Daman 1

5TH STREAM ALUMINA PLANT AT DAMANJODI
1.0 MTPA Alumina Refinery Project
at
Damanjodi
NOTICE INVITING TENDER (NIT)

FOR
AREA GRADING AND ENABLING WORKS
AT 5TH STREAM ALUMINA REFINERY PLANT AT
DAMANJODI, ORISSA
(BIDDING DOCUMENT NO.: 6695-CMG-G00-CA-0011)
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Plant Client Contract Code Document ID Contract No.
1.0 MTPA ALUMINA 6695-CMG-G00-CA-
REFINERY
NALCO NAL 66-6695
0011
AREA GRADING AND ENABLING WORKS FOR 5TH STREAM

ALUMINA PLANT AT DAMANJODI, ORISSA
(DOMESTIC COMPETITIVE BIDDING)
Rev 2 Page 1 of 5
MASTER INDEX
SL.
DESCRIPTION DETAILS PAGE NO:
NO
1 COVER PAGE 01-02
2 INDEX 03-06
3 CONTRACT DETAILS ----- 07
INSTRUCTION TO BIDDERS Annexure-AA 08-33
INSTRUCTIONS TO THE BIDDERS FOR THE E-SUBMISSION

OF THE BIDS Annexure-A to ITB 34-35
4
COMMERCIAL QUESTIONNAIRE Annexure-B to ITB 36-38
GUIDELINE TO BIDDERS ON REVERSE AUCTION Annexure-C to ITB 39-41
5 SCOPE OF WORK & SUPPLY- AREA GRADING & ENABLING Annexure-IA 42-48
WORKS
SCOPE OF WORK & SUPPLY - ELECTRICAL (6695-ELT-G00-
Annexure- I AB 49-58
CA-0001)
TENTATIVE CONSTRUCTION SCHEDULE (LEVEL-1) Annexure-I D 59
6 TECHNICAL SPECIFICATIONS Annexure-IAA 60-1130
A CIVIL, PAINTING & EQUIPMENT 60-551
I GENERAL ENGINEERING SPECIFICATIONS (CIVIL) 6695-CVC-G00-EC- REV-02

0001
TECHNICAL SPECIFICATIONS (CONSTRUCTION) FOR CIVIL 6695-CVC-G00-EC-
II REV-00
/ STRUCTURAL / ARCHITECTURAL WORKS 0002
6695-CVC-G00-EC-
III TECHNICAL SPECIFICATIONS FOR PORTA CABINS REV-01
0005
6695-CVC-G00-EC-
IV TECHNICAL SPECIFICATIONS FOR BORE-WELL REV-01
0006
6695-EQS-G000-
V GENERAL ENGINEERING SPECIFICATIONS (PAINTING) REV-01
EC-0007
VI TECHNICAL SPECIFICATION FOR WEIGH BRIDGE 6695-PIP-G00-EC- REV-00

0009
B PIPING 552-736
I PIPING SPECIFICATION 6695-PIP-G00-EC- REV-02

TECHNICAL REQUIREMENTS FOR PIPES, FITTINGS, 6695-PIP-G00-EC-
II REV-01
FLANGES, GASKETS & FASTENERS 0007
III TECHNICAL REQUIREMENTS FOR VALVES 6695-PIP-G00-EC- REV-02
0008
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29040-CON-DM-
IV GENERAL GUIDELINE FOR UNDERGROUND PIPELINE REV-00
007
C ELECTRICAL 737-1130
6695-ELT-G00-EC-
I GENERAL ENGINEERING SPECIFICATION - ELECTRICAL REV-03
0002
TECHNICAL SPECIFICATIONS – DISTRIBUTION 6695-ELT-G00-EC-

II REV-00
TRANSFORMER – ENERGEY EFFICIENCY CLASS 0006
TECHNICAL SPECIFICATIONS – HIGH VOLTAGE 6695-ELT-G00-EC-

III REV-02
SWITCHGEAR PANELS 0007
TECHNICAL SPECIFICATIONS – LOW VOLTAGE 6695-ELT-G00-EC- REV-02
IV
6695-ELT-G00-EC- REV-00
V TECHNICAL SPECIFICATIONS – LOW VOLTAGE CABLES
0019
TECHNICAL SPECIFICATIONS – MISC. LOW VOLTAGE 6695-ELT-G00-EC- REV-00
VI
TECHNICAL SPECIFICATIONS – INDUSTRIAL LED 6695-ELT-G00-EC- REV-00
VII
LUMINAIRES 0022
TECHNICAL SPECIFICATIONS – GI CABLE TRAY & 6695-ELT-G00-EC- REV-01
VIII
ACCESSORIES 0030
6695-ELT-G00-EC- REV-00
IX TECHNICAL SPECIFICATIONS – HIGH MAST FOR LIGHTING
0031
6695-ELT-G00-EC- REV-00
X TECHNICAL SPECIFICATIONS – BULK MATERIAL
0033
TECHNICAL SPECIFICATIONS – HIGH VOLTAGE CABLES 6695-ELT-G00-EC- REV-00
XI
(11kV & 33kV) 0052
TECHNICAL SPECIFICATIONS – ELECTRICAL 6695-ELT-G00-EC- REV-00
XII
INSTALLATION (CONSTRUCTION POWER SUPPLY) 0055
QAP FOR SITE INSTALLATION, TESTING & 6695-ELT-G00-QA- REV-00

XIII
COMMISSIONING - ELECTRICAL 0001
SPECIAL CONDITIONS OF CONTRACT “SCC” Annexure-IB 1131-1167
7 LIST OF NALCO APPROVED BANK Annexure I-BB 1168-1170
INTEGRITY PACT Annexure-IV BB 1172-1181
ANNEXURE FOR ONLINE SUBMISSION OF EARNEST

8 Appendix-X 1182
MONEY DEPOSIT
9 PRE QUALIFICATION CRITERIA Annexure-I C 1183-1187
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PROFORMA FOR SUBMISSION OF DETAILS OF SPECIFIC

10 EXPERIENCE SUBMITTED AS QUALIFYING WORK ORDER FORM-B 1188-1189
AGAINST PQC STIPULATED AT ANNEXURE- 1C
11 ANNUAL TURNOVER STATEMENT FORM-C 1190
Annexure-I-
12 PREAMBLE TO BOQ 1191-1193
D
13 BANK MANDATE FORM Annexure– V 1194-1195
14 ENVIRONMENT, HEALTH & SAFETY POLICY. Annexure– VIII 1196
15 SOCIAL ACCOUNTABILITY 8000 REQUIREMENTS Annexure– IX 1197-1202
PROFORMA FOR BANK GUARANTEE FOR EMD, SD,

16 Annexure– X 1203-1212
PERFORMANCE , ETC.
17 FORMAT FOR DECLARATION OF BIDDER’S RELATIVES IN Appendix-I & II 1213-1215

NALCO
18 DETAILS OF PRESENT COMMITMENTS Appendix-III 1216
19 DETAIL OF PROPOSED ORGANISATION Appendix-IV 1217
20 FORWARDING LETTER AND UNDERTAKING Appendix-V 1218-1219
21 EXCEPTION/DEVIATION STATEMENT Appendix-VI 1220
22 FORMAT OF DECLARATION BY BIDDER Appendix-VII 1221
23 FORMAT OF WAIVER LETTER Appendix-VIII 1222
22 AFFIDAVIT TOWARDS NON-CRIMINAL BACKGROUND Appendix-IX 1223
23 FORMAT FOR PRE-BID QUERIES Appendix-X 1224

24 KEY CONSTRUCTION PERSONNEL Appendix-XI 1225-1226
25 UNDERTAKING BY THE TENDERER(S) Appendix-XII 1227
26 METHODOLOGY OF EXECUTION Appendix-XIII 1228
27 LITIGATION / ARBITRATION DETAILS Appendix-XIV 1229
28 PAST EXPERIENCE FOR THE LAST 05 YEARS Appendix-XV 1230
29 DEPLOYMENT SCHEDULE OF CONSTRUCTION Appendix-XVI 1231-1232

EQUIPMENT
30 DEPLOYMENT SCHEDULE OF SUPERVISORY PERSONNEL Appendix-XVII 1233-1234
31 DECLARATION OF BLACK LISTING / HOLDING LISTING Appendix-XVIII 1235-1236
32 LIST OF WORKS TO BE SUB-CONTRACTED Appendix-XIX 1237
33 APPROVAL OF CONSTRUCTION SUB-CONTRACTOR Appendix-XX 1238
34 DETAILS OF SAFETY STATISTIC OF PAST 3 YEARS Appendix-XXI 1239
35 FORMAT FOR CONSORTIUM AGREEMENT Appendix-XXII 1240-1243
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Attached
separately
36 BOQ & PRICE BID FORMAT Annexure – II
in excel
files
37 INSPECTION TEST PLAN Annexure-III 1244-1268
38 tkIS OHS & E MANUAL AND CONSTRUCTION MANUAL Annexure-VII 1269-1407
39 TENDER DRAWINGS 1408-1418
6695-CVA-G00-LH-
A CLOSED WAREHOUSE – SCHEMATIC ARCHITECTURAL DRAWING REV-P1
0001
6695-CVA-G00-LH-
B SCHEMATIC ARCHITECTURAL FOR TOILET BLOCKS REV-P0
0002
SITE GRADING – FGL’S FOR SITE PREPARATION (SHEET 1 OF 2) – 6695-LAY-G00-LD-
C REV-R1
OVERALL PLOT PLAN 0001
6695-CVC-G00-LA-
D SITE GRADING – FGL’S FOR SITE PREPARATION (SHEET 2 OF 2) REV-P0
0005
6695-CVC-G00-LA-
E CONCEPTUAL LAYOUT AND DETAILS OF 3 METER HIGH BARRICADING REV-P0
0006
SUV/2018/4095/To
F TOPOGRAPHICAL SURVEY DRAWING Rev-R0
tal Plan
G STANDARD DRAWING FOR HAND RAIL PIN-LEP-CVC-1023 Rev.00
H STANDARD DRAWING FOR FENCING DETAILS PIN-LEP-CVC-1029 Rev.00
CONCEPTUAL PLAN OF CONSTRUCTION WATER & DRINKNIG WATER 6695-LAY-G00-LD-

I Rev.01
NETWORK 0005
6695-ELT-526-FA-
J SLD – CONSTRUCTION POWER FOR 5TH STREAM ALUMINA REFINERY Rev.01
0006
6695-ELT-G00-LD-
K OVERALL PLOT PLAN_ MARKUP , CSS, FEEDER PILLARS, HIGH MAST Rev.01
0001
40 GENERAL CONDITIONS OF CONTRACT “GCC” 1419-1516
41 VENDOR LIST (AREA GRADING AND ENABLING WORKS TENDER) Annexure-XI 1517-1528
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CONTRACT DETAILS
TENDER FOR AREA GRADING AND ENABLING

th
1. NAME OF THE WORK WORKS FOR 5 STREAM ALUMINA REFINERY AT
DAMANJODI, ODISHA
2. TENDER DOCUMENT NO. 6695-CMG-G00-CA-0011
Within 12 (Twelve) months from the date of issue of

3. COMPLETION PERIOD
LOA.
4. MODE OF TENDERING Open e-Tender ( Single Stage Two Part Bid)
5. NUMBER OF AGENCY REQUIRED 01
Rs.1,32,00,000 ( Rupees one crore thirty two lakhs only) –

6. E.M.D.
Through NEFT/RTGS/e-Transfer mode or in shape of BG
7. VALIDITY OF BG SUBMITTED AGAINST EMD 6 Months after validity of offer
8. PERIOD OF DOWNLOAD From 21/09/2018 to 12/11/2018
TENDER SUBMISSION AT CPP PORTAL DATE &

9. Before 16:00 Hrs of Dt. 12/11/2018
TIME (Ref. clause 19.9 of ITB)
TENDER OPENING DATE / TIME (Ref. clause 19.9
10. At 16:00 Hrs of 16/11/2018
of ITB)
Mr. Prashun Kr.Mishra / Mr. T. S. Bharadwaj / Mr.
Waibhav Raut. thyssenkrupp Industrial Solutions
(India) Private Limited, Uhde House, L. B. S. Marg,
11. CONTACT PERSON Vikhroli West, Mumbai, India-400083 Phone : +91-22-
4047 8314 / 8509 / 8622
Email: tkISIndia.nalcotf@thyssenkrupp.com
SUBMISSION OF ORIGINAL BG AGAINST EMD

12. AND ONE SET OF DOCUMENT AS STIPULATED By Dt. 12/11/2018
AT CL. 19 OF ITB AT TKIS OFFICE, MUMBAI
13. VALIDITY OF OFFER (Ref Clause 19.11 of ITB) 4 Months From bid opening date.
14. DEFECT LIABILITY PERIOD 12 Months ( as per clause no-68 of GCC)
PRICE VARIATION
15. Not Applicable
(ref cl no:17.4 of ITB)
16. APPLICABILITY OF GST Applicable
17. SITE VISIT BY BIDDER Before pre-bid meeting.
18. SUBMISSION OF BID QUERIES TO TKIS By Dt. 01/10/2018
Dt. 08/10/2018 Venue: tkIS India Mumbai Office as

19. DATE & VENUE OF PRE-BID MEETING
mentioned in sl.no-11 above.
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INSTRUCTIONS TO BIDDERS (ANNEXURE-AA)
Rev 2 Page 1 of 26
INDEX
1 SCOPE OF WORK: ................................................................................................................... 3

2 RATE: .......................................................................................................................................... 3
3 COMPLETION SCHEDULE: .................................................................................................... 3
4 EARNEST MONEY DEPOSIT (EMD): ................................................................................... 3
5 SECURITY DEPOSIT/PENALTY FOR LATE SUBMISSION OF SECURITY DEPOSIT: ........... 4
6 PAYMENT TERMS: ................................................................................................................... 5

7 TAXES & DUTIES: .................................................................................................................... 5
8 DECLARATION OF RELATIVES WORKING IN NALCO: ................................................. 7
9 MATERIALS; TOOLS & TACKLES; ENERGY/WATER REQUIREMENT: .................... 7
10 SUPERVISION: .......................................................................................................................... 8
11 EXECUTION OF AGREEMENT: ............................................................................................. 8
12 GATE PASS & SECURITY: ..................................................................................................... 8
13 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT SYSTEM : ............................ 10
14 ENVIRONMENTAL REQUIREMENTS: ............................................................................... 11
15 STATUTORY PROVISIONS: ................................................................................................. 12
16 PF ACCOUNT AND ESI CODE: ........................................................................................... 13
17 PAYMENT OF WAGES TO ENGAGED LABOUR AT SITE:........................................... 13
18 GENERAL INFORMATION : ................................................................................................. 14
19 SUBMISSION OF TENDER (E-SUBMISSION OF BIDS) ................................................. 15
20 EVALUATION OF BIDS : ....................................................................................................... 18
21 ACCEPTANCE OF TENDER : .............................................................................................. 19
22 OTHER TERMS & CONDITIONS : ....................................................................................... 20
23 CONDITIONS FOR DEBARRING A CONTRACTOR : ..................................................... 21
24 FORFEITURE OF EMD AND OTHER PENAL CONDITIONS: ........................................ 21
25 COST OF BIDDING ................................................................................................................. 22
26 SITE LOCATION / SITE VISIT............................................................................................... 22
27 BIDDING DOCUMENTS ......................................................................................................... 23
28 CLARIFICATION OF BIDDING DOCUMENT ..................................................................... 23
29 BID PRICES .............................................................................................................................. 24
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30 CURRENCY OF BID AND PAYMENT ................................................................................. 25

31 PRE-BID MEETING ................................................................................................................. 25
32 REBATE/PRICE INCREASE ................................................................................................. 25
33 EVALUATION AND COMPARISON OF PRICES .............................................................. 26
34 OWNER’S/CONSULTANT’S RIGHT TO ACCEPT/REJECT BIDS ................................ 26
35 TENDERER / BIDDER, TENDER / BIDDING DOCUMENT AND TENDER / BID....... 26
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INSTRUCTIONS TO BIDDERS (ITB)
1 SCOPE OF WORK:
The scope of work along with technical specification and drawing shall be as detailed in
Annexure-IA and Annexure- I AB..
2 RATE:
2.1 Bidders are required to submit digitally signed offer ONLINE only along with all
Annexures and Appendices downloaded from www.eprocure.gov.in . Price bid in .xls
format and all other enclosures as required in .pdf format shall be uploaded.
2.2 No premium or discount over quoted rate / total amount should be mentioned separately
in the offer except where asked for.
2.3 Bidders are required to quote for all items of the quantity and Bill of Quantity (Annexure-
II) otherwise the offer will be treated as incomplete offer and may be rejected.
2.4 Bidders are requested to note that there will be no negotiation with L-1 bidder except
under circumstances as per extant CVC guidelines. Reverse Auction shall be carried out
for this tender at CPP Portal after opening of price-bid. Guideline to bidders on Reverse
Auction are appended to this document as Annexure-C.
2.5 The tenderer must quote their most reasonable and workable rate. Overall total
evaluated price for all items of schedule of quantities shall be the basis for determining
gradations of the tenders.
3 COMPLETION SCHEDULE:
Time is the essence of the contract. The contractor shall complete the entire work covered
under this Tender within 12 (Twelve) months from the date of issue of NALCO’s Letter of
Acceptance (LOA).
4 EARNEST MONEY DEPOSIT (EMD):
4.1 The Bidder shall submit the Earnest Money for Rs. 1,32,00,000/- (Rupees One crore
thirty two lakhs only). The EMD shall be submitted in the form of a Bank Guarantee only
and the EMD Bank Guarantee shall be in the Format (Annexure- X to SCC) and from
any NALCO’s Approved Bank (listed in Annexure-1BB to SCC). The EMD Bank
Guarantee shall be valid for a period of eight months from the due date of submission of
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Bid. The Bidder shall submit the EMD Bank Guarantee along with his Techno
Commercial / Unpriced Bid. The offers received without EMD shall be rejected.
4.2 The Public Sectors, Government agencies and the Firms registered with
DGS&D/NSIC/District Industries Centres (DICs) / Khadi & Village Industries
Commission(KVIC)/ Khadi & Village Industries Board (KVIB)/Coir Board/ Directorate of
Handicrafts and Handloom or any other body specified by Ministry of Micro, Small &
Medium Enterprises (for the product for which they are registered), others for which
specific exemption has been granted by NALCO such as Ancillary Industries etc. and all
Startups recognized by Department of Policy and Promotion (DIPP), Ministry of
Commerce and Industry, Govt of India are exempted from submission of EMD, subject
to submission of attested documentary evidence in support of the same along with the
offer. E.M.D shall not carry any interest.
4.3 The EMD will be returned to all unsuccessful bidders within fifteen days of award of the
work. In case of technically rejected bidders, the EMD shall be returned to the bidder
within fifteen days of price bid opening. EMD of successful bidder shall be returned after
submission of Initial Security Deposit /Security Deposit.
4.4 EMD of the successful bidder shall be forfeited if the bidder fails to deposit the requisite
Initial Security Deposit / Security Deposit.
4.5 The Bidders shall have to upload the scanned copy of EMD BG along with the offer.
EMD BG in original shall have to be submitted/deposited to Tender Inviting Authority i.e.
in the office of Consultant thyssenkrupp Industrial Solutions (India) Private Limited,
Uhde house, LBS Marg, Vikhroli West, Mumbai, India – 400083 (the envelope
should be address to Mr. T. S. Bharadwaj, Procurement & Estimation(Tel No. +91
22 4047 8509), before due date as indicated above or within five working days
counted from the last bid submission date in case any extension is granted for bid
submission date.
5 SECURITY DEPOSIT/PENALTY FOR LATE SUBMISSION OF SECURITY

