The design and selection of the offered IT networking components by the Contractor shall be consistent
with the requirements of long term trouble free operation with highest degree of reliability and
maintainability.

10) The offered equipment by the Contractor shall be designed for continuous operation (24-hours a day
and 365-days an year).

11) All offered equipments should be standard proven product already available in the market. Offered
Item should not be end of life or end of sale.

12) MAF & a letter from OEM shall be submitted in regards of warranty support & Non –Refurbished
items, and no End of Life/End of Sale against the offered product. OEM has to ensure that the support
shall be provided for the offered products during the concurrency of the contract.

13) All types of spares and spare modules of the offered equipment shall be readily available with the
Contractor during life-time of the equipment, for maintenance, repairs and up keep of the equipment
during warranty & CAMC period, if applicable.

14) The offered equipment by the Contractor shall furnish the details of EMI and Safety Standards met by
his equipment and built-in safety features.

15) The offered equipment shall be constructed on a modular basis, using plug-in type units and
components to the extent possible. Parts subject to failure, wear, corrosion or other deteriorations or
requiring occasional inspection, adjustment or replacement shall be made accessible and capable of
convenient inspection and removal.

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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   
16) All offered/supplied Hardware system/component and Software by Contractor shall be licensed, as
applicable, in favour of Airports Authority of India and valid for lifetime of the offered system.

17) Contractor has to offer/supply Passive Cabling Components as specified in the NIT or better and latest
upgraded model/version if available in the market at the time of execution.

18) Items mentioned in document is minimum. Contractor has to provide all requisite accessories/items
which are not included in the document to achieve the functionality of the NIT.

19) General Guidelines Regarding Contractors

1) Installation/Configuration shall be carried out by technically well qualified and certified

personnel as per the requirements.

2) Contractors shall not outsource any part of the contract to any other vendor/third party contractor
without prior permission of AAI.

3) Liability, if anything, arising out of such third party contracts to any other vendor by contractor
shall be to the contractor’s account.

4) AAI shall not be liable on behalf of contractor to any other third party contractor/ Government
of India/State/Regulatory Authorities.

5) Any liabilities arising out of such third party contracts by contractor or its men working at site
shall be only to contractor’s account and shall be deducted out of its running bills.

6) Contractor shall submit Police Verification Certificates and obtain necessary Airport Entry
Permits, for allowing its men to work at AAI restricted premises.

7) Vendor has to survey for final bill of quantity before implementation of work or procurement or
approval from AAI Site In-charge.

5 Site Acceptance Test (SAT) & Commissioning

5.1 It shall be the responsibility of the Contractor firm to submit the system test procedure for conducting
the post-installation site acceptance testing. The procedure submitted by the Contractor firm shall be
drafted in line with the standard practices followed in the industry and shall be in accordance with the
test procedures & practices specified by the OEM. The acceptance test procedure on approval by AAI
shall become the document for acceptance of the equipment after installation at the site.

5.2 The draft copy of system test procedure shall be made available to AAI before THIRTY calendar days
of the schedule site acceptance date.

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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   
5.3 The Contractor firm shall supply, install, test and commission all hardware and software as per the
requirement of the tender with the system. Contractor firm shall supply Technical documents (hard and
soft copy - one set each) at site. The system shall be commissioned after successful completion of –
SAT approval, operational & maintenance training and all the works under the scope of the tender.

6 Patents, liability & compliance of regulations

6.1 Contractor firm shall protect and fully indemnify AAI from any claims for infringement of patents, copy
right, trademark or the like.

6.2 Contractor firm shall also protect and fully indemnify AAI from any claims from Contractor firm’s
workmen/ employees, their heirs, dependents, representatives, etc. or from any other person(s) or bodies/
companies, etc. for any act of commission or omission while executing the order.

6.3 Contractor firm shall be responsible for compliance with all requirements under the laws and shall
protect and indemnify AAI completely from any claims/penalties arising out of any infringements by
Contractor firm or its workmen/ employees.

7 Documentation & Training

Two set each of soft copy and hard copy of Installation, Operations including theory of operation,
Technical Manual, Maintenance manual; Troubleshooting of the system, procedure for loading of the
system and application software, etc. shall be supplied at site. The Operation, Technical and
Maintenance manual will cover:-

(a) Details of each active and passive component, serial no., IP address, Login Id and Password,
version reports, configuration reports, Detail Bill of Material, spares, Acceleration Matrix to log
a complaint etc.

(b) General technical description, Block Diagram, Schematic/ flow diagrams (I/O level), Drawing of
Passive Cabling laid in the building shall be required.

(c) Preventive maintenance procedures & Support Escalation Matrix

(d) Fault analysis - schematic diagrams

(e) Technical & operational manuals with user Operational Training.

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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   

Technical Specifications
Active Networking Equipment
Sr. No. DESCRIPTION
1 SITC of Core cum Distribution Switch (24 Port) in HA mode
2 SITC of 48 Port Access Switch Non-PoE
3 SITC of 24 Port Access Switch PoE+
4 SITC of 24 Port Access Switch Non PoE
5 SITC of Wireless LAN Controller/Manager in HA mode
6 SITC of Wireless AP (Indoor)
7 SITC of SFP modules 10G (SM) as per requirement
8 SITC of Stacking cable with Pair Stacking module

Passive Cabling Components

Sr. No. DESCRIPTION

9 Optical Fiber Cable 6 core (SM)
10 12 Core Fiber LIU Loaded with pigtail
11 LC to LC Fiber Patch Cord Single Mode 1 Meter
12 SITC of CAT 6A 4 pair U/UTP Cable
13 24 Port CAT 6A UTP jack Panel (Fully Loaded)
SITC of CAT 6A I/O, Face Plates- Single, Double, GI Box, as
14
per Requirement.
15 SITC of CAT6A Patch Chord -1 Meter
16 SITC of CAT6A Patch Chord -2 Meter
SITC of 12U/15U Wall Mount Network Racks fully
17
loaded with PDUs (with required depth.)
18 SITC of Integrated Modular Data Centre Rack
Preventive & Corrective comprehensive annual
19 maintenance (CAMC), as per best practice adopted.
(After 2 years of DLP)

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DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   

Technical Specifications
Active Networking Components
Item No. 1

Core cum Distribution Switch

S. No Generic Requirements

Switch should be with minimum 24 no. of 10 Gig SFP+ ports and 4 nos. of 40 Gig QSFP ports
1
from Day-1.

2 Switch should support for Active-Active High Availability or Virtual Chassis / Stacking.

Switching system shall have minimum 800 Gbps of switching fabric and minimum 570 Mpps of
3
forwarding rate. Switch should have 2GB DRAM and 2GB internal/external Flash.

4 Switch should have hot swappable 1:1 redundant internal power supply.

5 Power supply, fan modules and interface modules should be hot swappable.

6 Switching system shall have minimum 32k MAC Addresses and 1K active VLANs.

Switch should support minimum 1500 ACLs, 2k Multicast and 5k Unicast Routes for IPv4 and
7
IPv6.

Should support IEEE Standards of Ethernet: IEEE 802.1D, 802.1s, 802.1w, 802.3ad, 802.3x,
8
802.1p, 802.1Q

Should have static routing, OSPF, OSPFv3, BGP, HSRP for IPv6/VRRPv3, VRF (Virtual
9 routing and forwarding), IGMP v1/v2/v3 and PIM multicast routing, VXLAN, Policy based
routing.

Shall have 802.1p class of service, classification, policing/shaping. Should support strict priority
10
queuing.

Switch should support management features like SSHv2, SNMPv2c, SNMPv3, NTP, RADIUS
11
and TACACS+.

Switch should support port security, DHCP snooping, Dynamic ARP inspection, IP Source
12
guard, BPDU Guard, Spanning tree root guard.

13 Switch should have IPv6 security features to protect against ipv6 spoofing attack

Should support 802.1x authentication and accounting, IPv4 and IPv6 ACLs and Dynamic VLAN
14 assignment. Switch should support MACSEC. Switch should support control plane policing to
protect switch CPU from DoS attack

Switch shall support application visibility/ insight and traffic monitoring using net Flow/ s flow/
15
j flow entries.

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Switch shall conform to UL 60950 or IEC 60950 or CSA 60950 or EN 60950 Standards for
16
Safety requirements of Information Technology Equipment.

Switch shall conform to EN 55032 Class A/B or CISPR22 Class A/B or CE Class A/B or FCC
17
Class A/B Standards for EMC (Electro Magnetic Compatibility) requirements.

Switch/Switch Series should be tested and certified for EAL 2/NDPP or above under Common
18
Criteria Certification.

19 Switch/ Switch Series should be IPv6 Certified/IPv6 logo ready.

Switch should support Operating Temperature Range of 0°C to +40°C. ± 5°C Temp variation on
20
lower and higher side is acceptable.

Switch should support Operating Humidity of 15% to 85% noncondensing. Better Humidity
21
percentage variation is acceptable.

Item No. 2

Access Switch : 48 Port non PoE

S. No Generic Requirements

Switch should be 1RU with minimum 48 nos. 10/100/1000 Base-T ports and additional 4 nos.
1
SFP+ uplinks ports.

Switch should have slot/ports (excluding uplinks) for minimum 80 Gbps of stacking bandwidth
2
with dedicated stacking ports and cables with minimum 8 switch in stack.

3 Switch should support field replaceable and internal redundant power supply.

Switch shall have minimum 176 Gbps of switching fabric and 130 Mpps of forwarding rate.
4
Switch should have 2GB DRAM and 2GB internal/external Flash

5 Shall have minimum 16K MAC Addresses and 512 active VLANs.

Switch must have L3 functionality like static routing, RIP, PIM, OSPF, PBR & QoS features
6
from Day1. Shall have 802.1p class of service, classification, policing /shaping.

Switch should have IPv6 security features to protect against IPV6 spoofing attack. Switch should
7 support MACSEC. Switch should support control plane policing to protect switch CPU from
DoS attack

8 Should support 802.1x authentication and accounting, ACLs and VLAN assignment.

Switch shall support application visibility/ insight and traffic monitoring using net Flow/ s flow/
9
j flow entries.

Switch should be tested and certified for EAL 2/NDPP or above under Common Criteria
10
Certification.

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11 Switch/Switch Series should be IPv6 Certified/IPv6 logo ready.

Switch should support Operating Temperature Range of 0°C to +45°C. ± 5°C Temp variation on
12
lower and higher side is acceptable.

Switch should support Operating Humidity of 15% to 85% noncondensing. Better Humidity
13
percentage variation is acceptable.

Item No. 3 

Access Switch : 24 Port non PoE 

S. No  Generic Requirements 

Switch should be 1RU with minimum 24 nos. 10/100/1000 Base‐T ports and additional 4 nos. 
1 
SFP+ uplinks ports. 

Switch should have slot/ports (excluding uplinks) for minimum 80 Gbps of stacking bandwidth 
2 
with dedicated stacking ports and cables with minimum 8 switch in stack.  

3  Switch should support field replaceable and internal redundant power supply.  

Switch shall have minimum 128 Gbps of switching fabric and 95 Mpps of forwarding rate. 
4 
Switch should have 1GB DRAM and 2GB internal/external Flash. 

5  Shall have minimum 16K MAC Addresses and 512 active VLANs. 

Switch must have L3 functionality like static routing, RIP, PIM, OSPF, PBR &QoS features from 
6 
Day1. Shall have 802.1p class of service, classification, policing / shaping.  

Switch should have IPv6 security features to protect against ipv6 spoofing attack. Switch should 
7  support MACSEC. Switch should support control plane policing to protect switch CPU from DoS 
attack 

8  Should support 802.1x authentication and accounting, ACL, VLAN assignment.  

Switch shall support application visibility/insight and traffic monitoring using net Flow/ s flow/ j 
9 
flow entries. 

Switch should be tested and certified for EAL 2/NDPP or above under Common Criteria 
10 
Certification.  

11  Switch should be IPv6 Certified/IPv6 logo ready.  

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Switch should support Operating Temperature Range of 0°C to +45°C. ± 5°C Temp variation on 
12 
lower and higher side is acceptable. 

Switch should support Operating Humidity of 15% to 85% noncondensing. Better Humidity 
13 
percentage variation is acceptable. 

Item No. 4 

Access Switch : 24 Port PoE 

S. No  Generic Requirements 

Switch should be 1RU with minimum 24 nos. 10/100/1000 Base‐T ports with PoE+ capability 
1  and minimum 720W of PoE Power and additional 4 nos. SFP+ uplinks ports.  Switch should 
support minimum 8 Nos. of Multi Gigabit ports out asked 24 nos. of Base‐T ports. 

Switch should have slot/ports (excluding uplinks) for minimum 80 Gbps of stacking bandwidth 
2 
with dedicated stacking ports and cables with minimum 8 switch in stack.  

3  Switch should field replaceable and internal redundant power supply.  

Switch shall have minimum 272 Gbps of switching fabric and 112 Mpps of forwarding rate.  
4 
Switch should have 1GB DRAM and 2GB internal/external Flash. 

5  Shall have minimum 16K MAC Addresses and 512 active VLANs. 

Switch must have L3 functionality like static routing, RIP, PIM, OSPF, PBR & QoS features from 
6 
Day1. Shall have 802.1p class of service, classification, policing / shaping.  

Switch should have IPv6 security features to protect against IPv6 spoofing attack. Switch should 
7  support MACSec. Switch should support control plane policing to protect switch CPU from DoS 
attack. 

8  Should support 802.1x authentication and accounting, ACLs and VLAN assignment.  

Switch shall support application visibility and traffic monitoring using net Flow/ s flow/ j flow 
9 
entries. 

Switch should be tested and certified for EAL 2/NDPP or above under Common Criteria 
10 
Certification.  

11  Switch should be IPv6 Certified/IPv6 logo ready.  

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Switch should support Operating Temperature Range of 0°C to +45°C. ± 5°C Temp variation on 
12 
lower and higher side is acceptable. 

Switch should support Operating Humidity of 15% to 85% noncondensing. Better Humidity 
13 
percentage variation is acceptable. 

Item No. 5

WIRELESS LAN CONTROLLER/MANAGER

S. No Generic Requirements

1 Generic Requirements

Solution must be compliant with IEEE CAPWAP/LWAPP/HTTPS/VxLAN/IPSEC/EoGRE or

2
equivalent standard.

All required licences as per site requirement & mentioned specifications of complete solution to
3 achieve the functionality should be provided from day 1. Device should be scalable to minimum
250 AP in same hardware and minimum 5000 clients.

4 Device must have at least 2x10G or 2x1G Fiber uplink interfaces.

5 Solution Should have minimum 4 Gbps encryption throughput.

6 Device Must support 1:1 redundancy models

Device Must support an ability to dynamically adjust channel and power settings based on the
7
RF environment

Device Must support coverage hole detection and correction that can be adjusted on a per
8
WLAN basis.

9 Device should support L2 and L3 roaming of IPv6 clients

10 Device should support IP6 functionality

11 Device should support Native IPv6 and client IPv6.

Device Should adhere to the strictest level of security standards, including 802.11i, WPA3,
12 WPA2, WPA, 802.1X with multiple Extensible Authentication Protocol (EAP) types, PEAP,
EAP-TLS, EAP-TTLS

Device Should support Management frame protection for the authentication of 802.11
13
management frames by the wireless network infrastructure

14 Device should have rogue AP detection, classification and automatic containment feature

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Device should be able to detect attacks like Broadcast de-authentication / NULL probe from
15
day one for all access points

16 Device Must support 802.11e and WMM

Device should have Voice and Video Call Admission and Stream prioritization for preferential
17
QOS

Item No. 6

ACCESS POINT (INDOOR)

S. No Generic Requirements

Access Points proposed must include radios for 2.4 GHz and 5 GHz with 802.11ac Wave 2 and
1 802.11ax.

Must have a robust design for durability. AP should support operating temp 0 to 40 degree C and
2
Humidity: 5% to 93% non-condensing. Better specifications are acceptable.

3 Mounting kit should be standard from OEM directly.

Must support 4x4 multiple-input multiple-output (MIMO) with four spatial streams on 5 Ghz
4
along with support of OFDMA and MU- MIMO.

5 Must support data rates 2400 Mbps or more

6 Must support up to 21dbm of transmit power in both 2.4Ghz and 5Ghz radios.

Must have 1 nos. or more of multi gigabit ethernet (RJ-45) – IEEE 802.3bz supporting
7
POE/POE+ with data rate up to 100, 1000, 2500 Mbps

8 Must have minimum 16 SSIDs.

9 AP Should support detecting wireless interferences

10 AP Should support Radio resource management for optimum wireless

11 Must operate as a sensor for wireless IPS.

12 Access Points must support a distributed encryption/decryption model.

13 Must be plenum-rated (UL2043).

14 AP must be Wi-Fi 6 Certified.

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Item No. 7

10G SFP+ MODULES

S. No Generic Requirements

1 Connector types LC

2 10G Base-LR / 10G Base-SR

3 Support 10 Gbps up to 10 KM on SMF / up to 300 M on MMF

4 Should be from same OEM of switches.

Item No. 8

Stacking cable with Pair Module

S. No Generic Requirements

Minimum 48 Gbps of stacking bandwidth with dedicated stacking ports and cables with
1 minimum 8 switch in stack.

2 Should be from same OEM of switches.

Passive Cabling Components 

Item No. 9 
6 CORE Optical Fibre Cable (SM) 
S. No  Generic Requirements 
6-core OFC, Unitube /Multi tube, MDPE/HDPE Sheath, Single Mode, Gel Filled, Outdoor
1 
Stranded Loose Tube, RIP Cords -1 Nos., UV stabilized Cable.

2  Fibre Optic Cable:  9/125μm, OS2, IEC 60794‐1/IEC 60794‐3‐10, Qualifies as per TIA‐492CAAB 
(OS2).

3  Cable is tested in accordance with Telcordia GR‐20, Water Penetration Test Method: 24 h as per 
IEC 60794‐1 F5, RoHS Compliance, and Corrugated Steel tape Armour. 
Fibre cable Diameter Over Jacket should be max. 11.5 ± 0.5 mm, Tensile Strength, short
4 
term should be min. 2700 Newton and long term min. 810Newton

5  The Attenuation shall be max.0.40dB/km @ 1310nm, and max. 0.30dB/km @ 1550nm;

6  Operating Temperature: -30 degree Celsius to +60 degree Celsius; variation up to ±10
degree Celsius is acceptable.

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Item No. 10 
12 Core Fibre LIU Loaded with pigtail 
S. No  Generic Requirements 
12F, 1U, LC Style, OS2 SM with Pigtail, loaded with Splice tray & Couplers & Splice
1 
Protectors (Fiber Optic LC style fully loaded Patch Panel (FOPP)

19" Rack Mount with min 12 nos. of OS2, 9/125μ, Single mode, Low Smoke Zero Halogen
2 
(LSZH) Sheath Pigtails; RoHS Compliance.

Metal/Alloy housing fully powder coated, Splice tray and cable spools, grooves for fixing
3  splice protective sleeves (inbuilt or additionally). No. of OSP Cables for termination
Minimum 2. The Patch Panel shall provide a minimum of two cable entry point.

4  Optical Performance of Pigtails: Insertion Loss, maximum: 0.34 dB & Return Loss,
minimum: 50.0 dB

5  Optical Components Standard: ANSI/TIA-568-C.3/TIA-568-D.3

Item No. 11 
LC‐LC SM OS2 Patch Cord 
 S. No  Generic Requirements 
1  LC‐LC Style Single mode, LSZH, Sheath as per flame test method IEC 60332‐3/IEC 60332‐3C, IEC 
60754‐2/IEC 60754‐20,Duplex Patch Cord, Bend Insensitive Fiber Optic Patch Cable (LC‐LC), 1/2/3 
Mtrs. Long, ISO/IEC‐11801/ISO/IEC 11801‐1‐OS2 9μ Duplex, 

2  RoHS compliant fiber optic patch cords shall include LC, LC connectors on both ends. 

3  Cable Shall comply ANSI/ICEA S‐83‐596/TIA‐492CAAB, and Telcordia GR‐409/ Telcordia GR‐326‐
CORE issue 4, Optical Components Standard: ANSI/TIA‐568C.3/ANSI/TIA 568.3‐D 

4  Optical Performance of Pigtails: Insertion Loss, maximum: 0.34 dB & Return Loss, minimum: 50.0 
dB 

Item No. 12

Cat 6A , U/UTP Cable Box -305 Mtrs.

S. No Generic Requirements

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4-pair, Cat 6A UTP Cable, Channel performance up to 500 MHz or more, Category-6A with ETL
1 4 connector performance channel test report as per ISO/IEC 11801 and Factory verified test
report,23 AWG bare solid copper

Meets EIA/TIA 568-C.2/ANSI/TIA 568,2-D Category 6A specifications, Cat 6A U/UTP

2
Solution. RoHS Compliant/EN 50575 Class Eca.

Worst Case Cable Skew: ≤45 nsec/100 meters Characteristic Impendence: 100±6 Ù@ 1-
3 500 MHz or as per ANSI/TIA 568 C.2/ ANSI/TIA 568,2-D DC Resistance Max: 9.5
Ohms/100m, LSZH

Sheath should be LSZH as per flame rating standard IEC60332-3-22/IEC60332-1, IEC

4 61034-2/ IEC 61034, IEC 60754-2/ IEC 60754, Operational Temp: -20º to 60º

Item No. 13

Cat 6A UTP Information Outlet with Face Plate & Box

S. No Generic Requirements

Cat 6A UTP Jack PCB based Information Outlet (I/O) RJ45, TIA-568 C.2 / TIA-568 2.D
1
Category-6A. UL Listed

High-impact, flame-retardant, UL- RATED 94v 0 thermoplastic – ABS/Glass-reinforced

2
Nylon

Contact Resistance: maximum 100milli ohms; Insulating resistance minimum 500 milli
3
ohms; Current Rating : 1.5 A (max) , Contact : 50u'' gold over 100u'' nickel)

Meets and exceeds ISO/IEC 11801:2002 Category 6 ,EIA/TIA 568-C.2/ TIA-568 2.D
4
Category 6A ROHS compliant

Single Port / Dual Port Faceplate of size 3x3. Material should be ABS /UL94 V-0 with spring
5 shutter. Faceplates shall accept all Modules for UTP, STP, fiber-optic, and audio/video
applications.

Item No. 14
Jack Panel – loaded (24 Port)
S. No Generic Requirements

Cat 6A U/UTP, 24-port loaded Modular, Straight/Angled Jack Panel. Loaded

1 with 24 nos. UTP ports for PCB based IO Jacks, 1U size.

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Modular, PCB based and Keystone type Unshielded Twisted pair, EIA/TIA 568-C-2/ TIA-
568 2.D, UL Listed, RoHS. Current Rating” 1.5A @20ºC or 68ºF
2
3 Cable Guide way to guide the cable on the rear side

Item No. 15
Cat 6A Patch Cord – 1 Meter

S. No Generic Requirements

1 3 Feet Cat 6A U/UTP Patch Cable, TIA- 568C/ TIA-568 2.D Category- 6A, UL-listed/ETL, RoHS
2 Patch cords shall be of solid copper cable with UL/ETL Listed.

3 Plug Insertion Life Min. 750 times

4 Patch cords sheath shall be LSZH as per IEC 60332-3/ IEC 60332-3-22, IEC 60754-2/ IEC
60754, IEC 61034-2/ IEC 61034, Operational Temp: -20º to 60º Celsius

Item No. 16
Cat 6A Patch Cord – 2 Meter
S. No Generic Requirements

1 7 Feet Cat 6A U/UTP Patch Cable, TIA- 568C/ TIA-568 2.D Category- 6A, UL-listed/ETL, RoHS

2 Patch cords shall be of solid copper cable with UL/ETL Listed.

3 Plug Insertion Life Min. 750 times
4 Patch cords sheath shall be LSZH as per IEC 60332-3/ IEC 60332-3-22, IEC 60754-2/ IEC
60754, IEC 61034-2/ IEC 61034, Operational Temp: -20º to 60º Celsius

Item No. 17

Wall Mount 9U/12U/15U Rack

S. No Generic Requirements

Should be 9U/12U/15U Height Rack and have 19” mounting bracket in front & rear and wall
1
mountable with side panels, Front Glass Door with lock. Depth: min. 600 mm

2 Fans 90 CFM 230 VAC with 2 cooling fans on top

3 PDU Horizontal 5 Amp with 6 sockets

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4 1U Wire Manager; Mounting Hardware