DEPOSIT:
a) The contractor shall furnish a Security Deposit for 5% of the total order value plus
applicable GST within 21 days of placement of LOA by NALCO. The security deposit shall
be furnished in the form of a Bank Guarantee, as per NALCO’s format, executed by any of the
banks mentioned in this Tender. This Security Deposit Bank Guarantee (SDBG) shall be valid for a
period of three months beyond the expiry of the Contractual Defect Liability Period (DLP).
Each page of the Bank Guarantee must be stamped & signed by the authorized signatory(ies) of
the Bank. Corrections, if any, must also be initialled by the authorized signatory(ies) of the Bank.
The Bank is required to send the original Bank Guarantee(s) in confirmation directly to the
beneficiary. For reasons of non-fulfilment of any contractual obligation, if SDBG is invoked, the
same shall be inclusive of applicable GST, at the time of settlement
b) In case the successful bidder fails to submit the SDBG as mentioned above, the SDBG
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amount along with a simple interest @10% per annum as penalty, applicable from the
date of issue of work order till the date of submission of SDBG or submission of 1st RA
bill, shall be recovered starting from 1st RA bill along with applicable GST.
6 PAYMENT TERMS:
6.1 Payment shall be made as indicated in Special Conditions of Contract (SCC) Cl. 12
against Running Account bills duly approved and certified by the Engineer-in-charge.
Such Certificate/ approval by the EIC and passing of the amount so payable shall be
binding and conclusive subject to deduction as per contract, which is subject to
Arithmetical correction if any.
6.2 Payment facility is available under INTERNET mode through company banker as well as
in NEFT / RTGS (National Electronic Fund Transfer / Real Time Gross Settlement)
mode through designated branches. The contractor shall submit duly filled bank
mandate form in duplicate with due authentication from their bankers to avail e-payment
facility. All the payment shall be made only through e-mode. The prescribed form is
enclosed in Annexure-V.
6.3 The final bill shall be submitted by the contractor within one month of the completion of
contract otherwise the contract may be closed ex-parte’ on the basis of the Engineer-in-
Charge certificate of the measurement and the amount payable or recoverable as
certified by the EIC taking all recoveries into account shall be final and binding on the
contractor.
6.4 Wages & other payments to the workmen engaged by the contractor should be made
through Bank and the amount should be deposited in the respective account of the
individual workmen within the stipulated period as per statute. The copy of the payment
sheet along with the copy of bank statement is to be submitted to executing dept. & HRD
dept. for necessary verification and record.
7 TAXES & DUTIES:
7.1 Rate variation in Taxes and any new promulgated taxes after last date of the submission
of price bid only on the goods and/or services applicable to invoices raised on NALCO
within contractual completion period (including extension approved if any) shall be on
NALCO’s Account against submission of documentary evidence.
7.2 Further, in case of delay in delivery of goods and/or services, any upward rate variation
in Taxes and any new promulgated taxes imposed after the contractual completion
period shall be to the Contractor’s Account.
7.3 It would be the responsibility of the contractor to get the registration with the respective
Tax authorities under provision of GST. Any taxes being charged by the Contractors
would be claimed by issuing proper TAX Invoice in a GSTN (Goods & Services Tax
Network) acceptable format indicating details elements of all taxes charged and
necessary requirements as prescribed under the respective tax laws and also to mention
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his correct and valid GSTN number along with NALCO’s GSTN number as applicable for
particular supply on all invoices raised on NALCO under GST Regime.
7.4 The contractor would be liable to reimburse or make good of any loss/claim by NALCO
towards tax credit rejected /disallowed by any tax authorities due to non-deposit of taxes
or non updation of the data in GSTIN network or non-filling of returns or noncompliance
of tax laws by the Contractor by issuance of suitable credit note to NALCO. In case,
contractor does not issues credit note to NALCO, NALCO would be constrained to
recover the amount including interest payable along with Statutory levy/Tax, if any,
payable on such recovery.
7.5 Tax element on any Debit Note / Supplementary invoice, raised by the contractor will be
reimbursed by NALCO as long as the same is within the permissible time limit as per the
respective taxation laws and also permissible under the Contract terms and conditions.
Contractors to ensure that such debit Notes are uploaded while filing the Statutory
returns as may be prescribed from time to time.
7.6 The contractor will be under obligation for quoting/charging correct rate of tax as
prescribed under the respective Tax Laws. Further the Contractor shall avail and pass
on benefits of all exemptions/concessions/benefits/waiver or any other benefits of similar
nature or kind available under the Tax Laws. In no case, differential Tax Claims due to
wrong classification of goods and/or services or understanding of law or rules or
regulations or any other reasons of similar nature shall be entertained by NALCO.
7.7 In case, NALCO’s Input Tax Credit (ITC) is rejected on account of wrong levy of tax i.e.
payment of Integrated Tax in place of Central Tax+ State/Union Territory Tax or vice
versa, the contractor is liable to make good the loss suffered by NALCO by issuance of
suitable credit note to NALCO. In case, contractor does not issue credit note to NALCO,
NALCO would be constrained to recover the amount including interest payable alongwith
Statutory levy, if any, payable on such recovery.
7.8 NALCO shall reimburse GST levied as per invoice issued by the Contractor as
prescribed under section 46 of the CGST Rules 2017 and respective states Act and
Rules.
7.9 To enable NALCO to avail ITC, the contractor/supplier shall furnish/submit any and all
certificates, documents and declarations as are required by NALCO to avail of the ITC
with respect to GST reimbursed by NALCO on materials sold to NALCO.
7.10 The HSN Code under which the goods/service will fall should be clearly mentioned
along with the Rate at the time of submission of invoice for releasing payment.
7.11 In case, NALCO is not able to take Input Tax Credit due to any
noncompliance/default/negligence of the seller, the same shall be recovered from the
pending bills/dues (including any security available with NALCO).
7.12 Seller shall be responsible to indemnify NALCO for any loss, direct or implied, accrued to
NALCO on account of supplier’s failure to discharge his statutory liabilities like paying
taxes on time, filling appropriate returns within the prescribed time etc.
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7.13 Any benefit by way of reduction in rate of tax or increase in input tax credit arising due to
introduction of GST shall be passed on to NALCO through reduction in supply value by
way of commensurate reduction in Bill value
7.14 DEDUCTION OF INCOME TAX, AND TAX DEDUCTION AT SOURCE (TDS ) UNDER
GST
7.14.1 Income Tax as applicable at the prevailing rate on the gross amount billed shall be
deducted from the contractor’s bills.
7.14.2 As per section 51 of CGST Act 2017, NALCO shall deduct at source @ 1% CGST & @
1% SGST for intra state transaction and @2% IGST in the case of interstate transaction
from the payment made or credited to the supplier of taxable goods and/or services,
provided if the contract value is more that Rs.2,50,000/-. This provision is applicable
from the date to be notified by the Government. However, no deduction shall be made if
the location of the supplier & the place of supply is in a State or Union Territory, which is
different from the recipients registration State.
8 DECLARATION OF RELATIVES WORKING IN NALCO:
8.1 The contractors must furnish certificate as mentioned in Appendix – I & II enclosed,
disclosing in detail about their relative / relatives, working in the company. Suppression
of this information in any form if detected at any stage will be disqualification and lead to
rejection of the offer or termination of the contract as the case may be. The concerned
party may be debarred from participation in future tenders.
9 MATERIALS; TOOLS & TACKLES; ENERGY/WATER REQUIREMENT:
9.1 The contractor shall have to make his own arrangement for supply and storage of his
materials / consumables and general tools, tackles, welding sets, electrodes, chain
pulley blocks, slings, gas welding/cutting sets etc. in connection with execution of work.
No extra payment shall be applicable for such provisions. Wherever required
consumables of approved quality like general purpose welding electrodes, cleaning
agents, Oxygen, D.A. etc. to execute the contract shall be in Contractor’s scope and
contractor has to arrange for these materials at their own cost unless mentioned
otherwise in the tender documents attached herewith.
9.2 FREE ISSUE MATERIALS (FIM) / CONSUMABLES / FACILITIES FROM NALCO :
9.2.1 There shall not be any free issue material from NALCO. All materials required for works
are under scope of contractor.
9.2.2 Construction water – Subject to availability, Construction water shall be made available,
in line with provisions of Special Conditions of Contract (SCC), enclosed with this
Bidding Document.
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10 SUPERVISION:
10.1 The contractor shall have to work as per direction of the Engineer-in-charge, and shall
report to him daily regarding day-to-day progress. The contractor shall give full access to
the Engineer-in-charge/ authorized representative of Nalco to inspect day-to-day work
executed by the contractor. Besides the contractor shall have to engage his own
supervisor to ensure proper workmanship and good quality work, which is a part of the
scope of work.
10.2 If required under prevailing statute, the supervision should be carried out by person
holding valid licenses issued by appropriate statutory body.
11 EXECUTION OF AGREEMENT:
The contractor shall have to execute an agreement (in case order value is more than
Rs.1,00,000/-) on non-judicial stamp paper of Rs.50/- purchased in the name of the
Contractor from any registered stamp vendor under the jurisdiction of the Orissa High
Court, in the specific format of NALCO. The agreement shall be executed in the office of
AGM (Elect), P&T Dept, Bhubaneswar within 10 days of receipt by him of the notification
of acceptance of the tender.
Bidders are required to unconditionally accept the "Integrity Pact (IP)" (executed on plain
paper), as per format attached at Annexure-IV-BB of SCC, and submit the same duly
signed on all pages by the Bidder's Authorized Signatory in a separate sealed envelope
along with other documents by the date as stipulated at Pg-3. Bidder and its Subsidiary
(ies) and/or Holding Company and/or Subsidiary (ies) of its Holding Company /
Consortium members shall individually sign Integrity Pact (IP) and shall be submitted in a
separate sealed envelope before stipulated Project Proposal submission time at the
address specified in Data Sheet. Bidder's failure to comply with the aforesaid requirement
regarding submission of Integrity Pact (IP)' shall lead to outright rejection of Project
Proposal as being non-responsive and shall not be opened.
In case of selected bidder being a Joint Venture, in addition to above, after incorporation
of Joint Venture Company, Integrity Pact shall be signed by the Joint Venture Company
along with Project Agreement.
12 GATE PASS & SECURITY:
The contractor shall have to arrange valid gate passes for the labour/ workers engaged
by him in order to enter into the factory premises if the work is to be executed inside
Plant.
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12.1 TIME OF WORK: The factory timings are as follows:
Name of the Shift Duration
From TO
“A” Shift 06.00 AM 02.00 PM
“B” Shift 02.00 PM 10.00 PM
“C” Shift 10.00 PM 06.00 AM
08.00 AM 05.00 PM
General Shift
(Lunch hour 01.00 P.M. to 02.00 PM )
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13 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT SYSTEM :
13.1 SAFETY: The contractor shall have to take necessary safety arrangements / precautions
for the workmen engaged by him and shall be responsible for any First Aid/ Emergency
treatment for his labourers/ workmen. In addition, the contractor shall have to abide by
all fire & safety regulations of the Owner/Consultant. The contractor has to execute the
works after taking necessary instruction & clearance from the safety officer, available at
Plant.
13.2 All lifting/handling tools & tackles should be load-tested as required by law. Mobile
equipment such as Truck, Tractors, Tippers, Dumpers etc. shall have valid fitness
certificate with due insurance required as per law.
13.3 PERSONAL PROTECTIVE EQUIPMENTS (PPEs):
13.3.1 The contractor shall have to provide all necessary PERSONAL PROTECTIVE
EQUIPMENTS (PPEs) like safety shoes, gum boots, helmets, safety goggles, nose
masks etc as applicable to the workmen engaged by them as per the requirement.
Safety aprons and Masks should also be provided to all workmen engaged in caustic /
chemicals working areas. The contractor should ensure use of the above by his
workmen during the contract period. In case the contractor fails to provide PPEs as per
requirement, at the time of starting the job, they will not be allowed to carry out the
assigned job.
13.3.2 The contractor should be aware that the workers engaged by him shall not be allowed to
enter into the plant at the NALCO plant gate unless they wear the safety helmet and
safety shoe. The contractor shall take all necessary steps/actions so that his workmen
enter into the NALCO plant premises with safety helmet and safety shoe.
13.3.3 The occupational health & safety policy is enclosed. The contractor has to ensure
attendance in a training programme for all his contract workers conducted by safety
department and obtain a certificate before putting the workers to work front.
13.3.4 The contractor has to adhere to “NALCO’s safety code for contractors” while executing
the work and the same has to be collected from T & C department while receiving the
work order if awarded.
13.3.5 In case the contractor shows negligence in adherence to the above conditions and
results in causing loss to the company properties or causing obstruction for normal
movement inside the plant, NALCO may take suitable action as deemed fit and NALCO
may severe the business relation with the party.
13.4 Medical Checkup: Contractors will have to submit medical certificate from a Govt.
Hospital or registered medical practitioner in the prescribed format for the workmen
engaged by him along with application for gate pass and for annual renewal. No gate
pass will be issued / renewed unless the medical certificate is enclosed along with the
application.
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13.5 The Engineer in-charge executing the contract as per his assessment that the
Contractor is not performing as per the safety requirements may direct stoppage of work.
The contractor shall not proceed with the work until he has complied with such directions
to the satisfaction of concerned Engineer in-charge.
13.6 The contractor shall be fully responsible for accidents caused due to him or his agents
workmen’s negligence or carelessness in regard to the observance of the safety
requirements and shall be liable to pay compensations for injuries.
13.7 Without prejudice to the right conferred by the Clause 13.5 above for stoppage of work
for violating of safety requirements, the contractor shall be liable for penalty up to Rs.
3,000/- for the first violation and up to Rs.5,000/- for the second violation. For the third
violation, he shall be liable to be debarred from further contracts up to a period of one
year minimum from the date of completion of jobs in hand.
13.8 The Engineer in-charge executing the contract will assess the penalty amount having
regarded to all the circumstances, in particular the nature and the gravity of the violation
& will issue a show-cause notice specifying therein the proposed penalty. Considering
the cause shown by the Contractor, if any the Engineer in-charge executing the contract
shall pass final orders which shall then be final and binding on the contractor. The
penalty amount shall be recoverable from any bill and / or EMD / SD of the Contractor
without any further reference to him.
13.9 Whenever work at height is involved, contractor must obtain working at height permit
from concerned Dept. for the persons required to work at height.
13.10 The Contractor shall also adhere to all OHS requirements as specified elsewhere in this
Bidding document.
14 ENVIRONMENTAL REQUIREMENTS:
14.1 The contractor shall be responsible to promote awareness on the Environmental

requirements among the workmen engaged by them for the subject job and ensure
adherence to sound environmental practices as detailed in the "EHS POLICY"‚ enclosed
herewith.
14.2 The contractor shall remove all the waste/debris generated during the work on each
occasion & dispose off to a place identified by Engineer-in-charge. The thorough up
keeping of the work spot before the contractor leaves the work spot is essential. In case
the contractor fails to comply with the above, the owner may get the up keeping done &
recover the expenses with overheads from the contractor.
14.3 The contractor has to ensure efficient use of natural resources like water, fuel oil and
lubricants.
14.4 In case the contractors are quoting for oil, grease, chemicals and toxic substances or
these substances form a part of materials quoted they should ensure proper storage,
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handling, packing and shifting of materials to our site properly so that the same should
not pollute the environment.
14.5 The contractor should ensure that materials/ equipment quoted is manufactured/
supplied through Eco friendly process/ system.
14.6 The contractor should ensure proper awareness of workers working in their factory/ plant
to maintain for a green and clean environment inside/ outside their plant.
14.7 It will be the responsibility of the contractor to use Eco friendly packing materials.
14.8 The Contractor shall also adhere to all environmental requirements as specified
elsewhere in this Bidding document.
15 STATUTORY PROVISIONS:
15.1 The contractor shall abide by various statutory provisions to the satisfaction of
Central/State Government Authorities. The contractor has to comply with provisions
made in various statutes such as The Contract Labor (Regulation & Abolition) Act 1970,
The payment of Bonus Act 1965. The Employees compensation Act 1923, The
Employees Provident Fund & Misc. provisions Act 1952, The Employees State
Insurance Act 1948, The Payment of wages Act 1936, The Minimum wages Act 1948,
The Industrial Disputes Act 1947, The Factories Act 1948, and the Orissa factory Rules
and all the rules made there under at his own cost. The contractor should pay bonus/ex-
gratia minimum @ 8.33% of wages before Durga puja every year or at the time of full
and final settlement if it is a part of the financial year to all his workmen as per the
provisions of the payment of Bonus Act 1965. In case, the contractor has to engage 20
or more workmen at a time on a day, such contractor has to get his establishment
registered under the Contract Labor (R&A) Act 1970 and he has to obtain license from
the Office of the Assistant Labor Commissioner (Central) Bhubaneswar in time. The
contractor will be given order to work only after he produces labor license as above. In
case of failure of the contractor to comply with any statutory provisions, NALCO as
principal employer, shall have the right to withhold the bills and/or security deposit of the
contractor and/or take such action as it may be deemed fit.
15.2 The contractor shall ensure that the workers employed by him should not carry
excessive weight as per Orissa Factory Rule No.57. No person shall unaided by
another person, lift, carry or move by hand or on head any materials, article, tool or
appliance exceeding the maximum limit in weight i.e. for Adult Male 55 Kg and for Adult
Female 30 Kg.
15.3 The contractor should not engage persons, male or female below 18 years of age and
above 60 years of age for the execution of the work awarded to him.
15.4 In case of electrical contracts, the tenderer should have possessed valid electrical
contractor’s license of MV/HV/EHV as the case may be, issued by licensing authority of
government of Odisha, a copy of which shall be enclosed along with the offer.
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16 PF ACCOUNT AND ESI CODE:
16.1 P.F. ACCOUNT CODE:
The tenderer shall possess independent P.F. “Account Code” from the concerned
Regional Provident Fund Commissioner. A copy of evidence in this respect shall be
furnished as & when required.
16.2 ESI CODE:
The Tenderer/successful bidder shall possess an independent ESI code in the name of
the establishment, to be obtained from the Regional Director, ESI Corporation,
Bhubaneswar, for reporting ESI compliance of the workers engaged by him. A copy of
the letter of allotment of ESI code shall be furnished as evidence and submitted along
with the tender document.
In case the tenderer /contractor is already having an independent ESIC code of

other state/region, they can participate in the tendering process by submitting the
document pertaining to the other state ESIC code.
17 PAYMENT OF WAGES TO ENGAGED LABOUR AT SITE:
17.1 WAGES OF THE CONTRACT LABOR :
17.1.1 The payment of minimum wages to the contractor labors shall be as per the rates
notified by the central government, as per the minimum wages act – 1948 and as
adopted/circulated by the Nalco management from time to time.
17.1.2 The classified workers in different categories will be as per the notification issued by the
central government fixing the minimum wages for above scheduled appointment. Where
the minimum wages notified by the government of Odisha is higher than the rates
notified by the central government, the government of Odisha rates should apply to
concerned scheduled employment as long as the same remains higher than the central
government rates.
Therefore, the contractor must quote their rates considering the following conditions
applicable w.e.f 01.04.2018:
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Sl Category Basic rate of Rates of Additional Canteen Total Minimum