Item No. 18 
Integrated Modular Data Centre Rack 
1. General Requirements: 
Integrated Rack Data Centre Solution suitable for 15 kW IT load distributed in 3 Racks.  with 
A 
redundant UPS and Cooling. 
Integrated racks having minimum 5 out of 7 critical equipment like Precision cooling, UPS, 
Racks, IP PDU, Smart DB Panel  and Monitoring system along with temperature & humidity 
B  sensor, IP Camera from same OEM. 
OEM shall be responsible for overall design and optimum functioning of integrated rack 
infrastructure. A certificate/ undertaking in this regard shall be submitted from OEM. 
The    detail    specifications    of    the    intelligent    integrated/inbuilt infrastructure, 
C 
standalone system shall be in adherence to standard Data Centre guidelines  
2  Precision Cooling System:‐ (uniform distribution of cooling from 1U to 42U) 
A  Cooling System should be DX (Variable) type In‐Row closed loop precision cooling system of 
min.15 kW capacity with N+N redundancy. Shall have heater and humidifier for precise 
parameters 
C  Cooling system capacity must be rated at 45˚C ambient temperature, 22˚   +/‐1 C in front of 
server racks and maximum 28˚ C return air temperature. Condenser Size should be selected as 
per 45˚C ambient condition. 
  Each compressor variable capacity Scroll Compressor running on DC INVERTER brushless 
E  technology, R410 gas) should be equipped with preset high and low pressure switches for 
protection against high condensing and low evaporating temperatures. 
3  UPS 
A  Design, Installation, testing and commissioning of Rack /19” frame mountable  
2 x 15 KVA/15 kW UPS (LCD Display), in N+N redundancy 3‐Phase Input / 1‐Phase Output 
Technology and Capability : 
a) True Online configuration with double conversion UPS  
b) Nominal Output voltage for 1ɸ : 220, 230, 240 Vac (1Φ) 
c) UPS should have IGBT topology for both PFC (power factor correction) and inverter. 
Efficiency of 93% or higher 
B  Measurements (On LCD) :  
Input: Voltage / Frequency,  Output: Voltage / frequency/, Load percentage, Battery Voltage, 
C  Back‐up time – 30 min  with each UPS 
Battery Type: VRLA , Batteries are to be kept in Closed Cabinet. 
Battery Backup Calculation: to be provided by vendor 
4  Integrated Racks 

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A  42U size, Min. 600mm width Server/Network Rack with front glass door with comfort handle, 
lock insert, Top cover with cutout with cover plate for cable entry(with Horizontal and Vertical 
cable manager). 
Depth of 42U rack used in system is min. 1000mm.  Blanking panels for 100% rack U space 
required 
5  Power Distribution System 
Intelligent rack PDU 32A, 200‐240V with PDU level monitoring with minimum 24 nos. IEC C13 
  sockets and 4 nos. of IEC C19 with power cord for PDU input. Vertical installation saving 
A  valuable rack space, LCD/LED current display & overload warning indicator, Branch circuit 
breaker protection,  
  There shall be integrated electrical DB panel with energy meter and same to be mounted on 
B  separate utility cabinet. 
6  Fire Detection and Suppression System 
Integrated rack solution should have integrated fire detection and suppression system inbuilt 
  and entire enclosed volume of the rack containment should be protected with fire detection 
A  and suppression system. Fire suppression agent shall be Novec 1230 gas as per NFPA 2001 
guidelines. 
7  Access Control System 
Biometric access control system shall be deployed for access of integrated rack infrastructure 
  to authorized persons only. The system shall have dedicated access controller & biometric 
A  reader. Biometric Reader will be integrated with access controller & EM locks of both front & 
rear door of server racks to provide authorized entry.  

8  IP Camera  

Supply & Installation of 2 nos. of Fixed Dome type Network Camera, 2MP, 30 fps @ 
1920x1080, should be capable of Night Visibility, Built‐in IR Illuminators, and Effective up to 30 
A  Meters, Smart Motion Detection to reduce false alarm, Weather‐proof IP66 / Indoor 
application and Vandal‐proof IK10‐rated Protection. The IP camera shall be integrated with 
NVR system of 4 channel to allow storage up to minimum 30days.     

9  Environmental Monitoring System 
A  Integrated rack infrastructure shall have IP based monitoring system for all the rack 
parameters with sensors and notification system. It shall include sensors kit of Temperature/ 
Humidity, Water Leak Detection, Door, Smoke & Alarm Beacon and shall continuously collects 
critical information from environmental sensors & UPS system, Cooling Units be capable of 
sending Email notifications.  
10  Rodent Repellent system for integrated rack infrastructure 
11  Installation 
A  The entire system shall be installed and commissioned as per OEM recommendations & 
instructions including all interconnections for supply and control circuit. 
12  Past Experience 

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  OEM must have supplied min. 2 such systems using In‐Row type Cooling of min. 10Kw Cooling 
in N+N  
13  OEM must have ISO 9001, ISO 14001 and ISO 45001/50001 for factories in India. 

Item No. 19

(Comprehensive AMC)

All IT components are under 2 years OEM warranty.

Following points to be ensured by the contractor during warranty & AICMC of IT system
Sr. No. DESCRIPTION

Preventive & Corrective comprehensive annual maintenance (CAMC), as per best

practice adopted. All Inclusive Comprehensive Maintenance of all IT Components for
1 5 years after DLP including trouble shooting, preventive maintenance and breakdown
maintenance, supply of all spares and accessories and replacement of batteries of UPS
as required etc. as per good engineering practice, recommendation of the
manufacturer, instructions of Engineer-in-Charge/ as per terms and conditions
specified.
2 Technical support and diagnosis should be provided in case of failure of IT Equipment.

The contractor shall replace any parts, including the supplied software found defective
3 during Warranty period without any charges whatsoever to AAI. The services of the
contractor or his principals, if required during this period, for such work shall also be
made available without any cost to the Authority.
Least inconvenience to staff working in the offices must be ensured while carrying out
4 the work. The preventive maintenance is to be carried out independently during the
lean period without affecting the Airport operations.
5 The equipment and its accessories shall be handed over to AAI in fully serviceable
condition on expiry/termination of the contract.
6 The UPS Battery backup system check - once in a week and one UPS at a time, and
maintenance of battery voltage records and necessary rectification action.
7 Daily, Weekly, Monthly and quarterly monitoring with probable cause as a part of
proactive approach.
8 Restoration of operation of system after any failure using hot-standby/spare
equipment. Installation of software as and when required.
In case of any breakdown, the contractor maintenance personal shall rectify the fault and
restore the equipment and system to the satisfaction of the AAI Officer In-charge within
9 48 Hours of reporting of the fault.
After rectification, operation and performance of the system shall be checked and
maintained to the satisfaction of the AAI Officer In-charge.
10 Contractor shall replace UPS Battery after two years, within the warranty and subsequent
AICMC period. AAI shall not pay anything extra for replacement of batteries.

Page 22 of 23 
 
Page - 1073
DBR & Technical Specifications for IT Works at ATC cum Technical Block, Indore
   

The repairs/maintenance of equipment are to be carried out at site. In case of a defect in

equipment/its accessories, necessitating major repairs at the service centre of the
contractor, the same may be taken to service centre under intimation to the AAI Officer
In-charge. In such cases, all expenditure and arrangement to dispatch, repair and return of
the equipment/sub-assembly shall be borne/carried out by the contractor. Penalty shall be
levied for delay beyond the prescribed time in setting right the equipment. The original
11 equipment has to be reinstated at site after the repairs have been carried out at service
centre at the earliest.
Payment: Comprehensive AMC charges shall be paid by AAI quarterly, after the
completion of each quarter for the work done in previous quarter on production of bill and
submission of service reports, duly signed by AAI Officer In-Charge. All the necessary
recoveries/ deductions for which firm has made themselves liable for, shall be deducted
from the bills before releasing the payment.
All the complaints/TAC cases will be initiated within same day and the service provider
will have to ensure minimum uptime of 95% in a month and 97% in a year. Penalty shall
be levied for the delay, beyond the prescribed time under the scope in setting right the
equipment. In case of partial/complete failure of the equipment, on expiry of prescribed
12 time limit, recovery shall be made @ 1% of the Annual maintenance charges, per week
(part of the week shall be considered as one week) system or its accessories from the
quarterly bill of the running quarter. However, if a suitable fully functional replacement
(similar or higher technical specifications) is provided by the contractor in place of faulty
equipment within prescribed time, no penalty shall be levied.

Page 23 of 23 
 
Page - 1074
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

TO THE NOTICE OF DEPTT. OF PLANNING.

LAND FOR COMMERCIAL USE

(AREA: 5-7 ACRES) 10.0 ACRES OF LAND AREA FOR
AAICLAS CARGO AND E-COMMERCE
EXISTING
20.48 ACRES LAND TERMINAL BUILDING 1500 SQM ALLOTTED TO MP WAREHOUSING
2 AND LOGISTICS CORPORATION

PROPOSED HP
AR
KIN
G
EXISTING APRON
AC
CO
NEW MLCP BU
S/

3
BPCL
2000

1 SQ
.M.

PROPOSED NEW 1500

SQ
HP
CL EXISTING
.M.

TERMINAL BUILDING

GE
CARGO

N ED
No. PRINTS ISSUED TO DATE
EXIS

1
IN
A
GS TING

FA E OF
ID

RO
ID

NITB IS
(EXISTING CAR PARK)

GR
GR
E
6

CE
NITB

AP
SEPTIC TANK

LIN
AREA
4 ALL EXIST
INDI
AN
OIL FACILITY
5 A/C PLT & ESS UNDARY W ING
VEHIC

7
ULAR
LANE
BO
NG
ISTI NE EXIS

E OF EDGE
EX R LA GSE TING
LAND SHALL BE USED AS

1
GR IN
ULA

38M
ID
AREA

25M
RO
IC

25M
NITB IS

14M
G EH

100

CE
DV

AP
DIN

LIN

59M
SE

FA
UIL OLD
ADDITIONAL APRON AREA AFTER PO
M

M
24.51

R20
RO
LB

ES
7

BU TERM

E
EP
00

ICL
90°

R20M
M
320-2

INA
7 M.
WID
R20M

G VEH

39M
F
A

Q400
LINE 42M
WIDE
ILD INA
RM
EEL

6M
7M
R20M
E WH SHOU
ING L
F

DEMOLITION OF EXISTING

RIN
TE
NOS Q400

24.4
36M LDER

ATE

20M
W
A320-200
L 4.5
R20M

NE
WAL

G/C

00
0M
A320-2
TY
INING

R2
SAFE
3M

R20
RETA 32M

LIN
RAFT
15.6

0M
TING M

9.00M
AIRC ATR
320-20
EXIS 2 15.6
M ATR 72 24.45
0

M
LINE

UE
Y
ATR-7 1M

24.5
D
20.00
72
R20M

0M
STRUCTURES
25M
STRUCTURE

POSE Y
ROTUNDA
OF
COLUM
PIPE
DIA
MM
250

20M
MS

EEL
4-NOS

R20
R REF
32M

7M
PRO GENC

20.4
CAL E WH 72
ATR 72 R2 ATR-72
0M 46M

R
21.3
EMER
GE

Work.max
Oper.max
MEDI TRE

Oper.min

Work.min
ATR A320-200

M
NOSE

20
N ED
CEN A320-200

L0.0

M
LIN 00

200200

M
Work.max

FO
deg
321-2 ATR

Oper.max

/ U1.0

26.96

20-20-
RO ATR72

0M

%
Y ATR-7 44M

A3A3
6
72

0M
NOSE
AP

Work.min
2

Oper.min

25.5
STRUCTURE

0M
ROTUNDA
OF

LINE TIP
COLUM
PIPE

9M
DIA
MM
250
MS
4-NOS

72

E
E
E
A321-200 ATR 72

24.5
A321-200 M ATR

23.6
EA ATR

90.0
13.55 43M ATR 72 0M

15.0
8
E AR

X
72
R2

L0.0

0000
4.50M
ATR-7

F
5

deg
A

2M

1-21-2
2
M
72

/ U1.0
GS ATR72

A32
A
F

%
18M 15.8
5.50
F

9
A ATR

A32

M
F
ATR

1.9 0M 7M ATR72

R15
F
R20 72
R2 16.3

9M
A321-200
18M
M

25M
36M 9M 72

N
F

E
E

7.0
LL1
ATR 72
00 R15M

14.8
B737-900W(A)

4
A321-200(B)

X
ATR
737-9 00
4.75M
M. WI

7M

APRO
10

00

R20
EXISTING
A320-200

22M R20M

1-2
321-2
8 DE

7M
18M

Work.max

00
B737-800

27.1
A32

A320-2
24.5

8M
Oper.max
VEHIC

8M
8

4M
B737-900ER

M
800
A321-200
Y
2.50 M

27.0
A

F
A321-200

B737-

00ER
15.3
A

F
B737-900W

27.2
41M

Work.min
A321-200
M

12.5
00
STRUCTURE

B737-900W

B737-9
ROTUNDA

ULAR
OF
COLUM

Oper.min

R30M
PIPE
DIA

A321-2
MM
250
MS

18M 11
4-NOS

R2

Y WALL
52M

6
W00

0M
6M
LANE

W00
1-2F

00M
3

BOUNDAR
-900

9
1-2
-900
6

L0.0

A32

TING
8M
B737
E
00 9

deg

A32

23M
B737
18M

/ U1.0

R20
321-2 00

NE
%

24.4
767-4

FIRE STATION

10
HA)
E 20.01M

M
B737-900W
A321-200
42M

ROAD
5
A321-200

LAN
A321-200

40.3
B737-900
A321-200 F

00

R LA

00
A A321-200
B747-400

110.
F
LAR
A

A321-2
737-9 A
5M
ICU 40.