No wages (Rs) VDA (Rs) Element Subsidy wages day (Rs)
w.e.f. of wages (Rs)
01/04/2018 (Rs)
(01) (02) (03) (04) (05) (06)
1 Unskilled 350 20 32 12 414
2 Semiskilled 437 25 32 12 506
3 Skilled / 523 30 32 12 597

Clerical
4 Highly Skilled 610 35 32 12 689
17.1.3 The additional element of Rs. 32/- (rupees Thirty Two) per day indicated above would
qualify for all statutory payments, which are linked to wages like PF and other benefits,
so that the rates quoted by the bidder should include the same.
17.1.4 In addition to minimum wages, an amount of Rs.12/- per day as indicated above shall be
payable to each contract labourer towards canteen subsidy and this will be paid by the
contractor concerned which will qualify for deduction of provident fund only.
17.1.5 The minimum wage as notified by the chief labour commissioner (central) has a variable
component as special allowance which is linked to average AICPI for industrial workers,
which keeps on changing every six months. The contractor has to absorb all such
variations due to increase in minimum wage in their quoted price, and no claim
whatsoever on this account shall be entertained.
17.2 In case the contractor fails to pay wages to the workmen employed by him for the
subject work, NALCO will make the payment and recover the same from the
contractor's bill along with 10 % service charge for the amount paid.
17.3 The contractor failing to make payment of labour wages as per applicable Law, may be
debarred / banned for conducting future business with NALCO.
17.4 PRICE VARIATION AGAINST THE CONTRACT: Not applicable. This is a firm price
contract and agreed rates shall remain Firm without any escalation till completion of work
in all respects. Bidder shall take care of any changes in labour rates and quote
accordingly.
18 GENERAL INFORMATION :
18.1 Before submission of the bid, the bidders should read the entire bid documents carefully
and make themselves fully conversant with all bid documents. The bidder is expected to
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examine the Bidding Documents, including all instructions, FORMS, terms and
conditions of Contract, specifications, drawings and other documents and to fully
familiarize itself with the requirements of the Bidding Documents. Failure to furnish all
the information required by the Bidding Documents or the submission of a bid not
substantially responsive to the Bidding Documents in every respect may result in the
rejection of the Bid.
18.2 Throughout this Bidding Documents, the term "bid" and "tender" and their derivatives
("bidder/ tenderer", "Bid/tender", "bidding/tendering" etc.) are synonymous, and day
means calendar day. Singular also means plural The bidder should visit site and get
familiarized with the site conditions so that, no ambiguity may arise in these respect
subsequent to submission of the bids.
18.3 All the documents mentioned in this Tender and subsequent addendum / corrigendum (if
any) shall form part of the contract. The tenderer is advised to thoroughly read the same
and to seek clarification if any and get themselves satisfied before quoting the rates. It
will be taken for granted by NALCO that tenderer has seen and gone through the terms
and conditions and shall abide by these.
18.4 Wherever transport of material is applicable, the contractor has to ensure that goods
carried during transportation do not exceed permitted laden weight as certified by
registering authority for the respective vehicles.
18.5 Wherever applicable Bank Guarantee are to be submitted in Nalco's prescribed format
only from NALCO’s approved Banker.
18.6 The bidder is required to give the names of other firms / agencies / partnership firm /
wholly owned or partly owned subsidiary etc. where they are having financial /
professional stakes and also give a certificate if any such firm / agency are participating
in the subject tender.
19 SUBMISSION OF TENDER (E-SUBMISSION OF BIDS)
The bidder is required to submit digitally signed bids in the following manner:
19.1 PART – I: The PART-I shall contain the following:
19.1.1 Scanned copy of EMD BG in the approved format from Bank listed under Annexure-I
BB of SCC.
19.1.2 Scanned copy of the Forwarding letter and undertaking confirming acceptance of terms
and conditions of the tender without any deviation along with Pre-Contract Integrity Pact
attached with SCC duly signed and stamped by the bidder.
19.1.3 In case of any unavoidable deviations, scanned copy of deviation statement sheet only
as at Appendix-VI.
19.1.4 Bidder to submit scanned copy of the PF and ESI account duly signed and stamped by
the bidder.
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19.1.5 Scanned copy of Affidavit related to Criminal Background as stipulated Under PQC.
19.1.6 Scanned copy of FORM –B & C (ATTACHED UNDER ANNEXURE-1-C) duly filled up
and signed.
19.1.7 Scanned copy of Appendix-I to XXI, duly filled up and signed, along with all documents
specified in these Appendix-I to XXI.
19.1.8 Scanned copy of General Power of Attorney (GPA) of the signatory of the bid.
19.1.9 Scanned copy of PAN Certificate, PAN based GST registration Certificate, copy of
Proprietorship deed/ Partnership Deed / Articles of Association, & Memorandum of
Association of the bidder.
19.1.10 All documents mentioned in Annexure-1C evidencing fulfilment of the stipulated

Prequalification Criteria.
19.1.11 Bidders shall also submit the EMD instrument in original and the hard copies of all the
scanned documents indicated above along with Complete documentary evidence by
way of copies of Work Orders, Work Completion certificates mentioning the executed
value of the work and annual reports containing audited balance sheets and profit &
loss accounts, statements, duly certified by a qualified Chartered Accountant, in support
of their fulfilling the pre-qualification criteria, within the due date as indicated in document
titled “Contract Details” at the address given in Clause No. 19.8 below. The bidder shall
also note and abide by the instructions mentioned in the enclosed Annexure-1C.
19.2 PART-II:
Part-II comprises of price bid. Bidders shall quote rate in the XLS format for price bid
provided on website only. Bidders shall not send hard copies of price bids. The priced
part shall be unconditional and conditions (if any) shall be un-solicited, which shall be
ignored.
19.3 As the tender is hosted on website, the intending bidder is free to download the same
from the website. The tenderer are advised to submit the tender based strictly on the
Terms and Conditions and Specifications contained in the tender documents including
amendments, if any, issued prior to submission of offer. For amendment if any, with
financial implications, issued after submission of offer, the tenderer shall be entitled to
amend his price, however, no price implication shall be entitled due to any amendment
prior to submission of offer.
19.4 The offers shall be prepared and submitted in two parts e-tender mode. Bidders are
advised to go through Annexure-A to ITB before submitting their bids in e-tender mode.
Part-I comprises of EMD amount and technical bid and Part-II comprises of price bid as
per format uploaded in the CPP Portal.
19.5 The tender shall be complete in all respects with all their attachments/enclosures. All the
technical documents, annexure and forms filled in with respect to the tender document
should be duly signed and stamped by the bidder.
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19.6 CONSULTANT / OWNER expect the Bidder to comply with the requirements of the
Bidding Document without any deviation and submit substantially responsive bid. In
case deviation is unavoidable, bidders are instructed to give all deviations in the
enclosed deviation statement sheet only (Appendix-VI). Please be informed that only
deviations mentioned in Appendix-VI will be evaluated and considered.
Deviation(s) listed at any other place shall not be considered at all and shall not
be binding on NALCO. CONSULTANT / OWNER reserve the right to reject as non-
responsive any bid containing major deviation(s).
19.7 EMD amount in original along with hard copy of all the document as stipulated at Sl. No.
19.1 (Part-I) is to be submitted in a sealed envelope and the following shall be separately
SUPERSCRIBED prominently on the outside of the envelope:
NAME OF WORK : Area Grading and enabling works for 5th Stream Alumina
Refinery at Damanjodi and Related Facilities at
Vishakapatnam Port.
TENDER NO. : 6695-CMG-G00-CA-0011
The full name, postal address and telephone number / E-mail ID of the Tenderer shall be
written on the bottom left corner of the sealed envelope.
19.8 RECEIPT OF EMD INSTRUMENT IN ORIGINAL & OTHER DOCUMENT
EMD instrument along with other document as stipulated in Clause Number 19.1 above
shall be submitted by the Bidder at the following address by Registered
Post/Courier/hand delivery on or before the Bid submission due date and time indicated
in document titled “Contract Details”.
thyssenkrupp Industrial Solutions (India) Private Limited,
Uhde house, LBS Marg, Vikhroli West, Mumbai, India – 400083
Tel No. +91 22 4047 8509
Attention : Mr. T. S. Bharadwaj, Procurement & Estimation,
NALCO/tkIS is in no way responsible for late delivery of the documents.
19.9 Offers are to be uploaded in the e-procure site of CPP Portal (www.eprocure.gov.in) on
or before time & date specified at Sl. No. 9 of Page-7 of tender document. The PART-I
bids in case of two part tendering and Single part bid in case of single tendering shall be
opened at the time & date specified Sl. No. 10 of Page-7 of tender document.
19.10 In the event of the office remaining closed on the Bid opening date, tenders will be
opened on the next working day as per the convenience of the concerned officials.
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19.11 The validity period of the offers submitted by the bidders shall be as indicated in
document titled “Contract Details” from the date of opening of Tender (Part-I bid in case
of Two/Three part tender ) . However, NALCO reserves the right to defer the date of
tender opening in case the response is considered to be inadequate or due to any other
reasons. In such event, the bidders shall have to visit the site www.eprocure.gov.in to
see the next tender opening date. In such case, validity period of the offer shall be
reckoned from the date of actual tender opening.
The price bids of only the technically & commercially qualified bidders shall be opened on
a later date. The date & time of opening of price bid shall be intimated to the qualified
bidders. The price bids shall also be opened ON LINE.
19.12 deleted.
19.13 The tenderer shall ensure submission of complete information / documents in the first
instant itself. NALCO / Consultant reserves the right to evaluate the offer based on the
details furnished by the bidders on the scheduled date of tender submission without
seeking any subsequent additional information.
20 EVALUATION OF BIDS :
20.1 The price bids of the techno-commercially qualified bids in case of two part bid system &
bids in case of single part bidding shall be evaluated to arrive at the lowest (L-1) bidder
as indicated below.
20.2 Loading for unquoted items: In case any bidder(s) does not quote for any items, then
such offer(s) shall be evaluated by considering rate of such unquoted items as average
of the rates quoted by the other bidders against such items or estimated rate of that item
whichever is low. After evaluation if it is observed that the total value of unquoted items
is more than 10% of total evaluated price, then the offer shall be rejected as incomplete
offer. But if after evaluation it is observed that the total value of unquoted items is less
than 10% of total evaluated price and the items cannot be deleted from the scope of
tender certified by user dept. and such bidder happens to be the L-1 bidder, rate for the
unquoted items as calculated above shall be offered to the bidder for acceptance. On
acceptance of the offered rate by the bidder, offer of the bidder shall be accepted as
lowest against the tender and shall be processed for award of work. In case of more
than one offer with unquoted rates, such offer shall be evaluated as above and offer
shall be made to the bidders in order of their position as stipulated above, in case of
refusal by the lowest tender. In case all bidders with unquoted items with implication less
than 10% of the evaluated price refused to accept the offered rates, then offers of such
bidders shall be rejected against the tender as incomplete offer and the lowest complete
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offer against the tender shall be processed for award of work. Offered rates to the
bidder(s) as indicated above shall not be considered as negotiation.
20.3 Financial implications of the agreed deviation as per assessment of NALCO will be
loaded on the price quoted by the bidder. Deviation not accepted by NALCO will have to
be withdrawn by the bidder otherwise such bids may be disqualified/rejected.
20.4 The complete scope of supplies and work/services has been defined in the bidding
documents. Only those bidders who take complete responsibility and who bid for the
complete scope of supplies and work/services as contained in the bidding document
shall be considered for further evaluation.
20.5 Conditional discount if offered shall not be considered for evaluation.
20.6 Any uncalled for lumpsum / percentage or adhoc reduction / increase in prices offered by
the Bidders after opening of the prices, shall not be considered. However, if reduction is
from the recommended Bidder, such reduction shall be taken into account for arriving at
the total contract value and not for evaluation purpose.
20.7 The evaluation & comparison of prices shall be done based on prices quoted by bidders.
20.8 The prices will be loaded by GST at the presently applicable rate of 18%.
20.9 In case of Tie between two or more bidders at L1 position, all the L1 bidders shall be
asked to submit discount over previous quoted rate in sealed envelope (Unpriced &
Priced).
21 ACCEPTANCE OF TENDER :
21.1 Vendors may note that, any pending case or conviction by a Court of Law or indictment
/ adverse order by regulatory authority against the person, company or against any sister
concern which relates to a criminal offence would constitute disqualification’’
21.2 A bidder may seek clarification regarding the bidding document provisions, bidding
process and / or rejection of his bid. NALCO / Consultant shall respond to such queries
within a reasonable time.
21.3 Clarifications, if any, can be obtained from person indicated in in document titled
“Contract Details”.
21.4 NALCO/tkIS reserves the right to award the work in parts between two or more agencies
if considered expedient. Reference is invited to clause 9 of General conditions of
contract for the above conditions if arises.
21.5 Successful Bidders may note that, Letter of Award or work order issued to them is based
on acceptance of their offer and the contract is binding on the bidder. Bidder may return
a copy of the same duly signed by the authorized representative as a token of
acknowledgement of the order.
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22 OTHER TERMS & CONDITIONS :
22.1 If found suitable, Preference for engagement of labours under NALCO’s contractors
establishment may be given to the land affected persons.
22.2 The contractor has to dismantle the structure constructed by him for the purpose of
office-cum-store on completion of the contract as per the provision of GCC clause
no.2.4.2. If the same is not dismantled within two months of completion of contract he
will not be issued any tender paper or will not be allowed to participate in any tender
including with-holding of final bill besides initiation of other contractual/legal action as
deemed fit against the contractor.
22.3 The contract shall be subject to the provisions of GCC save those provisions of GCC,
which are superseded by the above clauses under instruction to Bidders.
22.4 If conflicts between documents, comprising the contract arise, the following shall prevail
in the order as below;
• FOA/ LOA/WO including any agreed variation.