0000

ROAD
EXIS
2

30M
1-2

11
E VEH

01-20000

1-2

LP
B767-400ER ATR

A32
-40A32A321-2
F

A32
72
WID F B737-900W

M. E
B737-900W

LA

K (A
7.5 44M

ER
A321-200 A321-200 LAN 4 72 ATR-7
ATR

0W W
400
LAR 5M 2

VEH B747
7-90 -900

00
00
40.

A321-2
A321-2
1 ICU

9M

0M
5M
A321-200

ICU

B737
67-
12

4
40. E VEH

00
B73
ATR

A321-2
B7

32.9
M
72
WID

TRAC
11M
B737-900W
B737-900W
M.
M

W
19.5
7.0

AAI & CISF

3

B737-900
72
44M
ATR-7

0W
14.5

B737-90
ATR
N 5M 2
RO 40.
AP I LINE
13

EXISTING

3
ATR
ER

19M
72
E TAX LD

5M
R LAN 28M OU

EXISTING ATC
72
SH
ATR-7

XI

20.7
2

0M
ULA ATR 2
HIC DE
E VE WI 14

LIE)
AR TA
E
ATR R20M
M.

WID LAN

2
72
WID
10.5 72

M
M. R

ROAD
7.5 ICULAR
7.5
M LDE

E
20M
ATR-7

.0
108
R30M 1 OU

43.5
ATR 2

)
E SH

HOUSING
A 321 1

O
52M 15

M.
N

VEH
ER WID

E
ATR
B 737-9 M.
IO

LAN

150
APRON
72
ULD

AV
(CH
7.5
E SHO 15
M
AT

LAR
WID
ST 72 ATR-7

E
WER
M. 0M ATR

(BR
WID
M 2

FIRE
7.5

7.5 ICU
12.8
11.5

M
C TO

ROAD
A321-200 16

13.6
M.
VEH

K
AT

AC
A 321

ATC

00
K

10.5

K
1-2
B 737-9

A32
M

AC
M
26.0

MAT2
AC
M
M
M
TR

TR
12.8 M

395

80
14.8
17 7.5

M
A321-200
XI

13.6
TA

TR
M

M
A 321
LLEL
PROPOSED APRON

00
11.5

R24
13.9

1-2

XI
B 737-9

A32
RA

M
PA

44.5
M R24M

TA

XI
17

MAT1
140
A321-200 18
42.5

17

TA

)
4M
00

(GF
ROAD
1-2

R2
A32
26M

CK
R24M
W

19 M 18

E-D
BUNGLO RS
42.5
M

D BLO
DIRECTO
M

14.5

18
M
26.0

TYP
26.0

M
M
R24
M EA

22.5
R E
E AR
HANGARS
0M
11.5
GS PAVE
M LAN 11.5

0M

TYPE
M
R24M 26.0

20
19 LAR 0M

R30.0
R24M K 11.5
TH

55
170.
ICU

E-C
WI
20
OC

11M

M
E VEH

19
M BL

TYP
20 21.5 WID

4M
26.0

.00
M.

R2
7.5
M E

21

OLD
GENERATOR

2
R24M

ROOM
36.5
E LIN
R 21 M

155
LDE 42.5
NC
RA

GARAGE
OPEN
OU

A32
KEND

)
E SH RA
21

M
M
SEVA

1-2
R24

ELTA

WALL
EA
M WID

00
CL

BOUNDARY

ROAD
M.

265

ROAD
22
7.5 R24M M TY K
M
267
A321-200
FE

ROAD
22
42.5
N SA
AC

04
TRR

44.5
A32
Proposed Hangar

.M.

TO
22

K (D
M
LDE

2 NOS.(10MX20 M)
RO XI

1-2
R24

M
OU

R-01
M
E B 737-9321

13.6
AP

E
00
E SH
TA

13.9

EN
A

LAN
M
LAN

SQ
14.8

23
LLM.EL

21.5
LAR R24M M M WID
A321-200

LAR
23
ICU

RD
11.5
RA7.5

E
42.5

.50
M

AC
M WID
E VEH
12.8
M

EA
Area of Plot =

34M

7.5 ICU

.00M
PA

A32
23 11.5

GA REN
WID

GA
1-2
R24

M.

2319
VEH
M. B 737-9

13.6

AR
E

EN
M
00

ROAD
13.9

TR
A 321

10.5
7.5

WID LAN
M

0M

24
14.8

PLOTS FOR LINE

R24M M 388. A321-200

ILD
RD
M. LAR
GARAGE
24 OPEN

E
42.5

0
M

3200 Sqm

M
R30.
12.8

R30
ICU
A32

XI

E-B
24

08
4M

CH
22m

1-2

M
00M

62.5
.3.4

44.5

VEH

TO
B 737-9

13.6
R2

E
00
A-1.2

TYP
A 321

7.5
WID LAN
M

R-05
TA
15.1

25
R24M

ROAD
.3.4
M A321-200

7.5 ICULAR
25 B-1.2

E
42.5 M

MAINTENANCE MRO
12.8

C
A32
25

BLOCK
TYPE
M

1-2
R24

M.
VEH
B 737-9321

13.6
M

00
A
E

E
M

2
.0
26
15.1
R

WID LAN
104
E LIN

ROAD
R24M M LDE E
12
26 A321-200 0.11.
42.5 OU LAN

M. LAR
B-9.1
E SH NC

E
LAR

A32
RA B-5.6

M
ICU

7.5 ICU
26

M
WID

ron
.7.8.
EA

R24

1-2
M.

M
E VEH

M
B 737-9321

13.6
E
00

13.9
CL

VEH
M
A 7.5

LAN

18.5
M
21.5
14.8
WID TY
M.
A321-200 7.5 FE

M. LAR
N SA

E
GARAGE
OPEN
M
M

5M

WID
12.8

ar
M

7.5 ICU
R30.

A32

ROAD
40.0
26.0 RO

Ap
.5M
1-2

O16
M

0M

)
ROOM

VEH
B 737-9 AP

R(36-37
MIOTER

13.6
E
13.9
00
A 321
00M
M

WID LAN

PUMP
ROOM
M

B-13T
14.8

16
11.5

ng

TO
WATER

500KLD.
SUMP
M A321-200

7.5 ICULAR
3.5

43.5
E

R-09
M M

ROAD
7.5

to24.
12.8

3.5
M M R
22.5 LDE

6.5M
M

M.

241
VEH
M
B 737-9321

B-21
13.6
OU

13.9

Ha
A
E SH
M
14.8 to20.
WID B-17
EA R M
7.5
M. E
E AR VE E LIN

E
12.8

TEMPL

+ 4) CK
GS PA NC
TH K

(ST B BLO
WI 5M RA
EA

M
OC

22
BL X 96. CL

96.6
M

TO
89M
40M
7.5 TY

ILT
R-17
FE

TYPE
R N SA

0M
OU
LDE RO
E SH
AP

26M
WID

11.5
M.
M 7.5

.00M
11.5
M
11.5

28
TO
R-23
ROAD
R30

R30
.0 0M OPERATIONAL
GATE

ROAD
34
TO
ARP

R-29
HARVESTING

BASIN
PUMP
ROOM

CATCH
M D

927
ROA

AD
RO
E
WID
M
6

376

ROAD
KS
AC

HARVESTING
M

BASIN
CATCH
RR ED ROA
D

0
BA ISF POS ED

12
POS
C RO PRO

0M
LL

.5 M
P
AD AD

PUMP
RO RO

23.0
A

M
E

ROO
WID
M
6

YW

400
R
D
ROA
WIDE
6M

DA
UN

M
L BO ROA
D

NA
WIDE
6M

.50M
30
TIO
315M
PROPOSED APRON & HANGER
RA

K
E

D
ROA
AC
D
ROA

OP

M WIDE
WIDE
6M

TR

10
WALL
DARY
BOUN
NAL
ATIO

XI
OPER

TA
90.8M

D
STAN
HARD
M WIDE
37
RAMP
UP 1

ROLLING

SHUTTER

ROAD
ION

37M
ROLLING 2
SHUTTER

STAT

3
RAMP
UP ROLLING
SHUTTER

FIRE

WIDE
10M
- VII
AIR ROLLING
SIDE SHUTTER

CAT
+150

4
W
(DOUBLE
UP C.F.T

L
CONTROL
5270 HEIGHT) PROJECTION

D1
+450 X 2952 PARKING ROLLING 2000

6M
Y WAL
ROOM WIDE
SHUTTER ABOVE

14
W2

D
+450

12
10 5270

D1
X 2953
S/IC ROLLING

8
RAMP OFFICE
SHUTTER
UP RAMP

7
6 1520 UP
3770 RISER=175 WIDE

4
X 6020
STORE-II WIDTH=1200
TREAD=300 2 D1 CORRIDOR
OF
REQUIRED
37.0mt.WIDE RAMP
STAIRCASE W ROLLING A

NDAR
UP
UP D1 ROLLING 5270 5270 SHUTTER RAMP
LOAD X CREW +450 X 2895
PANTRY

D1
HARD 6020 UP
CARRYING SHUTTER D1
STAND ROOM
ROLLING

B
STRENGTH RAMP ROLLING D1
UP 1520 5270X SHUTTER RAMP
SHUTTER W2 WIDE D1

BATH
2895 UP
CORRIDOR 3770X HOSE
D2
D1 SPARE 6020 REPAIR

D1

D1 C.B
RAMP 3770X6020 BATH
ROOM
C

BOU
UP ROLLING TOILET D2

D1
RAMP

W.C

W
SHUTTER D2 UP

D1

W.C
OPERATIONAL
5270

128.
+450 X 6020 D2
ROLLING STORE-I W.C

W
PROJECTION (DOUBLE

D2
D1
SHUTTER
2000 C.F.T
WIDE HEIGHT) V
PARKING

NAL
ABOVE 985X635 E
PIPE
DUCT

W
F
L
ROLLING

SHUTTER

ATIO
Y WAL

G
ROLLING
SHUTTER
H CITY
D
RAMP
UP SIDE
NDAR
J

OPER
ROLLING
SHUTTER

STAN

5M
RAMP

BOU

5M
UP

EXISTING SOLAR PLANT

ROLLING K

NAL HARD
SHUTTER

10M
RAMP
UP

GATE
ATIO
M WIDE
RAMP
UP

18.5M
M
OPER AIRSIDE OF
18.5 IC
REQUIRED
18.5mt.WIDE

STAT

N
7260M

3630M
LOAD
HARD
CARRYING
STAND
SHAFT

TANK

3630M
STRENGTH

SHAFT

10

D AREA
LIFT

UP
LOBBYMM
C/L + 450 SHAFT

7320M

C/L
LIFT
MM

9
±0.00

UP

5250M
SHAFT LEVEL

8
PAVE

TOWER
4
5250M

AND
7

BUILDING

5250M
MAIN
WALL

5250M
MM CANTEEN

OF
±0.00 61 SQ.M.

C/L
LEVEL ROOM

13650M
SQ.M.

WALL
FOR 35

DARY
52000M

TOILET
SHAFT RECREATIONAL
10000M

5
O.H.T
UP MM

ROAD
BOUN
+450
LEVEL CARE

4
W.C.

W.C. TAKER
SQ.M. FIRE
GENTS 17 DOOR

MM
5250M
NAL
TOILET

±0.00
- II UP

CORRIDOR
FOR
3

DARY
TOILET
SHAFT ESCAPE
FIRE

LEVEL
HAND FIRE- III

DRIER
LADIES STAIRCASE

ATIO

1500
N AREA
5250M

W.C. TOILET HYDRANT UP

MM
WIDE
FIRE STAIRCASE- 300
- 150

DRINKING
2

W.C.
DOOR

+450
WATER TREAD
RISER
-1500

2 M.
WIDTH

WIDE
5250M

W.C.

LEVEL
3000
W.C.

FOR

GREE OPER

MX
TOILET
DIFFERENTLY PANEL 1500

ABLED

JANITORS'
1
UPS EPABX

BOUN
Ø1500
SQM.