• Schedule of rates/Bill of Quantity
• Technical specifications
• Drawings
• Relevant Indian Standards
• Special Conditions of Contract
• Instruction to Bidders
• General Conditions of Contract
• Other documents
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22.5 If any alteration or modification to the tender document is done by the bidder, the offer
shall be rejected.
22.6 If any bidder is having any unauthorized structure / occupation inside Nalco Township /
Plant, their offer may not be considered for evaluation and shall be liable for rejection.
23 CONDITIONS FOR DEBARRING A CONTRACTOR :
23.1 Failure to mobilize for the work - The contractor does not mobilize and start work on the
scheduled date or within reasonable period.
23.2 Failure to maintain required quality of work - If the quality rating is less than 50% at any
instance. Subsequent fortnightly rating will be done and if the same is less than 50%, it
will be construed as a failure.
23.3 Failure to adhere to the time schedule of work - Time schedule indicated by executing
engineers will be compiled every week and default in adhering to schedule will have to
be reported to HOD for necessary action. Depending on the plant requirements HOD
may initiate debarring proposal.
23.4 Failure to make labour payment at least twice in a contract.
23.5 In case of any serious offence committed by the party: e.g.- fraud, sabotage, theft of
company property etc. starting from participation in the tender or any time during
execution of work if successful against the tender, debarring process starts immediately.
24 FORFEITURE OF EMD AND OTHER PENAL CONDITIONS:
EMD shall be forfeited and other penal actions may be taken in case any of the below
conditions are fulfilled.
If the Bidder withdraws or varies its bid suo motto during the period of Bid validity.
If the bidder / his representatives commit any fraud while competing for this contract
pursuant to Fraud Prevention Policy of NALCO
In case the bidder / contractor is disqualified from the bidding process in terms of section
3 & 4 of Integrity pact.
(Following data to be furnished by the bidder, which are mandatory)
Name of the Signatory:……………………………………………………………………….
Postal address of the firm: ……………………………………………………..……………
Email Address : ……………………………………………………………………………….
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Phone No. : …………………………… Mobile No. : …………………………………….
PF No. : …………………..…………… ESI No. : ………………………….……………..
PAN No. : …………………………...…… TIN No. : ………………………….……………
PAN based Service Tax Reg. No. : …………………………………………………….…
BANK Detail with IFS Code………………………………………………………
25 COST OF BIDDING
The bidder shall bear all costs associated with the preparation and delivery of its
bid including (but not limited to) costs and expenses related to visits to the site(s) and
other locations, and the cost of any tests, investigations, evaluations and
consultations. The OWNER will in no case be responsible or liable for any costs
regardless of the outcome of the bidding process.
26 SITE LOCATION / SITE VISIT
The Project Site is located at Damanjodi in the State of Odisha. The Site is well
connected by Rail and R o a d from other parts of India. Nearest Airport is at
Bhubaneshwar.
Bidder is advised to visit and examine the site, its surroundings and familiarize himself of
the existing facilities and environment, and collect all other information which he may
require for preparing and submitting the bid and entering into the Contract. Claims and
objections due to ignorance of existing conditions or inadequacy of information will not be
considered after submission of the bid and during implementation.
The Bidder and any of his personnel or agents will be granted permission by the Owner to
enter upon his premises and land for the purpose of such inspection, but only upon the
explicit condition that the Bidder, his personnel or agents will release and indemnify the
Owner and his personnel and agents from and against all liability in respect thereof and
will be responsible for personnel injury (whether fatal or otherwise), loss of or damage to
property and any other loss, damage, cost and expenses incurred as a result thereof.
For site visit, the bidder may contact :
Mr. Sushil Kumar Padhee
General Manager (Project & CRG) / M&R Complex
Mob: 9437030531
E-mail: sushil.padhee@nalcoindia.co.in
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27 BIDDING DOCUMENTS
The bidder is expected to examine the bidding documents, including all instructions,
FORMs, terms and conditions of Contract, specifications, drawings and other
documents and to fully familiarize itself with the requirements of the bidding documents.
Failure to furnish all the information required by the bidding documents or the
submission of a bid not substantially responsive to the bidding documents in every
respect may result in the rejection of the Bid.
28 CLARIFICATION OF BIDDING DOCUMENT
28.1 Bidder shall examine the Bidding Document thoroughly in all respect and if any conflict,
discrepancy, error or omission is observed, Bidder may request clarification within the
cut-off date as specified in Bidding Document or one week prior to the Bid Due Date.
Such clarification requests shall be directed to the e-mail address given in Bidding
Document.
28.2 Any failure by Bidder to comply with the aforesaid requirement shall not excuse the
Bidder, after subsequent award of Contract, from performing the work in accordance
with the Contract.
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28.3 Response to queries/ clarifications raised will be sent as expeditiously as possible to

all who have been issued the Bidding Document through e-mail and also hosted
on OWNER’s website. The response shall not form part of the Bidding Document
downloaded unless issued as an Addendum / Corrigendum / Amendment.
28.4 Bidders are expected to resolve all their clarifications/ queries to the Bidding
Document and submit their bid in total compliance to Bidding Document without any
deviation/ stipulation/ clarification.
28.5 Pre-bid meeting shall be organized as per details given in Bidding Document.
28.6 All questions and clarifications related to Bidding documents shall be

addressed in writing to:
Mr. Waibhav Raut / Mr. Prashun Kr. Mishra
thyssenKrupp Industrial Solutions (India) Private Limited
(Formerly Uhde India Private Limited)
Uhde House, L B S Marg, Vikhroli (W),
Mumbai - 400083, India.
Phone : +91-22-40478622 / 4047 8314
Email: tkISIndia.nalcotf@thyssenkrupp.com
28.7 All replies to such questions of common interest will be circulated to all bidders without
identifying the source of inquiry.
28.8 NALCO / Consultant also reserves the right to issue Addendum / Corrigendum /
Amendment subsequently.
29 BID PRICES
29.1 The Contract shall be for the total works as described in Bidding Document, based on
the Schedule of Rates submitted by the Bidder and accepted by the OWNER.
29.2 Bidder shall quote price after careful analysis of cost involved for the performance of
the work considering all parts of the Bidding Document. In case any activity though
specifically not covered in description of item under `Price Schedule (PS)' but is
required to complete the work which could be reasonably implied/ inferred from the
contents of the Bidding Document, the prices quoted shall be deemed to be inclusive of
cost incurred for such activity.
29.3 The prices shall be based on conditions specified in General Conditions of

Contract, Special Conditions of Contract, Scope of Work, Scope of Supply, Technical
Specifications, Drawings and other contents of Bidding Document
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29.4 Prices quoted by the bidder, shall remain firm, fixed and valid until completion of the
Contract performance and will not be subject to variation or escalation on any account.
29.5 Alternative bids will not be considered.
30 CURRENCY OF BID AND PAYMENT
The Currency of Bid and Payment shall be only in Indian Rupees (INR).
31 PRE-BID MEETING
The bidder or his authorized representative(s) (limited to 2 persons), is advised to

attend a pre-bid meeting in the office of Consultant in Mumbai. The purpose of the
meeting will be to clarify issues and to answer questions on any matter pertaining
to the Tender conditions that may be raised at that stage by Bidders to whom Bidding
Document have been issued.
The bidder may submit any queries/clarification/information pertaining to bidding

documents in writing delivered by hand or by e-mail as per Proposal
Appendix-X enclosed in the bidding documents so as to reach OWNER/Consultant not

later than the date specified in the Bidding Document (however, in any case, before the
pre-bid meeting). Queries/ Clarifications/ Information sought in any other manner shall
not be responded to.
The OWNER’s/Consultant’s responses to Bidder’s queries/clarifications raised will be

furnished as expeditiously as possible. Any modification of the Bidding Documents
which may become necessary as a result of the pre-bid meeting/conference shall be
sent to all bidders through the issue of an Addendum.
32 REBATE/PRICE INCREASE
32.1 No suo-moto reduction in price(s) by bidders is permissible after opening of the bid. If
any Bidder unilaterally reduces the price(s) quoted by him in his bid after opening of
bids, such reduction shall not be considered for comparison of prices but shall be
binding on the Bidder if he happens to be selected for award of work.
32.2 In the event of any suo-moto price increase sought by a Bidder subsequent to the bid
due date and which is not as a result of any change in scope of supply/services or terms
and conditions, the bid of such bidder shall be rejected.
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33 EVALUATION AND COMPARISON OF PRICES
Refer Clause No.20 above.
34 OWNER’S/CONSULTANT’S RIGHT TO ACCEPT/REJECT BIDS
34.1 The OWNER/CONSULTANT reserves the right to accept or reject any bid and to
annul the bidding process and reject all bids at any time prior to award of Contract
without thereby incurring any liability to the affected bidder(s) or any obligation to inform
the affected bidder(s) of the ground of OWNER’s/CONSULTANT’s action.
34.2 The OWNER shall not be obliged to award the Contract to the lowest evaluated bidder
if the OWNER apprehends that it will not be in the interest of the OWNER or the work to
award the Contract at the lowest evaluated price or to the lowest evaluated bidder.
35 TENDERER / BIDDER, TENDER / BIDDING DOCUMENT AND TENDER / BID
The terms TENDERER or BIDDER, TENDER DOCUMENT or BIDDING DOCUMENT

and TENDER or BID appearing in this bidding document are synonymous.
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NATIONAL ALUMINIUM COMPANY LIMITED
NALCO
Registered Office
th
IDCO Tower, 8 Floor, Janapath, Bhubaneswar-751007
Annexure-A to ITB
Instructions to the Bidders for the e-submission of the bids
1. Bidder should do the registration in the tender site http://eprocure.gov.in using the option available.
Then the Digital Signature registration has to be done with the e-token, after logging into the site.
2. Bidder then login to the site through giving user id / password chosen during registration. The e-token
that is registered should be used by the bidder and should not be misused by others.
3. Please go to the CPP portal. Search for the e-procurement tender No. 6695-CMG-G00-CA-0011
4. The Bidders can update well in advance, the documents such as certificates, work order details etc.,
under My Documents option and these can be selected as per tender requirements and then send
along with bid documents during bid submission.
5. After downloading / getting the tender schedules, the Bidder should go through them carefully and
then submit the documents as asked, otherwise, the bid will be rejected.
6. If there are any clarifications, this may be obtained online through the tender site, or through the
contact details. Bidder should take into account of the corrigendum/addendum published before
submitting the bids online.
7. Bidder, in advance, should get ready the bid documents to be submitted as indicated in the tender
schedule and they should be in PDF/xls/rar/dwf formats. If there is more than one document, they can
be clubbed together.
8. Bidder should get ready with the EMD as specified in the tender. Scan copy of the EMD instrument to
be uploaded along with other documents as requested. The original instrument along with all other
specified hard copy of documents (one set) should be posted/couriered/given in person so as to reach
the Tender Inviting Authority, within due date as indicated at Pg-3. Non receipt of the documents
along with original EMD instrument within the stipulated period may lead to rejection of the offer of
the bidder.
9. The bidder reads the terms & conditions and accepts the same to proceed further to submit the bids
10. The bidder has to submit the tender document online well in advance before the prescribed time to
avoid any delay or problem during the submission process.
11. After the bid submission, the acknowledgement number, given by the e-tendering system should be
printed by the bidder and kept as a record of evidence for online submission of bid for the particular
tender.
12. The Tender Inviting Authority (TIA) will not be held responsible for any sort of delay or the difficulties
faced during the submission of bids online by the bidders.
13. The bidder should see that the bid documents submitted should be free from virus and if the
documents could not be opened, due to virus, during tender opening, the bid is liable to be rejected
14. The time settings fixed in the server side & displayed at the top of the tender site, will be valid for all
actions of requesting, bid submission, bid opening etc., in the e-tender system. The bidders should
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15. All the data being entered by the bidders would be encrypted using PKI encryption techniques to
ensure the secrecy of the data. The data entered will not viewable by unauthorized persons during bid
submission & not be viewable by any one until the time of bid opening. Overall, the submitted tender
documents become readable only after the tender opening by the authorized individual.
16. The confidentiality of the bids is maintained since the secured Socket Layer 128 bit encryption
technology is used. Data storage encryption of sensitive fields is done.
17. The bidders are requested to submit the bids through online e-tendering system to the TIA well before
the bid submission end date & time (as per Server System Clock).
18. The bidder should logout of the tendering system using the normal logout option available at the top
right hand corner and not by selecting the (X) option in the browser.
19. If the bidder submits the bid in manual form (if permitted categorically in the tender), he should have
already registered in the tender site and he has to inform the registration ID in the bid submitted
otherwise his tender will not be considered.
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COMMERCIAL QUESTIONNAIRE (ANNEXURE-B) Rev Page of
2 1 3
SR. tkIS India ’s QUERY BIDDER’s REPLY /

NO. CONFIRMATION
1. Confirm that you have studied complete Bidding
Document including Technical and Commercial Part and
your Bid is in accordance with the requirements of the
Bidding Document.
2. Confirm that the Price Part does not include any terms
and condition.
No stipulation, overwriting, deviation, terms & conditions,
presumption, basis etc. shall be stipulated in Priced Bid.
Consultant / Owner shall not take cognizance of any
such statement and may at their discretion reject such
Priced Bid
3. Confirm your compliance to total scope of work
mentioned in the Bidding Document.
4. Confirm your acceptance for “SCOPE OF SUPPLY”
Please note that scope of supply mentioned in the
Bidding Document is not limitative and except for the
material specifically identified as that to be issued by
Owner. Contractor’s scope shall include supply of all
materials required for completion of Work irrespective of
whether such materials are mentioned in the Bidding
Document or not.
5. Confirm your acceptance for Time Schedule as
6. Confirm that your quoted price includes all type of taxes /
levies (except GST which will be paid by NALCO extra
as applicable as per the provisions of the bidding
documents) as per provisions of Bidding Document.
7. Confirm that your quoted price includes all type of
Insurances as per provisions of Bidding Document.
8. Confirm that your Bid is substantially responsive to the

requirements of the Bidding Document and you have not
stipulated any material deviation and submitted all details
as specified in the Bidding Document.
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9. Confirm that you have proposed adequate construction

equipment/machineries, tools and tackles with sufficient
quantity to complete the works in all respect as per the
provisions of the bidding document.
10. Confirm that you have proposed adequate project / site

organisation with qualified supervisory personnel having
sufficient experience.
11. Confirm that all costs resulting from safe execution of
Work, such as safety induction, use of protective
clothing, safety glasses and helmet, safety precaution
taken during monsoon, or any other safety measures to
be undertaken by the Contractor for execution of Work
are included in the quoted Price.
12. Please confirm that all safety rules & regulations as
mentioned in Bidding Document or notified at later date
by Owner during execution shall be adhered by
Contractor within the quoted Price.
13. Confirm that the following safety precautions shall be
followed by Contractor as mandatory :
- Use of safety goggles while grinding.
- Use of helmet / safety shoes.
- Crane movement area to be barricaded.
- Cylinders of flammable gases to be stacked upright
- Earthling of equipment to be made proper.
- Toe boards to be provided in the Scaffolding
platforms.
- Excavations to be properly shored / slopped.
- Safety net for construction
14. Confirm the following :-
“The planning schedule, S-curves, manpower estimates,
construction equipment deployment schedule etc.
submitted by the bidder with his bid are indicative and
shall not be basis for extra compensation in case actual
needs are higher.
Detailed planning schedule developed by
CONTRACTOR after award of Contract may be subject
to fluctuations depending upon actual progress of the
project and available Work front.
Co-ordination and making available by CONTRACTOR

staff, manpower, construction equipment, tools, cranes,
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etc. and materials as required for a timely completion of

all Work as per OWNER’s construction and priority
schedule and in accordance with the available Work front
are to be included in the pricing.
Notwithstanding the above provision, the bidder shall
submit these details in accordance with the volume of
work, which may be reviewed and commented by us
during pre-award stage /post award stage.
15. Please furnish the bio data of key project personnel as per
the requirement stipulated in the bidding document.
16. Please confirm that your quoted price includes cost of all
inspection and testing as per the provision of the Bidding
Document.
17. The scope of work mentioned under various sections shall
not be considered as limitative and CONTRACTOR’s
scope shall include completion of any activities of work not
mentioned in the bid package but required to complete the
Work in all respects and making it functional.
18. The safety measures as mentioned in GCC/SCC shall not
be considered as limitative. The Contractor will be required
to develop their stringent safety measures and submit the
same to Engineer-in - Charge with the provision of a
dedicated safety group closely monitoring the construction
activities in all working shifts.
19. Bidder to confirm whether they require Mobilization
advance - Yes/No
20. Confirm that your bid is valid for 04 months from the due
date for submission of bid.
(STAMP AND SIGNATURE OF BIDDER)
Date:
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Guideline to bidders on Reverse Auction (ANNEXURE-C) Rev Page of
2 1 3
1. If a bidder does not participate in the Reverse Auction, the price quoted by him in the
price bid shall be considered as the valid price of that bidder. The inter-se position of
the said bidder shall be considered based on their position on completion of reverse
auction.
2. Price bid shall be opened at --:-- Hrs on --.--.---- and Reverse Auction shall commence
at about --:-- Hrs on --.--.---- and shall remain open for minimum two hours. Date &
Time of Price bid opening shall be uploaded along with technical evaluation of the
tender at CPP Portal. Start & end time of Reverse Auction shall be configured at CPP
Portal after price bid opening and before start of reverse auction.
3. Starting bid price shall be the L1 offer price received against the tender.
4. Bid Decremental Value shall be Rs 50,000/-.
5. Elapsed time and Auto Extension Time shall be set as 10 Minutes
6. Other relevant parameters shall be displayed in the CPP Portal reverse auction
window.
7. CPP Portal Server time shall be the basis of Start time & Closing time for bidding and
shall be binding for all.
8. Auction flow is started and is closed after completion of the process. Once the Auction
process is initiated the system takes over for auto auction activity. Then, comparison
chart is generated.
9. The bidders to participate in tender-cum-auction process in CPP Portal, has to log into
CPP Portal (i.e. https://eprocure.gov.in/eprocure/app) with DSC to access the
application and quote from their own offices/place of their choice. Once logged in, the
software gives them a platform to place bids.
10. All electronic bids submitted during the reverse auction process shall be legally
binding on the bidder. The bid values submitted by the bidder are digitally signed by
the bidders before submitting. The bidder, after initial submission of a bid, cannot
subsequently increase the bid. They can only reduce their bid by the minimum
permissible decrement or its multiples. The last bid submitted by the bidder in the
Reverse Auction will be considered as the valid price bid offered by that bidder and
will be the basis for evaluation / acceptance by Nalco.
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11. System displays L1 landed price in auction creation form and allows TIA to edit the
value as ‘start bid’ price. Normally, TIAs will enter the L-1 Price as the start bid price.
12. Elapsed time & Auto Extension Time: Shall be set as 10 (Ten) minutes. All the
bidders shall get at least 10 minutes time period to submit their fresh bids, after receipt
of latest bid during reverse auction process. There will be auto extensions of time,
every time, (by ten minutes) on receipt of any valid bid with in the last 10 minutes time
period calculated from prevailing bid end time. For example, if bid end time is set as
11:00 Hrs and if any fresh bid is received during 10:50 and 11:00 Hrs, bid end time
shall be auto extended by 10 minutes to 11:10 Hrs. If bids are received during last 10
minutes of end time, bid end time keeps on auto extended by 10 minutes every time.
The reverse auction will come to a close only when there is no new bid recorded in the
last ten minutes slot of bid end time.
13. Maximum Seal Percentage: Shall be set as 3%. It is the maximum reduction that can
be allowed in the bidding process in a single go. Higher reduction will not be allowed
by the system. This protects any possible mistakes by bidders. For any higher
discount, the bidder has to repeat the action and the system allows it.
14. Only the chronologically last bid submitted by the bidder till the end of the auction shall
be considered as the valid price bid of that bidder. Any bid submitted earlier by the
bidder prior to submission of his last bid will not be considered as valid price bid.
15. Final BOQ-Comparative-Chart is generated from the system, by freezing the tender at
the end of reverse auction process. This chart contains original offer and L1 auction
price details. The log details of the entire reverse auction process will be generated by
the system once the process of reverse auction is completed. The above information
can also be accessed by the participating bidders, once the reverse auction is
completed.
16. In case of Item-rate-BOQ for placement of order on over-all-L-1 basis; after