1500
CLOSET

5250M

2100
SUPPORT CORRIDOR ROOM
SQM. 20
ROOM WIDE 15
2 M.

1500
CORRIDOR
APRON
TOCONTROL DRIVER'S
SQ.M.
25 ROOM
BATTERY SWITCH 17 SQ.M.

6M
ROOM ROOM
23 SQM. 15 SQ.M.

WIDE

ATC
BRIEFING
&
CREW
ROOM

2 M.
ROOM SQ.M.
IT SERVER

ROOM
FLIGHT SQ.M.
FOR TRAINING 17
INSTRUCTOR

ATE
A 95 SWITCHSQM. ELECTRICAL
SHAFT SUPPORT
- IV

NAL
23 FOR
SQ.M.

FIRE
AID HVAC
SHAFTSYSTEM)
20 CNS
HYDRANT FIRST (VRF
HOUSE ROOM ATC

WALL
COMMN.RISER
KEEPING 21 SQM. CABLE LIFT FOR
LECTURE/TRAINING ESTABLISHMENT
OFFICE

7750M
SQ.M.
18 SQM.
PAX
RISER 17 30 SQ.M.
ROOM FIRE - II 40
CABLE
AVIATION
HYDRANT

D
ATIO
G
ROOM

STORE
OFFICE

DARY
OPERATIONAL LIFT ATFMSQ.M.
30 SQ.M.
PAX

3000
OPERATIONAL 17 29

ROA
SQ.M.
17
- 300
TREAD
STAIRCASE 150
-
RISER -1500

AL
LIBRARY
B WIDTH ATC SQ.M.

BOUN

UP
29
TRNG.

CORRIDOR
CNS CNS ROOM

OPER
IN CHARGE CORRIDOR EQUIPMENT

MM
SQ.M. SQ.M.

NAL

±0.00 UP
15 TRAINING TRAINING
30 WIDE CCTV ROOM

1500
SQ.M.
SUPPORT 2 M. +450 29

M WIDE
MM
8900M

WIDE
ROOM LEVEL
19 SQ.M.

+450
N

LEVEL
ACCESS

2 M.
CONTROL

ATIO

3000
LEVEL
SERVER
ROOM
STAIRCASE- 300 21 SQ.M.
- 150

TIO
TREAD
RISER FIRE
-1500

1500

3000M
UP
WIDTH DOOR -I FIRE

FIRE
C FIRE
ESCAPE-
I
1500 HYDRANT
RECORD/
CONTROL
ROOM
18 SQM.
TRAY
OPER

36M
STAIRCASE
2100 DATA ROOM
INSTRUMENT

36000M

1500
STORE 20 SQ.M.
FIRE MBR (IMD)
DOOR (IMD)

6600M

10
/COMM. SQ.M.

RA
20 DFMD
AMSS

OFFICE 18 SQ.M. RECEPTION

ROOM. 50 SQ.M.
SQ.M.

6000M
20 MM
D OFFICE(IMD) +450
IN-CHARGE LEVEL

PE
ROOM
16 SQ.M.
DIRECTOR
(IMD) RAMPUP
IN-CHARGE

7750M
ROOM
MM
20 SQ.M.

UP
PORCH ±0.00

0
ENTRANCE LEVEL

O
CITYSIDE

+200
M

5000M
54.5
AREA D

F
PAVED ROA

75
WIDE
6M

ED
M OS N
W1

VER.

45.5 ROP TIO

ROOM

BMS
W1

RAMP

D2
STORE

D2

D3

V
RS

D3
TOILET

HE
SHE
DG ROOM

D2
TOILET

Y2
ROOM
W1 STAFF MAIN PANEL

D1
L.T.

P TA
9310X5000

IC

W1
750kVA

ES
SET
DG
ELECTR TION
W1

W1
SUBSTA

FIR
W1

ISOLATION BAY 70M SED

OP
O

A
PR ATC

W
R UN ATC TOWER
ING
IST
EX FIRE STATION

No. REVISIONS DATE

M
465 PROJECT TITLE

DRAFT MASTER PLAN

M
400 DRAWING TITLE

PROPOSED COOLING PIT ATC TOWER & FIRE STATION

(15 M AWAY FROM
DVOR
PERIMETER ROAD)
AIRPORTS AUTHORITY OF INDIA
DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03

JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR
AM (DWG/ PLN.) SR. MGR (ARCH)
RAJESH BALI MOHSIN KAMAL
G.M. (ARCH.) E.D. (ARCH.)
SUJOY DEY DEBASHIS KHAN
DATE
SCALE MARCH 2022

1075 DRG.NO. R
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.
75000 3. DISCREPANCY IF ANY, SHOULD BE BROUGHT
TO THE NOTICE OF DEPTT. OF PLANNING.
11200 52600 11200

OPERATIONAL BOUNDARY WALL

AIRSIDE

6 M. WIDE ROAD No. PRINTS ISSUED TO DATE

TOTAL PLOT AREA:

9528.75 SQM.
17521.4M

AIRSIDE PROJECTION ABOVE

GROUND COVERAGE
40450

7260

3630 3630 ACHIEVED:

SHAFT SHAFT
1735.5 SQM. (18.21%)
LIFT

7320
LOBBY
C/L

LIFT
+ 450 MM
BUILT UP AREA
C/L
UP
TECHNICAL BLOCK : 4407.7 SQM.
SHAFT SHAFT
TOWER BLOCK : 647 SQM
UP
LEVEL ±0.00 MM
ELECTRIC SUBSTATION : 200 SQM
C/L OF MAIN BUILDING AND TOWER

10000.3M
TOTAL BUILT UP AREA : 5254.7 SQM.

HEIGHT OF
13650

1 2 3 4 5 6 7 8 9 10 TECHNICAL BLOCK: 17.09 M

52000 LEVEL ±0.00 MM

5250 5250 5250 5250 10000 5250 5250 5250 5250

UP

A
SHAFT FOR
TOILET
LEVEL +450 MM SHAFT FOR
TOILET HEIGHT OF
W.C. LADIES
W.C. W.C.
ATC TOWER: 34.47 M
OF REQUIRED LOAD CARRYING STRENGTH
2 M. WIDE CORRIDOR

TOILET
HAND
DRIER
GENTS RECREATIONAL ROOM
W.C. TOILET 35 SQ.M.
SUPPORT
ROOM
7750

FLIGHT CREW BRIEFING TO APRON

W.C. CANTEEN
ROOM CONTROL W.C.
61 SQ.M.
95 SQ.M. 25 SQ.M.
TOILET FOR CARE
DIFFERENTLY
ABLED TAKER
Ø150
0 17 SQ.M.
DRINKING
JANITORS' WATER
6 M. WIDE RD.

CLOSET

6 M. WIDE RD.
2 M. WIDE CORRIDOR
FIRE FIRE
HYDRANT - IV HYDRANT - III

OPERATIONAL
OFFICE FIRE ESCAPE
FIRE FIRE
1500

30 SQ.M. HOUSE UPS PANEL DOOR STAIRCASE - II DOOR

UP
KEEPING ROOM
8900

18 SQM. IT SERVER & BATTERY 15 SQM.

FIRST AID
LEVEL ±0.00 MM

LEVEL ±0.00 MM
SWITCH ROOM ROOM STAIRCASE
ROOM EPABX TREAD - 300
3000

UP 23 SQM. 23 SQM. RISER - 150

UP
21 SQM. 20 SQM. WIDTH -1500

CNS TRNG. OPERATIONAL SWITCH

LEVEL +450 MM

LEVEL +450 MM

IN CHARGE STORE ROOM

36600

1500

OPERATIONAL BOUNDARY WALL

15 SQ.M. 17 SQ.M. SHAFT FOR SHAFT FOR 15 SQ.M.
AVIATION COMMN. HVAC ELECTRICAL
CABLE RISER CABLE RISER (VRF SYSTEM)
2 M. WIDE CORRIDOR

2 M. WIDE CORRIDOR

C 1500 2100 1500

36000

1500

DRIVER'S
LIFT TRAINING ROOM
TRAINING 17 PAX
STAIRCASE SUPPORT SUPPORT 17 SQ.M.
6600

STAIRCASE
CNS 3000 LECTURE/TRAINING ROOM
3000
127050

TREAD - 300
ROOM TREAD - 300
RISER - 150 TRAINING ROOM RISER - 150 ROOM FOR ATC 20 SQ.M.
WIDTH -1500 19 SQ.M. WIDTH -1500
30 SQ.M. 30 SQ.M.
ATC
LIFT
INSTRUCTOR
FIRE ESCAPE UP 17 PAX
FIRE 17 SQ.M.
1500

FIRE
DOOR STAIRCASE - I UP
1500 2100 1500
DOOR

D FIRE FIRE
HYDRANT - I HYDRANT - II
OFFICE 2 M. WIDE CORRIDOR
ROOM. LEVEL +450
20 SQ.M.

CNS
7750

ESTABLISHMENT
DATA RECORD/ FIRE ACCESS OFFICE
AMSS /COMM. MBR CCTV EQUIPMENT ATC LIBRARY ATFM ROOM
INSTRUMENT CONTROL CONTROL 40 SQ.M.
DIRECTOR (IMD) ROOM 29 SQ.M. 29 SQ.M.
STORE ROOM ROOM SERVER
IN-CHARGE 18 SQ.M. 20 SQ.M. (IMD) 20 SQ.M.
3000 29 SQ.M.
OFFICE 18 SQM. ROOM
ROOM (IMD) IN-CHARGE 21 SQ.M.
20 SQ.M. ROOM (IMD)
16 SQ.M.
E
TRAY
5000

DFMD

RAMP RECEPTION
UP 50 SQ.M.
F

LEVEL +450 MM
6000

UP

ENTRANCE PORCH

CITYSIDE LEVEL ±0.00 MM

PAVED AREA +200

OPERATIONAL BOUND

PARKING-2
50000

31 CAR PARKING

No. REVISIONS DATE

RAMP
VER.
W1 W1
RS

V
DG ROOM
STORE ROOM
BMS
D2 D2
PROJECT TITLE
PARKING -1 W1
D2

D3 D3
PARKING - 3 ATC TOWER CUM
CAR PARKING - 06 CAR PARKING - 06
ROOM
STAFF TOILET TOILET
750kVA
SECURITY DG SET
SHE HE V

SECURITY TECHNICAL BLOCK (CAT-II, IMD-II)

BIKE PARKING - 12 BIKE PARKING - 12
D1
W1

CABIN MAIN
L.T. PANEL
9310X5000 CABIN DRAWING TITLE
ELECTRIC
SITE PLAN
SUBSTATION
W1 W1 W1

AIRPORTS AUTHORITY OF INDIA

DEPARTMENT OF PLANNING
ENTRY EXIT ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN, "C" BLOCK SAFDARJUNG AIRPORT N. D.-37

JET (ARCH.) AM (ARCH.)

ANUP BHARTI DHURBAJYOTI SARDAR

6M. WIDE ROAD MGR (DRN./PLN)

RAJESH BALI
SR. MGR (ARCH.)
MOHSIN KAMAL
G.M. (ARCH.) E.D. (ARCH)
SUJOY DEY DEBASHIS KHAN
DATE
SCALE 1:400
1076 JUNE 2021

DRG.NO. I N D - A T C A 2 0 1 R
CITYSIDE JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

A
AIRSIDE
2. DRAWINGS NOT TO BE SCALED, ONLY
7260 WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3630 3630 3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

230 230 TO THE NOTICE OF DEPTT. OF PLANNING.
1500 900 2000 900 1500

230
230
750
D4 D4
SHAFT SHAFT
D6

600
230
2170 2000 2400
230 LIFT
230

7320
LOBBY

3700
C/L
+ 450 MM
LIFT
UP

230
C/L

600
D6
SHAFT

230
750
SHAFT
D4 D4

648
UP
LEVEL ±0.00 MM

C/L OF MAIN BUILDING AND TOWER

No. PRINTS ISSUED TO DATE

6130
COLUMN SIZE 600MM X 600MM

13650
LEGEND
1 2 3 4 5 6 7 8 9 10 TEXT

6130
CNS
52000 LEVEL ±0.00 MM
ATC
5250 5250 5250 5250 UP 10000 5250 5250 5250 5250
1000 WIDE PLINTH PROTECTION
ALL AROUND THE BUILDING 450 WIDE PROJECTION
COMMON REQ.
900 9900 900 SHAFT FOR 900 900
SHAFT FOR D4 D4 TOILET
+450 MM
IMD
230

230

230
TOILET 1200X1200
230
600

600
900

900
CG GL 1200X1200 GL CG
V V
A

565
D3

600

1063
115
965 965 700 700

1497
592 900 900 900 592
W.C. W.C.

792

700

4518
W W.C. LADIES W

887
TOILET
HAND
RECREATIONAL ROOM

700
DRIER

1654
SUPPORT W.C. AS/DETAIL DRG. 35 SQ.M.

887

688
CG1 CG1

115
115
ROOM CANTEEN
7750

7745
7750

W.C.

444

444
FLIGHT CREW BRIEFING TO APRON 887

ROOM
1497 1273
115
1000
115
2140 600
115
800 1200 615 600
61 SQ.M.
CONTROL

75
850

850
W.C. GENTS D
881

95 SQ.M. 25 SQ.M. TOILET D1

115

CARE

GLASS PARTITIONS
D1

850

850
AS/DETAIL DRG.
W TOILET FOR W
TAKER

3152
DIFFERENTLY D5

425

425
115
ABLED 2300X2100
230 17 SQ.M. 230
2100

230 Ø15 230

00 585 900 1085 1200

3426 4650 2300 1470 115 115 230 4654 5320 75 2500 7995 600

1200
600 225 600 225 230 D1 DRINKING
225 1800 600 1800 225
JANITORS' WATER
2251800 600 1800 225
75

1800 1800 CLOSET

D D
B GLASS PARTITIONS W W
900

W W D3
750

W W D W W
FIRE 2 M. WIDE CORRIDOR FIRE D3

230
HYDRANT - IV HYDRANT - III
230

DOUBLE SKIN PARTIONS D1 D1 230 TH.BRICK WALL

1800

900x1430 D1 900x1430
75

D1
W D1
230

230
OPERATIONAL
900 230 230 900

COVERED AREA ON
5872

OFFICE 230 D2 FIRE ESCAPE D2

1500
700

1430

1430
FIRE FIRE
GLASS PARTITIONS UPTO FALSE CEILING

230 HOUSE UPS PANEL STAIRCASE - II

GROUND FLOOR = 1487.5 SQ.M

3255
30 SQ.M. 4835 4705 DOOR DOOR
3797

UP
230

230
KEEPING ROOM
8900

5320 2000 IT SERVER & BATTERY

1800

D
18 SQM. ROOM 230 15 SQM.
5010

SWITCH ROOM

230
W FIRST AID
LEVEL ±0.00 MM

LEVEL ±0.00 MM
ROOM 23 SQM. 23 SQM. STAIRCASE

3000
GL2
UP EPABX TREAD - 300
75

UP
700

D1 RISER - 150
21 SQM.
75

20 SQM. WIDTH -1500

D D1 230 230 230 230 230
1800

CNS TRNG. 5420 75 3000 2303 2303 2087 2388 4650 3245
LEVEL +450 MM

LEVEL +450 MM
3023

230

3255
3178

W OPERATIONAL D4 SWITCH
IN CHARGE D4

1500
230
STORE D4 AVIATION D4 SHAFT FOR SHAFT FOR ROOM
15 SQ.M. 17 SQ.M. CABLE RISER COMMN. HVAC
600 750

ELECTRICAL

600
230

1500

CABLE RISER (VRF SYSTEM) 15 SQ.M.

230
2 M. WIDE CORRIDOR

2 M. WIDE CORRIDOR
C
75

1500 2100 1500

1000
D
36000

D1
1500

19 11

2965
GL2
DRIVER'S
2920

300 300 21

1800
LIFT TRAINING ROOM
2000 TRAINING 17 PAX LECTURE/TRAINING W

STAIRCASE SUPPORT CNS ROOM FOR ATC SUPPORT 17 SQ.M.

6600

STAIRCASE
TRAINING ROOM ROOM
6300
6000

3000

TREAD - 300
ROOM 30 SQ.M.
230

TREAD - 300
6300

617 1800 783

RISER - 150
WIDTH -1500 19 SQ.M. 75 30 SQ.M. RISER - 150
900 HIGH RAILING 230
75 20 SQ.M. D 230 300 300
WIDTH -1500
3475 5020 1500 2700 2720 2250 5020 3475 2000 5320 2000
1 LIFT No. REVISIONS DATE
2920

3335
ATC W
230

230
230 230
D2 FIRE ESCAPE UP 900 230
17 PAX 230 900

FIRE INSTRUCTOR
1500

FIRE SHAFT
230

DOOR STAIRCASE - I UP
DOOR 17 SQ.M.
1430

1430
230 1500 2100 1500 230 10 5 1
900

230

D2
230

230

D W W FIRE
D D
GLASS PARTITIONS D D
FIRE W W
600 UPTO FALSE CEILING 600
2000

HYDRANT - I HYDRANT - II D
2000

2000
230 OFFICE 2 M. WIDE CORRIDOR 900x1430 230
3560

GLASS PARTITIONS DOUBLE SKIN PARTIONS

ROOM. UPTO FALSE CEILING UPTO FALSE CEILING LEVEL +450 D
GLASS PARTITIONS
D
D D D D D
D
20 SQ.M. D OFFICE
D IN-CHARGE
CNS 1000 WIDE PLINTH PROTECTION
3071

ROOM (IMD)
75
7750

ALL AROUND THE BUILDING

PROJECT TITLE
7750

ESTABLISHMENT
DOUBLE SKIN PARTIONS D 12 SQ.M. MBR DATA RECORD/ ENGG. ACCESS
UPTO FALSE CEILING
1200 3975 FIRE CCTV EQUIPMENT ATFM ROOM OFFICE
MAINTENANCE ATC LIBRARY
CG1
(IMD) INSTRUMENT CONTROL CONTROL 40 SQ.M.
CG1
ATC TOWER CUM
5820

ROOM ROOM 29 SQ.M. 29 SQ.M.

75

DIRECTOR D 18 SQ.M. STORE ROOM ROOM SERVER

4255

IN-CHARGE (IMD) 20 SQ.M. 29 SQ.M.

ROOM (IMD) AMSS /COMM.
(IMD) 18 SQ.M. 18 SQM. ROOM
230
TECHNICAL BLOCK (CAT-II, IMD-II)
21 SQ.M.
2674

20 SQ.M. 16 SQ.M.
5475 75 5175 75 3140 75 3514 75 3621 75 3125 75 3000 75 3650 75 5175 75 5174 75 5176 75 5020 DRAWING TITLE

230
230

450 230

E
230

GROUND FLOOR PLAN

900
900

600

600
370

CG GL GL SD GL GL CG

900 9900 900

1500 1500
TRAY 900 900
1000 WIDE PLINTH PROTECTION
3500

ALL AROUND THE BUILDING

5000

DFMD AIRPORTS AUTHORITY OF INDIA

6500

RECEPTION DEPARTMENT OF PLANNING

RAMP
UP 50 SQ.M. ARCHITECTURAL CELL
F AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03
1350 SD 7900 1350
JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR
LEVEL +450 MM AM (DWG/ PLN.) SR. MGR (ARCH)
RAJESH BALI MOHSIN KAMAL
6000

G.M. (ARCH.) E.D. (ARCH.)

SUJOY DEY DEBASHIS KHAN
UP DATE
SCALE 1:250 JUNE 2021
1077
A

ENTRANCE PORCH
DRG.NO. I N D - A T C A 2 0 2 R
CITYSIDE LEVEL ±0.00 MM
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

A
2. DRAWINGS NOT TO BE SCALED, ONLY
WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

7260 3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

3630 3630 TO THE NOTICE OF DEPTT. OF PLANNING.
230 230
1500 900 2000 900 1500

230
750
230
SHAFT SHAFT

LIFT
230 2170 230 2000 2400
230

7320
LOBBY C/L OF TOWER

4900
STAIRCASE
LIFT W-1200
AS/APPROVAL T-250
UP DN
R-150mm

230
LEVEL +4950
SHAFT

750
230
SHAFT

C/L OF MAIN BUILDING AND TOWER

No. PRINTS ISSUED TO DATE

6130
COLUMN SIZE 600MM X 600MM

LEGEND
2230 TEXT

6130
1 2 3 4 5 6 7 8 9 10
CNS
52000
5250 5250 5250 5250 10000 5250 5250 5250 5250
ATC
230 230 230 230 230 230
10570 5320 4650 4650 5620 10270 COMMON REQ.
SHAFT

230

230

230
IMD
SHAFT
GL GL GL GL

230
565
1200X1200 1200X1200
V V
A

600
W

1063
115
965 965 700 700

1497

5063
592 900 900 900 592
W.C. W.C.

792

700
600 W W.C. LADIES W
NAV AIDS OFFICER,
GENTS REST

887
GENTS REST TOILET
HAND

700
AUTOMATION, ADS-B DRIER
MAINTENANCE, STORE

1654
ROOM WITH W.C. AS/DETAIL DRG. ROOM WITH
FACILITY ROOM AND WORKSHOP

887

688
LOCKER ROOM LOCKER

115
115
7750

7150

7745

80 SQ.M. 50 SQ.M.

7820
41 SQ.M. W.C. 43 SQ.M.

444

444
GL1

887
GL1 1497 1273 1000 2140 600 800 1200 615 600
115 115

850

850
W.C. GENTS

881
7820
D1
TOILET

115
D1

850

850
AS/DETAIL DRG. D
W TOILET FOR W NAV AIDS IN-CHARGE
DIFFERENTLY ROOM

425

425
115

2827
ABLED D5
15 SQ.M.

2100
Ø15
00 585 900 1085 1200

1200
2300 1470 115 115
225 600 225
JANITORS'
D1 DRINKING
WATER
225 1800 600 1800 225 4950 5320 230 600
225 1800 1800 225
75

1800 1800 CLOSET

600

230
D1 D1 D1
B

230
W W W W
750

W W
2000

2000
2070
2 M. WIDE CORRIDOR

2070
AUTOMATION FIRE GLASS PARTITIONS FIRE
3675

230
1800

HYDRANT - IV UPTO FALSE CEILING HYDRANT - III

W
IN-CHARGE 230 TH.BRICK WALL

230
W D D1 D D1 D1
230

230
D1
ROOM
700

900 230 230 900

15 SQ.M. D2 FIRE ESCAPE

5240
75

1430

1430

1500
UPS PANEL STAIRCASE - II COVERED AREA ON

3255
MESSAGE UP
230

230
5153
RADAR ROOM
8900

1800

D1
REST ROOM +
SIMULATION IT COMM. BATTERY 15 SQM.
D1
FIRST FLOOR = 1318.5 SQ.M

5010
W FEMALE/ STATISTICS
700

ROOM ROOM

230
AUTOMATION MALE ROOM ROOM
STAIRCASE
TREAD - 300

3000
230 41 SQ.M. 23 SQM. D1
MAINTENANCE, 9 SQ.M. 23 SQM. 14 SQ.M . RISER - 150
5220

5320 2000 2550 6020 230 4835 230 4705 230 4650 3320 1990 WIDTH -1500
230 230 230
STORE
1800

SWITCH 230
75

2303 2303 2087 2388

AND WORKSHOP

3255
W D1 ROOM
750

D4 D4 D4 D4
27 SQ.M. DOUBLE SKIN PARTIONS

1500
D1
UPTO FALSE CEILING
SHAFT FOR SHAFT FOR 15 SQ.M.
PANTRY

1972
1500
AVIATION COMMN. HVAC ELECTRICAL
CABLE RISER CABLE RISER (VRF SYSTEM) 7 SQ.M.