completion of auction process the rates of individual items are reduced proportionately
to match the lowest landed rate quoted by the L1 bidder, in the reverse auction
process.
17. In case of disruption of service at the CPP Portal end during Reverse Auction
Process, the Reverse Auction Process will start all over again. In such a situation, the
last recorded lowest price of prematurely ended Reverse Auction Process, will be the
‘Start Bid’ price for the restarted process. Disruption and restarting of Reverse Auction
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Process shall be intimated to all the bidders through system/SMS/e-mail through CPP
Portal. All the stipulations of pre-maturely ended Reverse Auction Process will be
applicable to the restarted process.
18. Bidders at their own interest should ensure uninterrupted internet connectivity at their
end during the reverse auction with necessary backups to take care of any
connectivity problem.
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SCOPE OF WORK AND SCOPE OF SUPPLY
ANNEXURE-I A Rev 2 Page 1 of 7
1.0 INTRODUCTION
M/S NALCO (National Aluminium Company Limited) intends to set up the fifth stream
Alumina Refinery at their Damanjodi Site in the state of Odisha, India. thyssenkrupp
Industrial Solutions (India) Private Limited (tkIS India) has been selected as EPCM
Consultant for the same.
In order to facilitate the construction activities for the 5th stream Refinery Project, it is
necessary to carry out the Area Grading & Enabling Works as a separate Contract prior to
the main works contracts.
1.1 The purpose of this document is to enumerate in brief the scope of work and activities to be
performed by the Contractor. This shall be read in conjunction with Schedule of Rates,
general conditions of contract, Special Condition of Contract, specifications, drawings and
all other documents forming part of this Bid.
1.2 Notwithstanding the sub-division of the documents into these separate sections and
columns, every part of each shall be deemed to be supplementary to and complementary to
every other part and shall be read with the contract.
2.0 BRIEF SCOPE OF WORK
The scope of work in general includes all works specified in various Technical
Specifications and Bill of Quantities enclosed in the Bid Document and shall include but not
limited to the followings.
The project site is at hilly terrain area and required area grading and enabling works to
develop the area for Process Units, laydown yard, office facility, store yard, parking area
and labour hutments. Under this contract, area grading, hard barricading, gates, road &
drains, retaining wall, culverts, fencing, temporary site office, training center, closed
warehouse structure, water distribution network, concrete water reservoir, dismantling of
existing structures, weigh bridge, bore well, submersible pumps, security gate, re-routing of
existing live cables, power distribution network and lighting masts are included.
2.1 The scope of work includes mobilization of required man and machineries and consumables
to carry out the area grading and enabling works and as per the schedule of rates and
technical specification.
2.2 Contractor to mobilize sufficient number of excavators, hard rock breakers, earth
compactors/rollers, dumpers and other required resources for execution of area grading
work within stipulated time.
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2.3 Contractor to transfer and establish bench marks using existing permanent bench marks
nearby.
2.4 Bidder shall carryout dewatering manually or by deploying sufficient pumps at no additional
cost to Owner and keep site clean from sub-soil water, flooding excavation / pits
due to rain, water from nearby plant, spillages or any other such instances.
2.5 All materials, equipment, consumables machinery etc., required for successful completion of
the work shall be supplied by the contractor in their quoted rates.
2.6 Supply, installation and commissioning of temporary Site Office, Store, Security Office with
handrails for queuing of labours, Training Centre, Structural Gate, hard barricading, Chain
link fencing, Closed Warehouse structure, weigh bridge, bore well, submersible pumps and
piping work to supply Water.
2.7 Other miscellaneous work to be carried out such as removal of existing structures (sheds,
lighting mast etc.), power distribution to construction site, offices, laydown area and labour
camp area.
2.8 It includes any other work not specifically mentioned but required to complete the work as
per specifications, drawings and instructions of Engineer-in-Charge.
2.9 Clearing of all debris, surplus earth, wild growth etc. from the construction area on “as is
where is” basis from time to time as per direction of the Engineer-in-charge.
2.10 The contractor shall also provide proper access to site for transportation of material, labour
etc., construct his site office, store, labour hutments etc. The land required for the site
office, store, laydown area etc. shall be provided by the NALCO as per the Special/General
Conditions of Contract.
3.0 DETAILED SCOPE OF WORK
Scope of work shall be read in conjunction with item description of Bill of Quantities and
Contractor’s scope shall include all activities required to complete the work as specified in
the item description of Bill of Quantities, Technical specification & Drawings.
3.1 Excavation, backfilling and disposal for area grading
• Earthwork shall consist of all necessary site cleaning and grubbing. All earthworks shall be
confined to the construction area as shown on the drawing and shall be done in an
approved procedure with proper equipment.
• Contractor shall take every precaution to protect existing utility services from damage
during construction operations. If damage occurs, the Owner of the utility shall be notified
immediately and repairs shall be made at Contractor’s own expenses.
• Selected excavated soil shall be used for backfilling work. Backfilling shall be done layer
wise with proper compaction as per specification.
• Surplus earth shall be disposed in area designated by client. Dozing and levelling of
dumped soil as per satisfaction of Engineer-In-Charge.
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• In case backfilling material needs to be brought from outside, the same shall be in
accordance with Technical Specifications and as approved by Engineer-in charge.
• The blasting is prohibited in the running plant. The excavation in rock shall be done through
alternate method like Rock breaker, Chiseling, Hydraulic splitting, Mechanical cutters, Rock
breaking by using chemical or any other suitable method without blasting.
3.2 Cutting of trees/shrubs, clearing and disposal of stems/logs /brush/rubbish etc. Uprooting of
roots, clearing and disposal of stumps/roots etc. levelling of depression caused by
grubbing. Tree cutting permission on behalf of NALCO shall be taken by the Contractor.
Necessary support (such as signing of documents etc.) shall be provided by NALCO. Party
should ascertain the same before quoting & the cost if any shall be loaded / included in their
price bid. No extra amount will be paid on this account.
3.3 Construction of roads & drains, Culverts
• Construction of roads, drains & culverts as per drawing, technical specifications and
instruction of Engineer-In-Charge.
3.4 Engineering, Supply and Installation of Temporary Site Office, Security Office,
Training Centre (Porta Cabins) with all materials including foundation works.
• Contractor shall provide Design and drawing/specification as per requirement of Offices for
approval by Engineer in Charge. Construction of toilet facilities as per drawings and
specifications.
• Supply and installation of Site office, training center & security office and associated
materials as per specification and drawings.
• Supply and installation of Security Office with handrails for queuing of labours, provision for
Biometric Machine with shelter shed.
• Design and Construction of civil foundation, flooring, sanitary and plumbing work with
Septic tank installation and soak pit execution including supply of all required
materials/fixtures.
• The above works shall consider 25 users for the temporary Site Office, 8 users for
warehouse, 25 for Training Centre and 6 for Security Office.
3.5 Fabrication and erection of Closed Warehouse with all materials including
foundation works, in accordance with tkIS drawings
3.6 Supply and installation of Chain link fencing and steel gate with all materials
including foundation works.
• Supply and installation of chain link fence and associated materials as per specification and
drawings.
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• Supply and installation of structural steel post and bracing including blasting and painting.
• Construction of civil foundation for erection of fencing post and bracing including supply of
all required materials.
• Supply, fabrication and installation of structural steel gates with gate post as per drawing
and specification including blasting, painting and civil foundation work.
3.7 Supply and installation of internal hard barricading work around labour colony
• Internal hard Barricading work. Supply and installation hard barricading including foundation
work.
• Supply and installation of structural steel post and bracing including blasting and painting.
• Construction of civil foundation for erection of posts and bracings including supply of all
required materials.
• Supply & installation of GI sheets.
• Supply and installation of gates.
3.8 Construction of Tube Wells and associated piping works for drawing & distributing water in
labour colony including supply of materials. Pipe lay-out drawing shall be done at site by
contractor and prior approval shall be taken from NALCO/tkIS for location, rout of piping,
number of tie-ins etc. Construction of concrete water reservoir as per tkIS drawings and
specifications.
3.9 Water distribution net-work for construction water: supply and installation of above ground
and underground pipe network as per technical specification and drawings for construction
purpose. The pipes shall be laid in laydown area and in various units. The provision of
tapings to be provided as per requirement / as directed by Engineer-In-Charge. Planning of
routing and tie-ins & pipe lay-out drawing shall be done at site by contractor and prior
approval shall be taken from NALCO/tkIS for location, rout of piping and number of tie-ins.
3.10 Dismantling of existing structures (made of reinforced concrete, brickwork, steel structure
etc.) and disposal of the same as directed by Engineer-in-charge.
3.11 Weigh Bridge (complete package): The Contractor’s scope of design, supply (Capacity:
60 MT, 18 x 3 m) & installation for one number of truck weigh bridge package shall include
but not limited to design, engineering, supply, transportation, third party inspection,
construction of all associated facilities including civil foundation, pits, Erection, calibration,
commissioning, performance guarantee test etc. all complete as per technical specification
no.6695-PIP-G00-EC-0009 and satisfaction of Engineer-In-Charge. It shall also include all
items and services but not limited to the following, along with necessary fittings, fixtures and
ancillaries, bolts, nuts, gaskets, hold-down clips, spare parts, special tools, instruments etc.
as detailed in various parts/sections of the specification. Bidders shall consider all
components to ensure complete and satisfactorily operable equipment. All items shall be
included which are required to run the equipment as per guaranteed parameters unless
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otherwise specifically has been asked to exclude the same. Therefore, the quoted rate
shall include all items stated above as a package.
4.0 SCOPE OF SUPPLY BY CONTRACTOR
The scope of Supply in general includes scope of supply specified in various Technical
Specifications and Bill of Quantities enclosed in the Bidding Document shall be supplied by
the Contractor, but not limited to the following. There will be no free issue material by
Owner in this contract. All bulk materials, consumables, equipment etc. are in the scope of
contractor.
The cost of such supply shall be deemed to be included in the quoted rates without any
additional liability on the part of the Owner.
 Weigh Bridge as specified in Bid Document

 Submersible pumps as specified in Bid Document
 Hume pipes
 Pipes & Fittings
 Porta cabins
 Plumbing & Sanitary items
 Cement, sand, aggregate, Grouting materials etc.
 Reinforcement steel.
 Structural steel sections, plates, gratings, chequered plates, hand rails, foundation
bolts, and associated accessories etc.
 Structural steel gates with all accessories.
 GI sheets/Tubular structural steel materials with all accessories
 Various types of Paints; blast cleaning equipment, technicians and all other all
associated materials etc.
 All consumables such as industrial gases, Cutting gas, welding electrodes, grinding
wheels etc.
 Automatic Concrete Batching plants or tie up with concrete Batching plant /Concrete
Mixer machines/Dewatering Pumps/Transit mixer/concrete pump/water tanker
/excavators/dumpers/road Rollers/earth compactors/vibrators/RCC Cutters/breakers with
accessories, survey instruments like theodolite, levelling instruments of adequate
numbers and capacity etc.
 Supply Laying of temporary water lines with pump as required for construction work,
curing and other activities within quoted rates.
 All welding equipment, diesel welding sets, welding machines Diesel generator set
,chain pulley blocks, hook chuck(Max pull) etc.
 Adequate quantity of steel tubular scaffolding materials/staging materials, Various types
of form work, shoring, strutting and shuttering materials with all associated accessories
etc.
 All the Plumbing, sanitary sheeting, flooring materials and other materials as indicated in
the SOR etc.
 Contractor shall provide covered distribution board with HRC fuse and ELCB’s for
welding set and other machinery, Contractor shall make his own arrangement for lighting
for his work area inclusive of lay down area etc.
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 Mobilization of required skilled /unskilled labour, supervisors, qualified safety engineer,

QA/QC engineer and other items such as PPE’s, fire extinguishers etc. as mentioned in
respective SOR as per the Instruction and to the full satisfaction of the Engineer In
charge.
 Bidder to consider adequate number of dewatering Pumps with associated accessories,
disposal arrangement etc. in the Quoted unit rates i.e. without any extra cost to NALCO
 All the materials, machinery, manpower scaffolding required for water proofing work at
various location and elevations etc. in the quoted rates.
 All the materials required for barricading the Contractor’s work place i.e. Steel
scaffolding, G.I sheets etc. wherever required in the quoted unit rates.
 Temporary labour rest shelter at site including ladies and gents toilets separately.
 Potable drinking water facility to workers.
Special note:
i. Contractor shall ensure quality of sand. Local sand in and around Damanjodi is not
suitable. Nearest location is Nawarangpur. Contractor should quote the rate
accordingly. No extra payment will be made on account of excess lead.
ii. OPC (Ordinary Portland Cement) of different grade is recommended (as per technical
specification) for use in the construction .The concrete design mix is recommended
considering fly ash which will be supplied by NALCO free of cost at its store point.
Other cement may not be recommended in the construction.
iii. Contractor should submit the statutory payment of royalty for minor minerals used for
the work up to-date along with R.A. Bills. No bills will be processed for payment without
statutory dues.
5.0 SCOPE OF SUPPLY BY NALCO
No material will be supplied by NALCO as either free issue material or materials on

chargeable basis.
Fly ash will be issued by NALCO free of cost from it’s storage point (for construction
purpose like mixing in concrete, making fly ash bricks etc. for this contract).
For construction water and construction power, please refer clause no.2 of SCC.
6.0 VOLUME OF WORK
Refer clause no. 29 of SCC.
7.0 COMPLETION
Preparation and submission of stage wise inspection/completion reports / Handing over

reports etc. are included in the quoted rates for the various site activities. Construction
works would be carried out under the supervision of NALCO / Consultant.
8.0 DOCUMENTATION
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The following key documents shall be submitted by the contractor (but not limited to).
a) Various inspection and testing records associated with construction of Site Civil and
structural works etc. as under.
o Material Identification report
o Daily Inspection report
o Levels before and after excavation,
o Pour card reports
o Compression test reports.
o Soil compaction reports.
b) Final certified Inspection reports
c) Test certificates from manufacturer for each batch of electrodes, filler wire, fluxes,
structural steel, cement reinforcement steel and other materials etc. (These shall be
submitted for approval before they are used on the job)
d) Test certificates for materials supplied by the Contractor.
e) Reconciliation statement for free issue material, if any.
f) As-Built Drawings
9.0 PROGRESS OF WORK
The contractor shall submit to NALCO / Consultant daily, weekly and monthly reports
regarding the status and progress of work as well as weekly / monthly look ahead schedule
indicating the total manpower / tools and tackles deployment and constraint if any etc.
*****************************
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ANNEXURE-1AB
Rev 01 Page 1 of 10
Finalized After NALCO’S Review

01 17.05.2018 BTK 17.05.2018 MSD 17.05.2018 SJP
And Issued For Engineering
00 Issued for Engineering 23.03.2018 BTK 23.03.2018 MSD 23.03.2018 SJP
Rev. Status Description Date Prepared Date Checked Date Approved AC
Cateory Code:4
Barcode
© Copyright 2016 : All rights reserved
ThyssenKrupp Industrial Solutions (India) Private Limited
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INDEX
Sr.No. Description Rev. No.
1.
INTRODUCTION
2.
GENERAL
2.1.
SCOPE & RESPONSIBILITY 01
2.2.
SUPPLY
2.3.
IMPLEMENTATION 01
2.4.
PROCUREMENT
2.5.
INSPECTION
2.6.
PROJECT MANAGEMENT
2.7.
CONSTRUCTION MANAGEMENT
2.8.
SPARES
2.9.
TOOLS & TACKLES
2.10.
STATUTORY APPROVALS 01
2.11.
DOCUMENTATION
3. PERFORMANCE GUARANTEE
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1 INTRODUCTION
This document describes the various technical requirements +ELECTRICAL, for the
implementation and execution of tender of construction power supply & Electrical enabling work.
2 GENERAL
The intent of this document is to define and describe the detail Scope of Work – Electrical for the
construction power supply & Electrical enabling work. This shall include, but not be limited to the
following -
• Scope & Responsibility
• Supply
• Engineering
• Procurement
• Inspection
• Project Management
• Construction Management
• Spares
• Tools & Tackles
• Statutory Approvals
• Documentation
and other associated activities of the tender.
2.1 SCOPE & RESPONSIBILITY

Contractor shall read this document in conjunction with other documents of Tender Package
along with all attachments /Annexures in order to understand the complete scope of work. All
parts of the Tender document, forms the complete requirement of the tender.
Effort is made to define the Scope of Work explicitly without any ambiguity. Any electrical related
item / work / activity which is explicitly not mentioned in this tender document but is necessary to
achieve successful completion and safe operation of the Electrical system of the units / facilities
of this project +in line with the Statutory requirements / Standards / Specifications and
internationally recognized good engineering practices, shall be included by the Contractor in his
scope of work without any cost and time implication to the OWNER.
It will be the Contractor’s responsibility to bring to the notice of OWNER / CONSULTANT any
irreconcilable conflict in the tender documents as a part of his bid /offer. Contractor shall bring
out such discrepancies very clearly in the offer and clarification shall be sought from OWNER /
CONSULTANT. Resolution of such conflicts shall be provided by OWNER / CONSULTANT.
In case Contractor brings to the notice of OWNER / CONSULTANT any conflicting requirements
during Project execution stage, then the OWNER / CONSULTANT shall provide resolution to such
conflicts and the final decision of the OWNER / CONSULTANT shall be binding on the Contractor
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without any time and cost implication to the OWNER.
In case of any conflict between the statutory requirements, codes and standards to be followed
and various specifications, data sheets etc. of this tender document, the contractor shall bring
out such conflicting requirements clearly prior to execution of work. These conflicting
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requirements shall be discussed and resolved with the OWNER / CONSULTANT. Any deviation /
extra claim on account of such contradictions shall not be accepted.
The assumptions made by Contractor for preparing the offer shall be brought out clearly to the
attention of OWNER / CONSULTANT. These assumptions shall be subject to approval by OWNER /
CONSULTANT.
All deviations shall be listed only in the format enclosed as Waiver / Deviation form available
elsewhere in the tender. Deviations mentioned elsewhere shall not be taken into account while
evaluating the offers. It shall be considered that the Contractor complies fully with the document
except for the deviations listed in the above format.
Acquiring all necessary information related to existing facilities of plant, new facilities being
installed by Owner +either directly or through other contractors, remains the responsibility of
Contractor.
It shall be the responsibility of the Contractor to conduct survey at site to understand the extent of
scope of work required in the existing facilities / systems for construction power supply &
Electrical enabling work before QUOTE.
All co-ordination work with the OWNER / CONSULTANT & with the other agencies / other
Contractors during the entire phase +upto handover, of the Project remains the responsibility of
Contractor.
Any of the item that has been dismantled, disconnected, not fit for future use shall be handed
over to Site Maintainance Engineer In charge.
Wherever Contractor is expected to work in the existing facilities / systems, the same shall be
performed without damaging the existing facilities aboveground / underground. It shall be the
responsibility of Contractor to rectify any damage caused to any existing facilities aboveground /
underground during the course of work.
2.1.1 Electrical Enabling Works
Following scope is envisaged in the various existing electrical facilities as a part of the Electrical
Enabling works –
2.1.1.1 Re-routing of existing 33kV feeders +2nos., to Mines from existing boundary wall to new boundary
wall for 5th Stream -
• Dismantling and removal of existing 33kV transmission lines on pole structures alongwith
the poles from the existing boundary wall upto the new boundary wall.
• Supply & installation of new 33kV cable in cable trays on overhead structure / direct
buried underground from 4pole structure near existing boundary wall to the 33kV
structure nearest to the new boundary wall.
• New 33kV cable shall be joined to the existing 33kV cable at the 4pole structure near
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existing boundary wall.