230
2 M. WIDE CORRIDOR

2 M. WIDE CORRIDOR

850
C D1
1500 2100 1500
230 TH.BRICK WALL
1500

D1
36000

D1

19 41

2920

1800
GL3
LIFT
LADIES REST
8185

W
17 PAX

700
STAIRCASE APPROACH ROOM WITH
6600

STAIRCASE CENTRALIZED
3000
6000

TREAD - 300 CONTROL CENTRE LOCKERS

230
TREAD - 300

6300
RISER - 150 UPS FTI
WIDTH -1500
75 66 SQ.M. 230 RISER - 150
900 HIGH RAILING 230 75 20 SQ.M. 35 SQ.M. 230
WIDTH -1500 30 SQ. M.
8425 1500 2700 2720 230 2250 5020 3475 2000 5320

1800
31 LIFT
2920
230

230
W
DNFIRE ESCAPE UP

850
900 230
17 PAX 900
1500

900 HIGH GLASS

30
STAIRCASE - I D2
UP 900 HIGH GLASS No. REVISIONS DATE
1430

1430
RAILING 230 1500 2100 1500 RAILING
D1
230

230
D FIRE DOUBLE SKIN PARTIONS D1 FIRE
Khura HYDRANT - I UPTO FALSE CEILING
2000

2 M. WIDE CORRIDOR
1800 512 1500

HYDRANT - II

1800 512 1500

2025

75 X 38 AL. IODIZED D3 D3
GLASS PARTITIONS LEVEL +4950
TUBULAR SECTION UPTO FALSE CEILING GLASS PARTITION UPTO 1200MM GLASS PARTITION UPTO 1200MM
D D D D
75
600 10500 230 10570 9850 75 4250 2000 4320 10500
230
PA TO PA TO
2908

W
7750

1025
DGM ATC DGM ATC
1025

TERRACE SITTIING SPACE FOR IN-CHARGE TRAINING TERRACE

JT. GM/DGM OFFICES CNS EXEC.(SR. MGR/MGR/ASST. 10 SQ.M. 10 SQ.M. PROJECT TITLE
D D
60 SQ.M. MGR.)
5820

ATC TOWER CUM

513 1800

513 1800
900 HIGH GLASS W
57 SQ.M. DGM ATC DGM ATC W 900 HIGH GLASS
2887

RAILING IN-CHARGE TRAINING RAILING

BRICK WALL UPTO 900MM & 15 SQ.M. 15 SQ.M. TECHNICAL BLOCK (CAT-II, IMD-II)
GLASS ABOVE UPTO FALSE CEILING
450 230
450 230

E
DRAWING TITLE
600

GL GL GL GL

FIRST FLOOR PLAN

5000

DOUBLE HEIGHT
RECEPTION BELOW

AIRPORTS AUTHORITY OF INDIA

F DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03

JE (ARCH) AM (ARCH.)

FRAMED GLASS CANOPY ANUP BHARTI DHRUBAJYOTI SARDAR

AS PER STRUCTURE AM (DWG/ PLN.) SR. MGR (ARCH)
RAJESH BALI MOHSIN KAMAL
G.M. (ARCH.) E.D. (ARCH.)
A

SUJOY DEY DEBASHIS KHAN

DATE
SCALE 1:250 JUNE 2021

ENTRANCE PORCH 1078 DRG.NO. I N D - A T C A 2 0 3 R

BELOW

JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

A
3. DISCREPANCY IF ANY, SHOULD BE BROUGHT
TO THE NOTICE OF DEPTT. OF PLANNING.

7260
3630 3630
230 230
1500 900 2000 900 1500

230
750
230
SHAFT SHAFT

230 2170 230 2000 2400

LIFT 230

7320
LOBBY C/L OF TOWER

4900
STAIRCASE
W-1200
LIFT T-250
UP DN
R-167mm

230
LEVEL +9450
SHAFT

750
230
SHAFT

C/L OF MAIN BUILDING AND TOWER

No. PRINTS ISSUED TO DATE

COLUMN SIZE 600MM X 600MM

6130
GL GL

LEGEND
TEXT
CNS
2000 ATC

6130
1 2 3 4 5 6 7 8 9 10
GL GL

52000 COMMON REQ.

5250 5250 5250 5250 10000 5250 5250 5250 5250
IMD

230
230

230
CG GL GL CG

230
Exp. Joint
A

565
D3

600

1063
115
965 965 700 700

1497
592 900 900 900 592
W.C. W.C.
IT WORKSHOP

792

3459
AND STORE

700
W W.C. LADIES W

887
TOILET
HAND 20 SQ.M.

700
DRIER

1654
NEGOTIATION W.C. AS/DETAIL DRG.
LADIES REST
ANTI-HIJACKING

75
887

688
CG1
ROOM CG1

115
115
ROOM WITH
7750

7745

7745
CONTROL ROOM D1
60 SQ.M. W.C.
IT STAFF

444

444
887
70 SQ.M. 1497 1273 1000 2140 600 800 1200 615 600 LOCKER
230 230 115 115 IT IN-CHARGE/ 38 SQ.M.
38 SQ.M.

850

850
75 GENTS
W.C.
IT EXECFUTIVES

881
600 7995 7820 4650 TOILET 230
10868

115
D1 15 SQ.M. 75 75 230

850

850
AS/DETAIL DRG.
W W
TOILET FOR
DIFFERENTLY
5020 3505 2120 5020

425

425

4211
115
115
ABLED D5
75

2100
Ø15
00 585 900 1085 1200

200
2300 1470 115 115

1200
D1

1000
DRINKING
D1
600 1800 225
JANITORS' WATER
225 1800
75
D1

75

75
CLOSET
750

230
W W W W D1
D1
W

2070
W
2000

230 2000
W W

2370
FIRE
COVERED AREA ON

230
FIRE

230
1800

75

HYDRANT - IV D1 D1 230 TH.BRICK WALL HYDRANT - III

W

230
W D1
D1 D1
SECOND FLOOR = 1434.5 SQ.M
700

230 900
75

D1

2301430
FIRE ESCAPE

1500
UPS PANEL STAIRCASE - II

3255
UP
ROOM
8900

1800

GL2
7050

OPERATION D1

5010
W
IT SERVER & BATTERY 15 SQM.
COMMUNICATION DSCN ROOM
700

ROOM

230
VHF STORE SWITCH ROOM STAIRCASE

3263
ROOM 14 SQ.M. TREAD - 300

3000
75 AMSS & AIS 20 SQ.M. 23 SQM. 23 SQM. D1 RISER - 150
5847

33 SQ.M. 75
(SERVER AND4615
75 230 230 230 230 WIDTH -1500
5245 2000 3805 4835 4705 4650 3245 75 1990
230

75
MAINTANANCE
1800

SWITCH

230
2303 230 2303 2087 230 2388

3255
W ROOM) D4 D4 ROOM
750

D4 D4
30 SQ.M. SHAFT FOR

1500
D1
15 SQ.M.

1897
HVAC SHAFT FOR
AVIATION COMMN. PANTRY 1500 2100 1500

230
ELECTRICAL
230

CABLE RISER CABLE RISER (VRF SYSTEM)

7 SQ.M.

1500
230

230
75

850
C

75
D1
1500

D1 D1
36000

REST ROOM SSO

2743
2205
MAINTENANCE Group - D ROOM

2920
UP AND LEVEL +9450 (Gents)

1800
GL2 CNS LIBRARY LIFT 15 SQ.M.
WORKSHOP 5 SQ.M. W
19 SQ.M.

75
17 PAX CENTRALIZED

75
STAIRCASE AS/DETAIL
6225

STAIRCASE AS/DETAIL ROOM TREAD - 300

UPS
6600

3000

75 REST ROOM D1

6225
6000

6000

TREAD - 300
6070

RISER - 150

700
30 SQ.M.
230

2130
230 230
RISER - 150
WIDTH -1500
230 1990 3375 4950
WIDTH -1500
4200
900 HIGH RAILING
2790 2250
30 SQ. M.
5020
75 Group - D
(Ladies)3400 2000
75
5245
No. REVISIONS DATE

1800
100 5 SQ.M.
230 LIFT 230
2920

230
W
FIRE ESCAPE UP

850
17 PAX 2345 230 900
1500

2301430
STAIRCASE - I UP 225 1800 600 1800 225
230
230

1500 2100 1500

230
900

900
75

75
D1
D W W FIRE D1 D1 D1 FIRE W W
2000

2000

HYDRANT - I HYDRANT - II
GLASS PARTITION
75

11602
75

D1
UPTO 1200MM D1 D1 D1 D1 D1

RNFC PROJECT TITLE

OFFICE PA TO CNS
2800

CONFERENCE DATABASE
IN-CHARGE IN-CHARGE ATC TOWER CUM
7750

7890

HALL FOR ATC 75 MANAGEMENT/ EQUIPMENT ROOM

RNFC 8 SQ.M. 8 SQ.M. VCS/DVR
79 SQ.M. SYSTEM ADMN. CNS STORES REPLAY 100 SQ.M.
75

OFFICE 2774 2850

CG1
28 SQ.M.
GAGAN ROOM
22 SQ.M.
22 SQ.M. AND ROOM ROOM CG1
TECHNICAL BLOCK (CAT-II, IMD-II)
D
20 SQ.M. 25 SQ.M.
5745

OFFICES
CNS
230 75 20 SQ.M. 75
75 IN-CHARGE 230 DRAWING TITLE
2870

10570 4875 CABIN 5700 3833 3820 3540 3757 4950 10495
15 SQ.M.
75 75 75 75 75 SECOND FLOOR PLAN
230
230

E
750

CG CG

900 GL GL GL GL 900

AIRPORTS AUTHORITY OF INDIA

5000

5000

TERRACE
900 HIGH GLASS
DEPARTMENT OF PLANNING
RAILING ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03

F JE (ARCH) AM (ARCH.)
10600 ANUP BHARTI DHRUBAJYOTI SARDAR
AM (DWG/ PLN.) SR. MGR (ARCH)
A

RAJESH BALI MOHSIN KAMAL

G.M. (ARCH.) E.D. (ARCH.)
SUJOY DEY DEBASHIS KHAN
DATE
SCALE 1:250 JUNE 2021
1079 DRG.NO. I N D - A T C A 2 0 4 R
JOB NO.
 C/L OF MAIN BUILDING AND TOWER
NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

TO THE NOTICE OF DEPTT. OF PLANNING.

A
7260
3630 3630
230 230
1500 900 2000 900 1500

230
750
230
SHAFT SHAFT

230 2170 230 2000 2400

LIFT 230

7320
LOBBY C/L OF TOWER

4900
STAIRCASE
W-1200
LIFT T-250
R-167mm
UP DN

230
LEVEL +13950
SHAFT No. PRINTS ISSUED TO DATE

750
230
SHAFT

COLUMN SIZE 600MM X 600MM

LEGEND

TERRACE
TEXT
CNS
ATC

1 2 3 4 5 6 7 8 9 10
COMMON REQ.
52000 IMD
5250 5250 5250 5250 10000 5250 5250 5250 5250

A
7750

COVERED AREA OF
B
HEADROOMS ON TERRACE
= 126 SQ.M
1200

1200
OPEN AREA FOR DN
8900

OUT DOOR UNITS OF VRF SYSTEM

(150 SQM. APPROX.)

1000

TERRACE TERRACE
LEVEL + 13950
LEVEL + 13950
C
No. REVISIONS DATE
36000

DN

1000
6600

DN

PROJECT TITLE
D
ATC TOWER CUM
TECHNICAL BLOCK (CAT-II, IMD-II)
DRAWING TITLE
7750

THIRD FLOOR (TERRACE) PLAN

AIRPORTS AUTHORITY OF INDIA

E DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03
5000

JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR
AM (DWG/ PLN.) SR. MGR (ARCH)
A

RAJESH BALI MOHSIN KAMAL

G.M. (ARCH.) E.D. (ARCH.)
F SUJOY DEY DEBASHIS KHAN
DATE
SCALE 1:250 JUNE 2021
1080 DRG.NO. I N D - A T C A 2 0 5 R
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

A
TO THE NOTICE OF DEPTT. OF PLANNING.

A
7260 7260 7260
3630 3630 3630 3630
230 230 230 230 230 3630 3630 230
1500 900 2000 900 1500

230
1500 900 2000 900 1500

230
1500 900 2000 900 1500

230
750
230

750
230

750
230
SHAFT SHAFT SHAFT SHAFT
SHAFT SHAFT

230 2170 230 2000 2400 230 2170 230 2000 2400 230 2170 230 2000 2400
LIFT 230 230 230
LIFT
7320

LIFT

7320
LOBBY C/L OF TOWER

7320
LOBBY C/L OF TOWER

4900
LOBBY C/L OF TOWER

4900

4900
STAIRCASE STAIRCASE STAIRCASE
W-1200 W-1200 W-1200
LIFT T-250 LIFT T-250 LIFT
UP DN
R-167mm R-150 mm
T-250
R-167mm No. PRINTS ISSUED TO DATE
UP DN UP DN

230
C/L

230

230
LEVEL +9450
SHAFT
750
230
SHAFT

750
SHAFT

230
SHAFT

750
SHAFT

230
SHAFT

LEGEND
230 2000 230 TEXT

C/L OF MAIN BUILDING AND TOWER

CNS
A

A
ATC

6130
GL GL
COMMON REQ.
IMD

TYPICAL FLOOR PLAN

(GROUND-SECOND FLOOR) TYPICAL FLOOR PLAN
COVERED AREA PER FLOOR: 48 SQ.M. (THIRD - FIFTH FLOOR) SECOND FLOOR OF TOWER WITH
FLOOR TO FLOOR HEIGHT: 4500MM COVERED AREA PER FLOOR: 48 SQ.M. CONNECTING BRIDGE TO TECHNICAL BLOCK
FLOOR TO FLOOR HEIGHT: 3140MM
A

A
1200

AIRSIDE
AIRSIDE
3840

Railing 1M.High 1500 HIGH RCC WALL

APRON
CONTROL ROOM CONTROL TOWER
23.50 SQ.M. 117 SQ.M.
UPS AND DATIS EQUIP.
BATTERY ROOM
ROOM 12 SQ.M.
D
1000

12 SQ.M.688 573 115 6510 115 573 688

1000

D4 D4
D SHAFT SHAFT D

LEVEL +32400 COLUMN

D1 D1
R7 AS/APPROVED
No. REVISIONS DATE
BALCONY FOR ANTENNA

BALCONY FOR ANTENNA

LIFT Raised Floor 70 STR. DETAIL

REST ROOM REST ROOM 0 4355
7160

LADIES LOBBY GENTS 1500 HIGH WALL

16.5 SQ.M. 16.5 SQ.M. 1200 500
R6
R85

2400 3670
R9700

LIFT
00

1655 1200
UP DN DN
D9

D9
TOILET
SHAFT SHAFT TOILET
D4 D4 PROJECT TITLE
D1
D1
OFFICE SPACE ATC TOWER CUM
1000

837 2040 D LEVEL +23370 D9

TOILET (IMD) DN
IT AND D 6 SQ.M. LEVEL +34470 TECHNICAL BLOCK (CAT-II, IMD-II)
COMM. UHF LINK
60
ROOM ROOM 30
23 SQ.M. DRAWING TITLE
24.75 SQ.M.
3840

TOWER FLOORS (CONTROL TOWER

& BELOW CONTROL TOWER)
LEVEL +27870
Railing 1M.High
AIRPORTS AUTHORITY OF INDIA
1200

DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03
A

A
JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR

SIXTH FLOOR SEVENTH FLOOR ROOF PLAN

AM (DWG/ PLN.)
RAJESH BALI
G.M. (ARCH.)
SR. MGR (ARCH)
MOHSIN KAMAL
E.D. (ARCH.)

(BELOW CONTROL TOWER) ( CONTROL TOWER) ( CONTROL TOWER)

SUJOY DEY DEBASHIS KHAN
DATE
TOTAL COVERED AREA: 132 SQ.M. SCALE 1:250
TOTAL COVERED AREA: 227 SQ.M. JUNE 2021
1081 DRG.NO. I N D - A T C A 2 0 6 R
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

TO THE NOTICE OF DEPTT. OF PLANNING.

NOC for Height claerance for ATC Tower

with 5.50 M high VHF Antenna=39.97m

No. PRINTS ISSUED TO DATE

LEVEL +34470 NOC for Height claerance for TERRACE

ATC Tower =34.47m LVL + 34470
(CONTROL TOWER)
NOC for Height claerance for
Technical Block =32.0 m
6600

LEVEL +27870 SEVENTH FLOOR

LVL + 27870
(BELOW CONTROL TOWER)
4500

LEVEL +23370 SIXTH LEVEL

LVL + 23370
EQ

GLAZING LVL 00

FIFTH LEVEL
LVL + 20230
9420
EQ

FOURTH LEVEL

150
LVL + 17090
3140
EQ

1000 900

1000 900
1100

THIRD FLOOR

1100
LVL +450
LEVEL +13950 LVL+ 750

LVL + 13950
725

900 FIXED GLASS FIXED GLASS FIXED GLASS

3550

3550
4500

GLAZING LVL 00
2600

900 GLAZING LVL 00 900

1875

GLAZING LVL ±0.00

FIXED GLASS FIXED GLASS FIXED GLASS
LVL 00
1000 900

1000 900

GLASS RAILING
LVL +600 LVL +450 LVL +450
LVL +600 SECOND FLOOR
850 900

LEVEL +9450

900
LVL 00 LVL 00 LVL + 9450
800

FIXED GLASS FIXED GLASS

4500

2600

GLAZING
1800

3500

FIXED GLASS FIXED GLASS

LVL 00
1000 900

LEVEL +4950 LVL +450

FIRST FLOOR No. REVISIONS DATE
1000

1000

GLASS CANOPY
LVL + 4950

1000
LVL +600
LVL +600
FIXED GLASS FIXED GLASS
4500

2600
3050

900 900

3050
4500
3500

3500

3500

FIXED GLASS FIXED GLASS

GLAZING LVL 00
GLAZING LVL 00
450900

LEVEL +450 LVL +450

LVL +600 PLINTH FLOOR
900

900
900
450

LVL +600

LVL +450 PROJECT TITLE

GLAZING LVL ±0.00
LEVEL ± 0.0 GROUND LEVEL
5250 5250 5250 5250 10000 5250 5250 5250 5250
LVL ±0.00 ATC TOWER CUM
TECHNICAL BLOCK (CAT-II, IMD-II)
DRAWING TITLE
1 2 3 4 5 6 7 8 9 10
FRONT ELEVATION

AIRPORTS AUTHORITY OF INDIA

DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03

JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR
AM (DWG/ PLN.) SR. MGR (ARCH)
RAJESH BALI MOHSIN KAMAL
G.M. (ARCH.) E.D. (ARCH.)
SUJOY DEY DEBASHIS KHAN
DATE
SCALE 1:250 JUNE 2021
1082 DRG.NO. I N D - A T C A 2 0 7 R
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

TO THE NOTICE OF DEPTT. OF PLANNING.

NOC for Height claerance for ATC Tower

with 5.50 M high VHF Antenna=39.97m

No. PRINTS ISSUED TO DATE

LEVEL +34470 NOC for Height claerance for TERRACE

ATC Tower =34.47m LVL + 34470
(CONTROL TOWER)
NOC for Height claerance for
Technical Block =32.0 m
6600

LEVEL +27870 SEVENTH FLOOR

LVL + 27870
(BELOW CONTROL TOWER)
4500

LEVEL +23370 SIXTH LEVEL

LVL + 23370
EQ

FIFTH LEVEL
LVL + 20230
9420
EQ

FOURTH LEVEL
LVL + 17090
3140
EQ

900
1100
LEVEL +13950 LVL +600 LVL +600 THIRD FLOOR
LVL + 13950

1800
3550
4500

1800
900
SECOND FLOOR
850 900

LEVEL +9450 LVL +600 LVL +600

LVL -5250 LVL ±0.00 LVL + 9450

1800
800
4500

1800

1800
3500

No. REVISIONS DATE

1000 900

900

LEVEL +4950 FIRST FLOOR

LVL +600 LVL +600 LVL + 4950
1800
4500

3050

3050

4500
1800

900 900 GLAZING

LVL ±0.00
450 900

LEVEL +450 PLINTH FLOOR

450
450

LVL +600 LVL +600 PROJECT TITLE

LVL +450
450

LEVEL ± 0.0 GROUND LEVEL ATC TOWER CUM

7750 8900 6600 7750 5000
LVL ±0.00 TECHNICAL BLOCK (CAT-II, IMD-II)
36000

DRAWING TITLE

A B C D E F RIGHT SIDE ELEVATION

AIRPORTS AUTHORITY OF INDIA

DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03

JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR
AM (DWG/ PLN.) SR. MGR (ARCH)
RAJESH BALI MOHSIN KAMAL
G.M. (ARCH.) E.D. (ARCH.)
SUJOY DEY DEBASHIS KHAN
DATE
SCALE 1:250 JUNE 2021
1083 DRG.NO. I N D - A T C A 2 0 8 R
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

TO THE NOTICE OF DEPTT. OF PLANNING.

NOC for Height claerance for ATC Tower

with 5.50 M high VHF Antenna=39.97m

No. PRINTS ISSUED TO DATE

LEVEL +34470 NOC for Height claerance for TERRACE

ATC Tower =34.47m LVL + 34470
(CONTROL TOWER)
NOC for Height claerance for
Technical Block =32.0 m
6600

LEVEL +27870 SEVENTH FLOOR

LVL + 27870
(BELOW CONTROL TOWER)
4500

LEVEL +23370
SIXTH LEVEL
LVL + 23370
EQ

FIFTH LEVEL
LVL + 20230
9420
EQ

FOURTH LEVEL
LVL + 17090
3140
EQ

900

LEVEL +13950

1100
LVL +600 LVL +600 THIRD FLOOR
LVL + 13950
1800

3550
4500

1800
900

LEVEL +9450

850 900
LVL +600 LVL +600 SECOND FLOOR
LVL ±0.00 LVL -5250 LVL + 9450
1800

800
4500

1800

1800
3500

LEVEL +4950 No. REVISIONS DATE

900

1000 900

FIRST FLOOR
LVL +600 LVL +600 LVL + 4950
1800
4500

3050

3050
4500

1800

GLAZING 900 900

LVL ±0.00
LEVEL +450
450 900

450

PLINTH FLOOR
450

LVL +600 LVL +600 PROJECT TITLE

LVL +450
450

LEVEL ± 0.0 GROUND LEVEL ATC TOWER CUM

5000 7750 6600 8900 7750
LVL ±0.00 TECHNICAL BLOCK (CAT-II, IMD-II)
36000

DRAWING TITLE

F E D C B A LEFT SIDE ELEVATION

AIRPORTS AUTHORITY OF INDIA

DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03

JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR
AM (DWG/ PLN.) SR. MGR (ARCH)
RAJESH BALI MOHSIN KAMAL
G.M. (ARCH.) E.D. (ARCH.)
SUJOY DEY DEBASHIS KHAN
DATE
SCALE 1:250 JUNE 2021
1084 DRG.NO. I N D - A T C A 2 0 9 R
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

TO THE NOTICE OF DEPTT. OF PLANNING.

NOC for Height claerance for ATC Tower

with 5.50 M high VHF Antenna=39.97m

No. PRINTS ISSUED TO DATE

LEVEL +34470 NOC for Height claerance for TERRACE

ATC Tower =34.47m LVL + 34470
(CONTROL TOWER)
NOC for Height claerance for
Technical Block =32.0 m
6600

LEVEL +27870 SEVENTH FLOOR

LVL + 27870
(BELOW CONTROL TOWER)
4500

LEVEL +23370 SIXTH LEVEL

LVL + 23370
EQ

FIFTH LEVEL
LVL + 20230
9420
EQ

FOURTH LEVEL
LVL + 17090
3140
EQ

LEVEL +13950 THIRD FLOOR

LVL + 13950
FIXED GLASS FIXED GLASS
4500

FIXED GLASS FIXED GLASS

LEVEL +9450 SECOND FLOOR

LVL + 9450
FIXED GLASS FIXED GLASS FIXED GLASS FIXED GLASS FIXED GLASS FIXED GLASS
4500

FIXED GLASS FIXED GLASS FIXED GLASS FIXED GLASS FIXED GLASS FIXED GLASS

LEVEL +4950 FIRST FLOOR No. REVISIONS DATE

LVL + 4950
FIXED GLASS FIXED GLASS
900
4500

FIXED GLASS FIXED GLASS

450

LEVEL +450 PLINTH FLOOR

450

LVL +600
LVL +450 PROJECT TITLE

LEVEL ± 0.0 GROUND LEVEL ATC TOWER CUM

5250 5250 5250 5250 10000 5250 5250 5250 5250
LVL ±0.00
TECHNICAL BLOCK (CAT-II, IMD-II)
DRAWING TITLE
10 9 8 7 6 5 4 3 2 1
REAR ELEVATION

AIRPORTS AUTHORITY OF INDIA

DEPARTMENT OF PLANNING
ARCHITECTURAL CELL
AIRPORTS AUTHORITY OF INDIA
RAJIV GANDHI BHAWAN "C" WING SAFDARJUNG AIRPORT. N. DELHI-03

JE (ARCH) AM (ARCH.)
ANUP BHARTI DHRUBAJYOTI SARDAR
AM (DWG/ PLN.) SR. MGR (ARCH)
RAJESH BALI MOHSIN KAMAL
G.M. (ARCH.) E.D. (ARCH.)
SUJOY DEY DEBASHIS KHAN
DATE
SCALE 1:250 JUNE 2021
1085 DRG.NO. I N D - A T C A 2 1 0 R
JOB NO.
 NOTES
1. ALL DIMENSIONS ARE IN MM.

2. DRAWINGS NOT TO BE SCALED, ONLY

WRITTEN DIMENSIONS ARE TO BE FOLLOWED.

3. DISCREPANCY IF ANY, SHOULD BE BROUGHT

TO THE NOTICE OF DEPTT. OF PLANNING.

NOC for Height claerance for ATC Tower

with 5.50 M high VHF Antenna=39.97m

No. PRINTS ISSUED TO DATE

1500
150

LEVEL +34470 R.C.C. SLAB AS PER STRUCTURAL DESIGN NOC for Height claerance for TERRACE
ATC Tower =34.47m LVL + 34470
BEAM AS PER STRUCTURAL DESIGN