• New 33kV cable shall be joined to the overhead 33kV transmission line at the nearest
structure at new boundary wall.
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2.1.1.2 Re-routing of existing 11kV feeder to Ash pond +New bauxite stock pile area, -
the poles.
• Supply & installation of new 11kV cable in cable trays on overhead structure / direct
buried underground.
• New 11kV cable shall be joined to the existing 11kV cable within the plant.
• New 11kV cable shall be joined to the overhead 11kV transmission line at the nearest
structure outside the plant boundary.
2.1.1.3 Re-routing of existing 33kV Construction power network from CSS-2 to CSS-5 –
the poles from CSS-2 to CSS-5.
2.1.1.4 Re-routing of existing cables coming under new Railway Expansion area –
• Dismantling & removal of cables trays alongwith cables coming under the new railway
expansion area
• Re-routing of cable trays & cables including supply, installation, termination & jointing +if
required,
2.1.1.5 Removal of high mast tower including dismantling & disposal of civil foundation in existing
Calcination area and re-locating the high mast tower at a suitable location in new Fabrication yard
alongwith its civil foundation.
2.1.1.6 Re-routing of existing cable trays, cables, electric posts in existing Evaporation area.
2.1.1.7 Dismantling of transformers, 2pole / 4pole structures including removal of all equipments, cable
terminations, removal of cables including removal of glands, etc.
2.1.1.8 All statutory approval / obtaining clearance for performing various activities of dismantling,
removal and installation shall be in the scope of the Contractor. All statutory approvals including
approval from CEA for energisation of HT equipments including preparation of documents,
submission to CEA, arranging for inspection, etc. shall be in the scope of the Contractor.
2.1.1.9 All related civil & structural works for dismantling, removal & installing shall be in the scope of the
Contractor.
2.1.2 Construction Power Distribution
Following scope as a minimum is envisaged in the Construction power distribution for the new
5th Stream Alumina Refinery. Contractor shall refer to the documents 6695-ELT-526-FA-0006
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SLD - Construction Power and the Mark-up on the Overall Plot plan for location of the new
facilities +CSS, feeder pillars, high mast, for understanding of the complete scope of work -
2.1.2.1 New 11kV Extension panel shall be added to the existing Siemens make 11kV switchgear in GTS.
New extension panel shall be identical in all respects with the existing switchgear. All AC, DC
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auxiliary supplies shall be tapped from the existing switchboard. Any modification / changes
required to be done in the existing switchboard in order to hook-up the new extension panel shall
be in the scope of the Contractor.
2.1.2.2 New Construction Substations shall be in the scope of the Contractor as per details below :
• CSS-10 +approx. Dimensions 8m LX 5m BX 3.5m H,
• CSS-11+approx. Dimensions 6m LX 4m BX 3.5m H,

• CSS-9A +approx. Dimensions 6m LX 4mBX 3.5m H, for feeding construction power

requirement of power plant expansion. Location shall be close to power plant area +exact
location shall be decided later,.
2.1.2.3 New 11kV panel comprising of 1no. 11kV Incomer and 1no. Outgoing shall be considered in
CSS-10.
2.1.2.4 11kV cable shall be supplied from new 11kV Extension panel in GTS to new 11kV panel at CSS-
10. Cable shall be laid in overhead cable trays above ground. Contractor shall lay the cable either
in existing cable tray or consider new cable tray alongwith supporting structure as required based
on the site conditions.
2.1.2.5 4pole structures shall be considered at all new CSS.
2.1.2.6 1000kVA 11/0.433kV, oil-filled transformers shall be located outdoors near CSS-10, 11, 12, 14,
9A.
2.1.2.7 415V switchboard shall be located indoor at CSS-10, 11, 12, 14, 9A.
2.1.2.8 Feeder pillars, high mast light, flood lights, lighting fixtures for CSS.
2.1.2.9 HV, LV power cables.
2.1.2.10 Earthing & lightning protection material
2.1.2.11 All related civil & structural works for new facilities shall be in the scope of the Contractor.
2.1.2.12 Any other item / equipment not explicitly mentioned but required for successful completion &
operation shall also be included in the scope by the Contractor
2.1.2.13 All statutory approval / obtaining clearance for performing various activities of the new facilities
shall be in the scope of the Contractor.
2.1.2.14 All locations indicated for CSS, feeder pillar, high mast are tentative. Contractor shall finalise
these locations with NALCO during execution.
2.2 SUPPLY
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Supply of all major electrical equipment and material for construction power & Electrical enabling
work as per the Bill Of quantities, SLD and various other documents attached in the tender.
Safety equipment including all Safety PPE required in the CSS, Insulation coat paint +Both sides
of all electrical panels installed in indoor, shall also be included in the scope of supply by the
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Contractor
Contractor shall also consider supply of any other electrical equipment, materials, accessories
not explicitly mentioned but required for successful completion & safe operation of the electrical
work.
2.3 IMPLEMENTATION
All electrical equipment shall be new with state of the art technology and proven track record.
Prototype equipment shall not be offered. Contractor shall procure all the electrical equipments
as per the Technical specifications +all major electrical equipments, that are available as a part of
this tender.
The materials, design and workmanship shall satisfy the applicable standards, the specifications
enclosed & codes referred to. Where the specifications stipulate requirements in addition to those
contained in the standard codes and specifications, these additional requirements shall also be
satisfied.
The drawings/ documents and other attachments with Tender define the basic system design for
the entire package. This is based on preliminary data, layouts and other data and same are for
guidance & further implementation.
Contractor shall carryout further implementation after verification of the same with respect to the
actual site conditions and after finalization of changes with Owner / Consultant, if any required,
due to the actual site conditions.
Specific attention is brought to the following for the Contractor while performing the activities as
described in the tender documents –
• GES +6695-ELT-G00-EC-0002, - To be referred only for the applicable portion
• Single line diagram – Construction power for 5th Stream Alumina Refinery
• Technical specifications of Electrical equipments
2.4 PROCUREMENT
2.4.1 PROCUREMENT ENGINEERING

Contractor shall perform Procurement engineering consisting of preparation of Material
Requisitions +Inquiry specifications,, Technical Bid Analysis, Purchase Requisitions / Order
specifications, checking and approval of vendor drawings, etc. for all electrical equipment/ items
defined in the Tender package.
2.4.2 VENDOR LIST

Contractor shall refer to document Vendor List available elsewhere in the tender. All the electrical
equipments shall be procured from the vendors as indicated in the Approved Vendor list only.
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2.4.3 VENDOR DOCUMENTATION

Requirement of Vendor Documentation is defined in the technical specification of individual
equipments.
2.5 INSPECTION
2.5.1 FACTORY ACCEPTANCE TEST &FAT' REQUIREMENTS

Contractor shall refer to the Inspection test plans +ITP, available as a part of the technical
specifications of individual electrical equipments.
Contractor shall be responsible for review of Test Certificates of all electrical equipments.
In general routine tests, type tests, acceptance tests and special tests shall be performed on all
electrical equipments as per the relevant applicable codes and standards at the Vendor’s works.
In the absence of ITP for any electrical equipment, Contractor shall develop the same based on
the applicable codes & standards and implement the same with the approval of OWNER /
CONSULTANT.
Detail requirements of Inspection at Vendor’s works are defined elsewhere in the tender.
2.6 PROJECT MANAGEMENT

2.6.1 PROJECT IMPLEMENTATION
Contractor shall be responsible for carrying out all Project management related activities
including planning & scheduling, progress monitoring for successful implementation of the
project as per stipulated time schedule.
2.6.2 PROJECT CO-ORDINATION

Contractor shall be responsible for co-ordination with OWNER / CONSULTANT and with various
external agencies like statutory authorities, suppliers of all electrical equipments / items,
package vendors, any third party agencies +if applicable,, other Contractor, sub-contractors for
this project as well as co-ordination among Contractors own departments / offices involved in
implementation of this project for smooth & trouble-free completion of the project.
Contractor shall attend meetings at OWNER / CONSULTANT / Vendor / Sub-Contractors office
as per the requirements during the entire phase of the project.
Detail requirements of Project implementation & Co-ordination are defined elsewhere in the
tender.
2.7 CONSTRUCTION MANAGEMENT
2.7.1 CONSTRUCTION
Contractor shall be responsible for the complete construction activities for all the electrical
equipments / items supplied for this project. Contractor shall ensure the use of appropriate
machinery, tools & tackles for the construction activities.
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Contractor shall ensure that services of the Vendor / OEM personnel are considered at site for
supervision of installation of switchgears +for providing guidance to installation contractor and
ensuring that necessary precautions are taken for proper alignment and assembly of the panels,,
elevator / lifts.
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Contractor shall be responsible for providing sufficient man-power for execution as well as
supervising construction, pre-commissioning, commissioning and closure of works activities.
Detail requirements of construction & construction management are defined elsewhere in the
tender.
2.7.2 SITE EXECUTION & CO-ORDINATION

Contractor shall be responsible for carrying out all the site related activities for successful
implementation of the project within stipulated time schedule.
Contractor shall be responsible for safe and efficient management of site stores, materials and
equipments and timely mobilisation of all the required resources. Contractor shall follow good
house-keeping practices. Contractor shall prepare and maintain all documentation for site work
as per approved site procedures.
Detail requirements of site execution & co-ordination are defined elsewhere in the tender.
2.7.3 PRE-COMMISSIONING, TESTING & COMMISSIONING INCLUDING SITE ACCEPTANCE TESTING

&SAT'
Contractor shall be responsible for carrying out the pre-commissioning checks, testing and
commissioning of the electrical equipments installed.
Contractor shall ensure the services of specialists of Vendor / OEM at site during testing
and commissioning phase, to check proper configuration of all relays and meters,
assistance for carrying out relay testing and setting, demonstrating connectivity, boxing up
etc. for switchgears.
Contractor shall also consider the Supervision of Testing and Commissioning by equipment
manufacturer for major electrical equipments including HV switchgear.
The requirements of Site Acceptance Testing +SAT, are covered in the doc. No. 6695-ELT-G00-
QA-0001 available elsewhere in this tender. The requirement indicated in this document is
minimum and as a general guideline. Contractor shall also carry out all the required installation
checks and tests as per OEM & Site requirement.
Contractor shall ensure that all electrical equipments shall be put into service only after all safety
checks, functional checks and specific instructions from OEM / OWNER / CONSULTANT are
complied. Contractor shall ensure to close all punch points before the electrical equipments are
put into service.
Other detail requirements of pre-commissioning, testing & commissioning are defined
elsewhere in the tender.
2.8 SPARES
Contractor shall supply following types of spares –
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• Mandatory spares
• Commissioning spares
• One years operation & maintenance spares
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2.9 TOOLS & TACKLES

Contractor shall supply the tools & tackles and miscellaneous accessories for maintenance and
operation of all electrical equipment.
2.10 STATUTORY APPROVALS
Contractor shall be responsible for obtaining all statutory approvals +applicable for Construction
power & Electrical enabling work, as per GENERAL CONDITIONS OF CONTRACT.
Anything not explicitly covered in the tender document, but is required for compliance to statutory
requirement / observations raised by CEA/DGMS during the inspection shall be complied by the
Contractor.
2.11 DOCUMENTATION
After completion of work, and prior to start-up / energisation of electrical equipment /

systems, Contractor shall mark-up the ‘As Built’ details / information on all ‘Released for
Construction +RFC,’ drawings / documents and Manufacturer’s drawings / documents related
to the electrical works and submit the same to Owner.
One set of up-to-date ‘As-built‘ drawings / documents shall be suitably stored in respective
Substation+s, for all equipment installed therein.
All tests results and associated checklists generated as part of the pre-commissioning checks,
testing and commissioning of the electrical systems shall form a part of the Final
Documentation submitted by Contractor to Owner.
All technical specifications, inspection reports and certificates of equipment / material supplied
by Contractor shall become a part of this Final Documentation.
The mode of submission of these drawings / documents, their required format+s, and number
of sets shall be as defined in the Tender Document.
3 PERFORMANCE GUARANTEE
Contractor shall be responsible for demonstrating the performance guarantee of the

equipment as per the guaranteed technical parameters within the tolerance permitted by
relevant standards during the testing of the equipment at the vendor’s works.
If any equipment supplied by the Contractor fails at site during erection, testing,
commissioning or service +within guarantee period,, the Contractor shall repair and put
back into successful operation the failed equipment within the time frame and procedure of
repair agreed with the OWNER depending on nature of failure, at no extra cost to the
OWNER.
In case of failure of the equipment +including bought out items, to meet the guaranteed
performance, OWNER / CONSULTANT reserves the right to reject the equipment. However,
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OWNER also reserves the right to use the rejected equipment until the new equipment
meeting the guaranteed performance requirement is supplied by the Contractor.
All the equipments and material supplied by Contractor shall be guaranteed for a period as
specified elsewhere in the tender.
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Tentative Construction Schedule (Level-1) for Area Grading & Enabling Works Annexure-I D
PROJECT NAME: 5TH STREAM ALUMINA PLANT AT DAMANJODI, ORISSA
Sl.No. Major activities Duration 1 2 3 4 5 6 7 8
Al storage
1 Effective Date of contract Calcination / 220kV/ Condensate TF/ &handling/Red mud Cooling towers/Lime
Evaporation / Plant air inst air/ Evaporation /Digestion disposal /Mud settl.& slaking/Substaion/Contr Reservoir//Hydrate
Precipitation Security filtration / Product hydrate fil./ washing/IBSH ol room filtration/HID
2 Site grading (Refinery) works 350
3 Construction Power 160 0
4 Weigh Bridge 90
5 Ware house including open yard 135
6 Security Gate and associated facilities 70
7 Roads & Drains 180
8 Labour colony 90
9 Construction Water pipeline 135
Completion of the Project / Mechanical

completion
Note: Contractor to submit the detailed schedule including engineering & procurement as per bid document. The above schedule is indicative schedule.
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Rev 02 Page 1 of 3
Wind and Seismic Parameters

02 18.01.18 BHK 18.01.18 VBV 18.01.18 GLP
Revised & Issued For Engineering
01 Issued for Engineering 27.10.17 BHK 27.10.17 VBV 27.10.17 GLP
00 Issued for NALCO Review 15.09.17 BHK 15.09.17 VBV 18.09.17 GLP / SJP -
Based on : PIN-LES-CVC-0001 F01
Category Code: -
Barcode
© thyssenkrupp Industrial Solutions (India) Private Limited 2016
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Contents:
1 ADDENDUM TO STANDARD GES PIN-LES-CVC-0001 F02 REV 00 .............................................................. 3
Enclosures :
Civil – General Engineering Specifications &GES' STANDARD : PIN-LES-CVC-0001 F02………………………Sh 1 to 18

Civil – General Engineering Specifications &GES' ANNEXURE A,B,C: PIN-LES-CVC-0001 F03…………………Sh 11 to
to 24
25
Civil and Structural Guidelines &RTAIL Document' Z02-000-1-DC-003.........................................................Sh 1 to 41
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1. ADDENDUM TO STANDARD GES PIN-LES-CVC-0001 F02 REV 00

This addendum is to be read in conjunction with GES Standard Doc. No
PIN-LES-CVC-0001 F02 REV 00
The changes are as follows:
Superseded Revised Text as per change required Reason for Change

Clause no. In
Standard Doc. No
PIN-LES-CVC-0001
F02 REV 00
4.1.1 Office rooms and Control Rooms shall have clear Client recommendation
height of 3300mm. All other areas / buildings,
minimum ceiling height shall be as specified in
the original clause.
4.1.2 Single Door Access: 1000 x 2100mm Client recommendation
Toilet & Shower Door: 750 x 2100mm
Equipment Door: 2100 x 2400mm
ADD Clause 7.0 Waterproofing of Buildings: Client recommendation
Waterproofing of buildings shall be carried out
using APP &Atactic Polypropylene' membrane.
ADD Clause 8.0 PAINTING OF BUILDINGS AND STEEL
STRUCTURES
ADD Clause 8.1 Painting of Buildings: Client recommendation
External Painting of Buildings shall be carried out
with weather-proof paint of approved
manufacturer over suitable primer coat. The
weather-proof paint shall be suitable for the local
climate and shall have a comprehensive 7 &seven'
years performance warranty.
ADD Clause 8.2 Painting of steel structures:
Painting of steel structures shall be as per 6695-
EQS-G00-EC-0007_GES for Painting.
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Annexure to Civil - General Engineering

Specifications (GES)
Rev 02 Page 1 of 25
Wind and Seismic Parameters

02 18.01.18 BHK 18.01.18 VBV 18.01.18 GLP
Revised & Issued For Engineering
01 Issued For Engineering 27.10.17 BHK 27.10.17 VBV 27.10.17 GLP
00 Issued for NALCO Review 15.09.17 BHK 15.09.17 VBV 18.09.17 GLP -
Based on : PIN-LES-CVC-0001 F03
Category Code: -
Barcode
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Contents:
Annexure A Load combinations ................................................................................................................ 3
Annexure B Additional terms and conditions ............................................................................................... 4
B.1 Related engineering specifications ............................................................................................ 4
B.2 Regulatory requirements........................................................................................................ 17
B.2.1 Important Applicable governmental requirements "not limited to# ................................................. 17
B.2.2 Conflict between regulatory requirements and specification ........................................................ 17
B.2.3 Subjects not covered by regulatory requirements ...................................................................... 17
B.3 Applicable codes and standards ............................................................................................. 17
B.3.1 International codes and standards .......................................................................................... 17
B.3.1.1 Indian codes and standards ................................................................................................... 17
B.3.2 Client's regulations and standards........................................................................................... 24
Annexure C Report on blast load design.................................................................................................... 25
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Annexure A Load combinations
The following table for load combinations applies for both the calculation of the bearing capacity and the
calculation of the serviceability limit stage. The serviceability need only be checked for the load combinations
in the case of operating.
The safety factors shall be in accordance with codes and standards stipulated in Annexure B .
Table A1. Load combinations1#

Loading Load combinations
Component Type Empty Operating Test Erection
a
Weight of structure P X X X X
.
b Weight of equipment category I,
P X X X X
. piping "Ø < 300 mm# and cabling
Empty weight of
c. equipment category II and P X X2# X3#
empty piping "Ø ≥ 300 mm#
Operating weight of
d
equipment category II and P X2#
.
Hydrostatic test load of
e
equipment category II and P X
.
f. Exchanger bundle pull force V X
g
Thermal loads V X
.
h
Moving loads V X X X
.
i. Live loads V X4#
X4#
j. Wind loads V X 6#8#
X6#8# X5#6#7# X5#7#
k. Snow loads V X9# X9#
l. Rainwater loads V X X
m
Earthquake loads V X6# X6#
.
n
Other loads V X6# X6# X6#
.
P = Permanent load
V = Variable load
1# The load combinations given below cover the minimum requirements. In case of conflict with applicable standards the most stringent
requirements shall govern.
2# The most unfavorable load combination shall be taken into account.
3# The weight of the equipment as shipped, excluding the weight of all parts that are field installed after erection. For field assembled equipment,
it shall be the minimum weight of the complete shells, excluding the weight of all internal and external parts, fireproofing, etc.
4# Live load shall be taken into account only when this is an unfavorable case.
5# The effect of wind forces acting on scaffolding shall be considered. The actual projected area of the scaffold members together with the correct
shape factor and drag coefficient should be used. As an approximation, the overall width of the scaffolding may be taken as 1.5 m on each
side of the vessel or column, with 50 % closed surface and shape factor 1.
6# Structures should not be designed for earthquake - blast - design load and wind load occurring simultaneously.
7# Only 50 % wind load shall be taken into account.
8# Wind load on equipment shall include an allowance for piping and platforms. Values for wind taken from datasheets prepared by the
department responsible for designing the static equipment.
9# In countries with relatively low snow loads, snow may be included in live load.
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Annexure B Additional terms and conditions

B.1 Related engineering specifications
B.1.1 Engineering Specification - Preparation of civil documents

6695-CVC-G00-EC-0003
B.1.2 Engineering specification – Concrete
B.1.2.1 Cement for RCC :

Ordinary Portland Cement of Grade 33 as per IS269 or Grade 43 as per IS8112 or Grade 53
as per IS12269 subject to recommendations in Soil Investigation Report
B.1.2.2 Reinforcement :
HYSD rebars of Grade Fe500 conforming to requirements of IS1786 "As ductile detailing is
not required#
B.1.2.3 Chemical resistant lining: As per duty conditions & temperature
B.1.2.4 As per IS 456:2000,Table 3, the exposure conditions for concrete during working life shall be
SEVERE. Based on the above environmental exposure condition, the following shall be adopted,
UNO.
B.1.2.5 Minimum grade of concrete shall be as follows: "CL.8.2.2, Table 5 of IS456:2000#
a1 Environmental exposure Severe Remarks
condition for all concrete
i# Grade of plain concrete M15 As per Licensor
used as Blinding Concrete, Specification
Lean Concrete, Mudmat,
ii# Grade of plain concrete M20
used as structural concrete
iii# Grade of reinforced M30
concrete - Footing
- Piles, Columns M30 As per Licensor
Specification
- Beams, Floor slabs, M30 As per Licensor
walls Specification
b1 Grade of concrete for RCC M30
flooring at plinth / paving /
grade slab
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B.1.2.6 Minimum Nominal cover to all reinforcement including links shall be as follows:
"CL.8.2.2 , Table 16 of IS456:2000#
Environmental exposure Severe Remarks
condition
i# Footings "on all sides# and 50 mm As per IS Code
Pilecap – Top & sides
Pilecap – Bottom 150mm
Ii# Beams - on all sides for 45mm As per IS Code
beams below Ground
5Sub structure1
Beams - on all sides for 45mm As per IS Code
beams above Ground
5Super structure1
iii# Slabs - on all sides 45mm As per IS Code
iv# Columns - on all sides above 45mm As per IS Code
Ground 5Super structure1
Columns - on all sides below 45mm As per IS Code
Ground 5Sub structure1
iv# Walls - on all sides 45mm As per IS Code
above Ground 5Super
structure1
Walls - on all sides 45mm As per IS Code
below Ground 5Sub
structure1
iv# Slabs, Walls, Beams, 65mm As per Licensor
Columns – Exposed to Specification
Process Fluids - on all
sides above Ground
5Super structure1
Slabs, Walls, Beams, 65mm As per Licensor
Columns – Exposed to Specification
Process Fluids - on all
sides below Ground
5Sub structure1
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B.1.2.7 Minimum grade of concrete for Liquid retaining structures shall be as follows: "CL.8.2.2
, Table 5 of IS456:2000 and CL.6.1 of IS3370 "Part1#:2009
a1 Environmental exposure Severe

condition for all
concrete
i# Grade of plain concrete M10
used as Blinding
Concrete, Lean Concrete,
Mudmat,
ii# Grade of plain concrete M20
used as structural
concrete
iii# Grade of reinforced M30
concrete
B.1.2.8 Minimum Nominal cover to all reinforcement including links for Liquid retaining
structures shall be as follows: "CL.8.2.2, Table 16 of IS456:2000 and CL.6.2 of IS3370
"Part 1#:2009
Environmental exposure Severe Remarks
condition
i# Base slab "on all sides# and 50mm
Pilecap – Top & sides
Pilecap – Bottom 150mm
Ii# Beams - on all sides 45mm 65mm for Process Fluid
iii# Slabs - on all sides 45mm 65mm for Process Fluid
iv# Columns - on all sides 45mm 65mm for Process Fluid
iv# Walls - on all sides 45mm 65mm for Process Fluid
B.1.2.9 Grout
Non-shrink cementitious grout "minimum compressive strength = 65 MPa# shall be provided
under base plates and in anchor bolt pockets for all structures and equipment foundation.
Non-shrink epoxy grout "minimum compressive strength = 80 MPa# shall be used for all
rotating equipments like pumps and compressors, if recommended by the Manufacturer.
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B.1.3 Engineering specification – Steel
Anchor Bolts : Class 4.6 Grade E250"Fe410W# Quality A as per IS2062
Structural steel : E250"Fe410W# Quality A as per IS2062
OR
British Universal Beams, Columns and Plates – Grade 275JR/JO

and S355JO to BS EN 10025 "as per availability#.
Connection bolts : Turned and Fitted bolts Class 8.8 Grade B as per IS3640
And nuts as per IS1367
All connection bolts shall be galvanised
Cladding / sheeting : Pre-coated GI Sheets with 0.5mm TCT sheet and accessories
Grating : Electroforged MS- Galvanized- 25/30mm thk. As per tkIS

standard Drg. PIN-LEP-CVS-1014; FRP gratings for Caustic
environments.
Chequered plates : As per tkIS standard Drg. PIN-LEP-CVS-1016/1017
Handrail : As per tkIS standard Drg. PIN-LEP-CVS-1023
B.1.4 Engineering specification – Buildings / Structures

2
B.1.4.1 Wind data 5As per IS 875 5Part-31: 2015
Wind load on plant buildings / structures "Damanjodi# shall be calculated in accordance with IS875 -
Part-3 - 2015 based on following parameters:-
DESCRIPTION / ITEM APPLICABLE REMARK
Basic wind speed Vb 44 m/s CL. 6.2 of IS:875 Part-3 – 2015

Risk coefficient K1 1 "for All Buildings & As per Table 1 of IS:875 Part-3 - 2015
Structures#
Terrain roughness and As per Table 2 of IS:875 Part-3 - 2015
height factor K2
Category "Terrain# 2
Topography factor,K3 1 Cl. 6.3.3 of IS875 Part 3 -
2015
Importance Factor for 1 "NA for areas beyond Cl. 6.3.4 of IS875 Part 3 -
Cyclonic Region k4 60km range from 2015
coast#
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Design wind speed, VZ = Vb * K1 * K2 * K3 * K4
Wind pressure, Pz = 0.6 * VZ 2
Based on above K1, K2, K3 and K4 factors, the wind pressure for different heights shall not be
less than following:
Height z "m# above k2 for Terrain Vz "m/s# Pz "kPa#

FGL Category-2
Up to 10 1.00 44 1.16
15 1.05 46.2 1.28
20 1.07 47.08 1.33
2 25 1.095 48.18 1.39
30 1.12 49.28 1.46
35 1.1325 49.83 1.49
40 1.145 50.38 1.52
50 1.17 51.48 1.59
100 1.24 54.56 1.78
Note :-
1# Linear interpolation shall be followed for intermediate heights.
2# Wind pressures may be reduced by 20% for structures with height less than 10 meters.
Wind load on plant buildings / structures "Vishakhapatnam Port# shall be calculated in accordance
with IS875 - Part-3 based on following parameters:-
Basic wind speed Vb 50 m/s CL. 6.2 of IS:875 Part-3 – 2015

Risk coefficient K1 1 "for All Buildings & As per Table 1 of IS:875 Part-3 - 2015
Structures#
Terrain roughness and As per Table 2 of IS:875 Part-3 - 2015
height factor K2
Category "Terrain# 2
Topography factor,K3 1 Cl. 6.3.3 of IS875 Part 3 -
2015
Importance Factor for 1.15 "Industrial Cl. 6.3.4 of IS875 Part 3 -
Cyclonic Region k4 Structures# 2015
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Design wind speed, VZ = Vb * K1 * K2 * K3 * K4
Wind pressure, Pz = 0.6 * VZ 2
Based on above K1, K2, K3 and K4 factors, the wind pressure for different heights shall not be
less than following:
Height z "m# above k2 for Terrain Vz "m/s# Pz "kPa#

FGL Category-2
Up to 10 1.00 57.5 1.98
15 1.05 60.375 2.19
20 1.07 61.525 2.27
2
25 1.095 62.96 2.38
30 1.12 64.4 2.49
35 1.1325 65.12 2.54
40 1.145 65.84 2.60
50 1.17 67.275 2.715
100 1.24 71.3 3.05
Note :-
1# Linear interpolation shall be followed for intermediate heights.
2# Wind pressures may be reduced by 20% for structures with height less than 10 meters.
2 Additionally for Vishakhapatnam Port area, reference shall be made to IS 15498 for guidelines for
improving the cyclonic resistance of the structures.
Design Wind Pressure:
The Design Wind Pressure shall be calculated, in accordance with IS 875 Part 3:2015, as
2
Pd = Kd * Ka * Kc * Pz; where
Kd = Wind directionality factor
Ka = Area averaging factor
Kc = Combination factor
However, the value of Pd shall not be taken as less than 0.70 times Pz.
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B.1.4.2 Earthquake data as per IS 1983 5Part IV1: 2015 for Industrial structures

Seismic Zone II For both Damanjodi and
Vishakhapatnam Port
Zone Factor, Z 0.10 As per Annexure A of
IS1893-Part 4:2015
Ductile detailing is not necessary, as per the provisions of IS1893 & IS13920.
The Spectral acceleration coefficient for rock and soil sites, Sa/g, is considered as per Annexure B
of IS1893-Part 4:2015 for HOLD 5pending Soil Investigation Report1
Name of structure Category Importance Reduction Type of Analysis

Factor, I Factor, R as per Cl 10.2 of
As per Table 6 of
IS1893-Part
2 IS1893-Part As per Table 3 of As per Table-4
4:2005
4:2015 IS1893-Part of IS1893-Part
4:2015 4:2015 and
IS800:2007 for
steel structures
Process 2 1.5 3 Simplified

Structures Analysis
Pipe-rack 2 1.5 3 Simplified

Analysis
Compressor 2 1.5 3 Simplified

House Analysis
Substations and 2 1.5 3 Simplified

Control Room Analysis
NOTE: In case of braced steel structures Response reduction factor, R = 4.
2
Damping ratio coefficient shall be as per Table 5 of IS1893-Part 4:2015 as follows:
Structural Steel – 2%
RCC – 5%
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As per Cl 8.3.2.1 of IS1893-Part 4: 2015:

2
Where the plan wise distribution of mass and stiffness of the structural system is not symmetrical
about X & Y directions, the response due to each component may be combined using the
assumption that when the maximum response from one component occurs, the response from
other two components are 30 percent of corresponding maximum.
As an alternative to this procedure, the response due to combined effect of three components can
be obtained on the basis of square root of sum of squares "SRSS#.
Where the plan wise distribution of mass and stiffness of the structural system is symmetrical about
two lateral directions X & Y, the structure shall be designed for the effects due to full design
earthquake load in one horizontal direction at a time.
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B.1.4.3 SUB-SOIL DATA FOR FOUNDATIONS 5HOLD – pending Soil Investigation and Report1
Subsoil data is based on the soil investigation report HOLD dated HOLD
For Main Plant Site at Damanjodi:
a# Net safe bearing capacity of soil at : X KN/Sq.m.

X.XX m below Existing Ground level. Considering permissible total settlement of 25 mm
b# Depth ground water table : X m below existing ground level.

However, for design of underground tanks, pits
, basins etc. water level shall be assumed upto
Finished Ground level "FGL#
c# Type of foundation : Open foundations / / Raft foundation

Pile foundations
d# Bulk unit weight of Soil, γb : .......... KN/cu.m

Saturated unit weight of Soil, γsat : .......... KN/cu.m
Submerged unit weight of Soil, γsub : "γsat-10# KN/cu.m
e# Type of Pile : Bored cast in citu / Driven cast in citu / Bored precast / Driven precast
and
End Bearing on Rock / End Bearing on Hard Stratum / Friction pile
Pile capacities "Working#:
Pile dia Axial Shear "KN# – Shear "KN# –

Uplift "KN#
"mm# dp compression "KN# Free Head Fixed Head
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Minimum c/c distance between two piles,s :

" Clause 6.6 - IS 2911 Part 1 /Sec 1 to 4 : 2010#
s = 2.0 * dp for End Bearing on Rock
s = 2.5 * dp for End Bearing on Hard Stratum
s = 3.0 * dp for Friction pile
Group efficiency for pile group is HOLD 5Refer doc. ……1
Allowable increase in SBC / Pile capacities in event of

- Wind : 25%
- Earthquake : HOLD As per Table 1 of IS1893 "Part 4#:2005
For Facilities at Vishakhapatnam Port:
a# Net safe bearing capacity of soil at : X KN/Sq.m.

X.XX m below Existing Ground level. Considering permissible total settlement of 25 mm
b# Depth ground water table : X m below existing ground level.

However, for design of underground tanks, pits
, basins etc. water level shall be assumed upto
Finished Ground level "FGL#
c# Type of foundation : Open foundations / / Raft foundation

Pile foundations
d# Bulk unit weight of Soil, γb : .......... KN/cu.m

Saturated unit weight of Soil, γsat : .......... KN/cu.m
Submerged unit weight of Soil, γsub : "γsat-10# KN/cu.m
e# Type of Pile : Bored cast in citu / Driven cast in citu / Bored precast / Driven precast
and
End Bearing on Rock / End Bearing on Hard Stratum / Friction pile
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Pile capacities "Working#:
Pile dia Axial Shear "KN# – Shear "KN# –

Uplift "KN#
"mm# dp compression "KN# Free Head Fixed Head
Minimum c/c distance between two piles,s :

" Clause 6.6 - IS 2911 Part 1 /Sec 1 to 4 : 2010#
s = 2.0 * dp for End Bearing on Rock
s = 2.5 * dp for End Bearing on Hard Stratum
s = 3.0 * dp for Friction pile
Group efficiency for pile group is HOLD 5Refer doc. ……1
Allowable increase in SBC / Pile capacities in event of

- Wind : 25%
- Earthquake : HOLD As per Table 1 of IS1893 "Part 4#:2015
f# Factor of safety against
Sliding – 5Refer Cl.17.1.1 of IS19041

The factor of safety against sliding of structures which resist lateral forces "such as retaining
walls# shall be not less than 1.5 when dead load, live load and earth pressures are considered
together with wind load or seismic forces. When dead load, live load and earth pressure only
are considered, the factor of safety shall be not less than 1.75.
Overturning – 5Refer Cl.17.2 of IS19041

The factor of safety for shallow foundation against overturning shall be not less than 1.5 when
dead load, live load and earth pressures are considered together with wind load or seismic
forces. When dead load, live load and earth pressures only are considered, the factor of safety
shall be not less than 2.
Uplift / buoyancy –Factor of safety against uplift / buoyancy shall be 1.2.
g1 The following friction coefficient shall be considered in calculating the sliding

friction forces:
In absence of data given in Geotechnical investigation report, Friction coefficient between
soil and concrete shall be limited to 0.5
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h1 Modulus of Subgrade reaction 5Ks1 shall be considered as follows:
In absence of data given in Geotechnical investigation report, following values can be adopted
Soil Ks in KN/m3
Sr.no
1 Loose sand 4800 - 16000
2 Medium dense sand 9600 - 80000
3 Dense sand 64000 - 128000
4 Clayey medium dense sand 32000 - 80000
5 Silty medium dense sand 24000 - 48000
6 Clayey soil
"i# qa ≤ 200 KN/Sq.m "kPa# 12000 - 24000
"ii# 200 < qa ≤ 400 KN/Sq.m "kPa# 24000 - 48000
"iii# qa > 800 KN/Sq.m "kPa# > 48000
Where qa = Allowable bearing Capacity
i1 Coefficients for Earth pressures
Active earth pressure coefficient Ka = "1 – sin"Φ ## / "1 + sin"Φ ##
Passive earth pressure coefficient Kp = "1 + sin"Φ ## / "1 - sin"Φ ##
Earth pressure at rest = K0 = 1 − Sin Φ
Where Φ is Angle of internal friction
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B.1.4.4 DESIGN CRITERIA FOR STORM WATER DRAINAGE SYSTEM
Maximum Design discharge shall be calculated considering
a# Maximum Design hourly rainfall : 80 mm /hr. at Damanjodi
100 mm /hr. at Vizag Port
RUN OFF COEFFICIENT
- For building roof : 1.0

- For paved areas : 1.0
- For roads and drains : 1.0
- For gravelled areas : 0.8
- For undeveloped areas / Lightly cultivated areas : 0.3
- For exposed areas covered with equipment "Tank roofs etc.# : 1.0
B.1.4.5 DESIGN CRITERIA FOR LIQUID RETAINING STRUCTURES
5IS:3370 5Part 1 & 21 – 2009 & IS:456 -20001

– Check for buoyancy effect when empty tank is totally submerged in saturated soil upto
ground level. Factor of safety against uplift / buoyancy shall be 1.2. "CL.7.2 b of IS3370
"Part1#:2009#
– All liquid retaining/storage/conveying structures shall be designed assuming liquid up to full
height of wall irrespective of provision of any over flow arrangement.
– The design shall be Limit state design as per Cl.4.4 of IS3370 "Part2#:2009
– Calculation of Crackwidth due to Temperaturenand moisture shall be done as per Annex A of
IS3370 "Part 2#:2009
– Calculation of Crackwidth in mature concrete shall be done as per Annex B of IS3370
"Part2#:2009
– For particularly aggressive environment, such as the ‘severe’ category, the assessed surface
width of cracks should not in general, exceed 0.1 mm. "CL.35.3.2 of IS456:2000#
B.1.4.5 DESIGN CRITERIA FOR TEMPERATURE

Temperature analysis is not required to be carried out.
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B.2 Regulatory requirements

The work covered in this specification shall comply with all relevant planning and building
permissions, governmental and local laws, regulations and standards applicable for the
relevant project.
B.2.1 Important Applicable governmental requirements "not limited to#
Not applicable
B.2.2 Conflict between regulatory requirements and specification
Stringent of both
B.2.3 Subjects not covered by regulatory requirements "Specification by Licenser – RTAIL,

DOCUMENT # Z02-000-1-DC-0031 –
Stringent of both.
B.3 Applicable codes and standards
The following codes "including applicable addenda# and standards shall constitute the minimum
requirements for this specification. The latest edition of codes, standards, etc., shall be used,
valid as per date, when the contract between CLIENT and tkIS is concluded.
B.3.1 International codes and standards
Not applicable
B.3.1.1 Indian codes and standards
The list of applicable codes includes but is not limited to the following:
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List of applicable Indian Codes / Eurocodes

RE-AFFIRMED APPLICABLE
IN THE YEAR AMENDMENTS
1. BRICK BLOCK, MORTAR
IS-4860 (1968) - Acid Resistant Bricks RA2016 -
IS-1077 (1992) - Common burnt clay building RA2011 1

bricks.
IS-2185 - Concrete masonry units -

Part-1 (2005) RA2010 -
Part-2 (1983) RA2010 -
Part-3 (1984) RA2010 1
IS-4457 (2007) - Ceramic unglazed vitreous RA 2012 -

acid resisting tiles.
IS-4832 - Chemical resistant mortar

Part-1(1969) RA2016 1
Part-2 (1969) RA2016 1
Part-3 (1968) RA2016 1
IS-4443 (1980) - Resin type chemical RA2016 1

Resistant mortar.
IS-9510 (1980) - Bitumen Mastic - A.R. Grade RA2016
IS-1580 (1991) - Bituminous Compounds RA2010 -
IS-4995 - Chemical resistant mortar RA2008 1

Part-II (1974)
IS-12894 (2002) - Pulverized Fuel Ash-lime Bricks RA2002
2. CEMENT
IS-269 (2015) - Ordinary Portland Cement (OPC)
IS-455 (2015) - Portland Slag Cement(BFS)
IS-1489 - Specification for Portland

Pozzolana Cement (PPC)
Part I : 2015
Part II : 2015
IS-8112 (2013) - Ordinary Portland Cement,43 Grade.
IS-12269 (2013) - Specification for OPC 53 Grade
IS-12330 (1988) - Sulphate Resisting Portland RA2009 1,2,3,4,5,6
IS-3812 (2013) - Pulverized Fuel Ash – For use as RA2013

Pozzolana in Cement, Cement mortar and
Concrete
3. CONCRETE
98 of 1528
REFINERY STREAM-5

(GES)
IS-456 (2000) - Code of Practice for Plain & RA2016 1,2,3,4
Reinforced Concrete.
IS-516 (1959) - Method of test for strength RA2008 1,2

Of concrete.
IS-3370 - Design of Liquid Retaining

Structures.
Part-I (2009)
Part-II (2009)
Part-III (1967) RA2008 1
Part-IV (1967) RA2008 1,2
IS-4991 (1968) - Blast proof design of RA2008 -

structures.
4 STRUCTURAL STEEL
IS-800 (2007) - General construction in steel 1
Code of practice
IS-806 (1968) - Code of Practice of Steel tubes RA2013 1

in general construction
IS-808(1989 ) - Dimensions for Hot Rolled

Steel beam, column, channel RA2009 1,2
And angle sections.
IS-816 (1969) - Metal arc welding for 1

general conditions in mild RA2008 -
steel.
IS-813(1986) - Scheme of symbols for RA2008 -

Welding.
IS-9595 (1996) - Metal arc welding of carbon

& carbon manganese steel. RA 2007
IS-2062 (2011) - Steel for general structural - 1

purpose.
IS-3502 (2009) - Steel chequered plates RA 2015
IS-1363 - Hexagon head bolts, screws, -

Part 1,2 (2002) nuts of product grade C RA 2007
Part 3 (2002) (Size range M5 to M64) RA 2007
IS-1364 - Hexagon head bolts, screws,

99 of 1528
REFINERY STREAM-5

(GES)
Part 1 to 3 (2002) nuts of producte grades A & B RA 2007
Part 4 (2003) RA2008
Part 5 (2002) RA 2007
IS-1367 (2002) - Technical Supply Conditions for Threaded -

Steel Fasteners (Part 1 & Part 2)
IS-2062 (2011) - Steel for general structural - 1

purpose.
IS-3502 (2009) - Steel chequered plates RA 2015
IS-1161 (2014) - Steel tubes for structural purpose
IS-801 (1975) - Code of Practice for use of RA2010 1

Cold formed light gauge steel
structural members in general
building construction.
IS-2629 (1985) - Recommended practice for

hot dip galvanizing on iron & RA2010 1,2,3
steel.
-
IS-2633(1986) - Methods of testing uniformity
of coating of zinc coated RA2016
articles.
IS-3640( 1982) - Hexagon Fit Bolts (PGD 31: Bolts, nuts and RA2011
fasteners accessories)
BS EN 10025 - Hot Rolled Products of Structural Steels 2004
IS-6745(1972) - Method of determination of RA2016 1,2,3,4,5

mass of zinc coating on zinc
Coated iron & steel articles.
5. DOORS & WINDOWS
IS-1948 (1961) - Aluminium doors, windows and RA2011 1

ventilators.
IS-1949 (1961) - Aluminium windows for RA2006 1

Industrial buildings.
IS-1038 (1983) - Steel doors, windows and RA2011 1,2,3

Ventilators.
IS-1361 (1978) - Steel windows for industrial Buildings RA2011 1,2
IS-4043 (1969) - Symbolic designation of direc- -

100 of 1528
REFINERY STREAM-5

(GES)
tion of closing of doors etc. RA2011
IS-4021 (1995) - Timber doors, windows and RA2016 3

ventilator frames.
IS-1003 - Timber panelled door & in

window shutters.
Part-1 (2003) RA2008 2
Part-2 (1994) RA2006 3
IS-2191 - Wooden flush door shutters

Part-1 & 2 (1983) RA2011 1
IS-1081 (1960) - Fixing & glazing of metal RA2011 1

(steel & aluminium) doors,
windows & ventilators.
6. FOUNDATION ENGG.
IS-8009 - Calculation of Settlement of

foundation.
Part-1 (1976) RA2008 1,2,3
Part-2 (1980) RA2010 1
IS-2974 - Design and construction of -

machine foundations.
Part-1 (1982) RA2008 1
Part-2 (1980) RA2008 1
Part-3 (1992) RA2010 -
Part-4 (1979) RA2010 1
Part-5 (1987) RA2008 -
IS-2950 (Part I) - Design and construction of RA2008 1

(1981) Raft Foundation.
IS-1892 (1979) - Sub surface investigation for RA2011 -

Foundations.
IS-1904 (1986) - Design & construction of RA2010 -

foundations in soils: General
requirements.
IS-11089(1984) -Design and construction of Ring foundation RA2011 1
IS-2911 - Design and construction of

pile foundation.
Part-1
101 of 1528
REFINERY STREAM-5

(GES)
Sec. 1,2,3,4 Sect.1 (2010)
Sect.2 (2010)
Sect.3 (2010)
Sec. 4 (2010)
Part-2 (1980) RA2010 1
Part-3 (1980) RA2010 1,2,3,4
Part-4 (2013)
IS-1080 (1985) - Design and construction of RA2011 -

Shallow foundation.
IS-6403 (1981) - Determination of bearing RA2011 1

capacity of shallow
foundations.
7. FUNCTIONAL DESIGN OF BUILDINGS
IS-2440 (1975) - Code of Practice for RA2008 -

daylighting of buildings
IS-6060 (1971) - Code of Practice for RA2008 -

daylighting of factory
buildings.
8. LOADING STANDARDS
IS-875 (1987) - Loading Standards

Part 1 :1987 RA2008 1
Part 2 :1987 RA2008 1
Part 3 :2015 1
Part 4 :1987 RA2008 -
Part 5 :1987 RA2008 1
IS-1893 - Criteria for earthquake - -

resistantdesign of Structures.
Part 1 (2016) -
Part 4 (2015)
IS-4326 (2013) - Criteria for earthquake 1

Resistant design
& construction of bldgs.
IS-13920 (2016) -Ductile detailing of RC Structures subjected

to Seismic forces.
IS 15498: Guidelines for Improving the Cyclonic Resistance of RA2010

Low Rise Houses and Other Buildings/Structures
9. REINFORCEMENT
102 of 1528
REFINERY STREAM-5

(GES)
IS-432 - Mild Steel & medium tensile
Part 1 (1982) bars & wires for concrete RA2015 2
Part 2 (1982) RA2009 2
IS-1786 (2008) - High strength deformed steel bars & wires 1,2,3
for concrete reinforcement.
- -
IS-2502 (1963) - Bending and fixing bars for RA2008
Concrete reinforcement.
-
IS-5525 (1969) - Recommendation for detailing. RA2008
10 ANCHOR BOLTS RA2004 -
IS-5624 (1993) - Foundation Bolts RA2008
11. WATER PROOFING AND DAMP PROOFING -
IS-4365 (1967) - Application of bitumen mastic RA2010
IS-7198 (1974) - Damp proofing using bitumen RA2010 -

felts.
-
IS-1346 (1991) - Waterproofing of roof using RA2010
bitumen felts.
-
IS-2645 (2003) - Integral cement water proofing RA2007
Compounds.
- -
12. DESIGN AIDS
SP-7 (2016) - National Building Code of India.

SP-34 (1987) - Handbook on concrete
reinforcement detailing. 1
SP-36 – Compendium of Indian standards on Soil Engg.
Part 1(1987) - -
Part 2 (1988)
SP-6(5) (1980) -Handbook on cold formed

Light gauge steel sections. 1
103 of 1528
REFINERY STREAM-5

(GES)
B.3.1.2 Applicable Software with their version & limitations
1. StaadPro V8i "SELECT Series 5#
2. Autocad 2013 or Lower
3. MS Office 2010 or Lower
B.3.2 Client's regulations and standards
Not applicable
104 of 1528
REFINERY STREAM-5

(GES)
1 Annexure C Report on blast load design

Buildings / structures in this project are not required to be designed for Blast load.
105 of 1528
REV.
Rio Tinto Alcan International Limited

Z02-000-1-DC-003 A
400 1190 avenue des Canadiens-de-
NALCO
Montréal, Montréal, Quebec H3B 0E3 Writer : QUINCIEUC Chapter :
FORMAT
A4
Canada
T +61(0) 736 254 661 NALCO REFINERY LINE 5 Project O/Ref. Page
F +61(0) 439 029 774
Z02 1/41
CIVIL AND STRUCTURAL
GUIDELINES
PREPARED BY
RTAIL
A 25/08/2017 ISSUED FOR PACKAGE 2 QUINCIEUC SANTALUCIAG ELKADIB
Rev. Date Description Written by Verified by Approved by
© 2017 Rio Tinto Alcan International Limited (RTAIL). The information disclosed in this document is confidential and contains
RTAIL Technology. It is not to be copied, reproduced in any form or given to any person whatsoever without the express consent
of RTAIL, which may have been contractually provided.
106 of 1528
RIO TINTO ALCAN INTERNATIONAL LIMITED
REVISION GRID
Page Revision index Page Revision index

N° A B C D E F G H I J N° A B C D E F G H I J
1 X 26 X
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5 X 30 X
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7 X 32 X
8 X 33 X
9 X 34 X
10 X 35 X
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19 X 44
20 X 45
21 X 46
22 X 47
23 X 48
24 X 49
25 X 50
Z02-000-1-DC-003/A CIVIL AND STRUCTURAL GUIDELINES 2/41

© 2017 Rio Tinto Alcan International Limited (RTAIL). The information disclosed in this document is confidential and
contains RTAIL Technology. It is not to be copied, reproduced in any form or given to any person whatsoever without the
express consent of RTAIL, which may have been contractually provided.
107 of 1528
TABLE OF CONTENTS
1. SCOPE AND APPLICATION ................................................................................... 6

1.1. Application .............................................................................................................. 6
1.2. Exclusions ............................................................................................................... 6
2. INFORMATION REQUIREMENTS ........................................................................... 7
2.1. Site Environmental Data .......................................................................................... 7
2.1.1. Wind.......................................................................................................................................7
2.1.2. Earthquake ............................................................................................................................8
2.1.3. Soil Properties .......................................................................................................................8
2.2. Process Requirements ............................................................................................ 9
2.3. Incidental Loads ...................................................................................................... 9
2.3.1. Thermal Loads .......................................................................................................................9
2.3.2. Spillage Loads .................................................................................................................... 10
2.3.3. Scale Loads ........................................................................................................................ 10
2.3.4. Live Loads .......................................................................................................................... 10
3. ENGINEERING REQUIREMENTS ......................................................................... 11
3.1. Standards and Codes of Practice ...........................................................................11
3.2. Design ....................................................................................................................11
3.2.1. Choice of Design Method ................................................................................................... 11
3.2.2. Loads .................................................................................................................................. 11
3.3. Loadings ................................................................................................................12
3.3.1. Structure Selfweight ........................................................................................................... 12
3.3.2. Equipment Weight .............................................................................................................. 12
3.3.3. Dynamic .............................................................................................................................. 12
3.3.4. Vehicle Loads ..................................................................................................................... 13
3.3.5. Soil and Water Pressures ................................................................................................... 13
3.4. Design Load CombinatIons ....................................................................................13
3.5. Robustness and Rigidity .........................................................................................14
3.5.1. General Design Principles .................................................................................................. 14
3.6. Deflection Limits .....................................................................................................14
3.6.1. Pipe Racks.......................................................................................................................... 14
3.6.2. Process Buildings Clad or Unclad (without cranes) ........................................................... 14
3.6.3. Buildings Housing Gantry Cranes ...................................................................................... 15
4. DOCUMENTATION REQUIREMENTS .................................................................. 16
4.1. Units .......................................................................................................................16
4.2. Design Calculations................................................................................................16
4.3. Computer Programs for Design ..............................................................................16
4.4. Drawings ................................................................................................................16
5. CONSTRUCTION MATERIALS - STEELWORK AND TANKAGE ........................ 17
5.1. Hot-rolled Steel ......................................................................................................17
5.1.1. Structural Steel Plate and Sections .................................................................................... 17
5.1.2. Flooring Materials ............................................................................................................... 17

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5.2. Other Materials.......................................................................................................17

5.2.1. Cold Rolled Sections .......................................................................................................... 17
5.2.2. Bolting ................................................................................................................................. 17
5.2.3. Cladding .............................................................................................................................. 18
6. CONSTRUCTION MATERIALS - REINFORCED CONCRETE ............................. 19
6.1. Concrete Materials and Manufacture ......................................................................19
6.1.1. Minimum Strength Properties ............................................................................................. 20
6.2. Ancillary Materials ..................................................................................................20
6.2.1. Reinforcement .................................................................................................................... 20
6.2.2. Embedments....................................................................................................................... 20
6.2.3. Proprietary Items ................................................................................................................ 21
7. SPECIFIC TECHNICAL REQUIREMENTS - CIVIL ................................................ 22
7.1. Roadways ..............................................................................................................22
7.1.1. Layouts, Widths .................................................................................................................. 22
7.1.2. Design Loadings ................................................................................................................. 22
7.1.3. Traffic Control, Guardrails and Kerbs ................................................................................. 22
7.1.4. Drainage ............................................................................................................................. 22
7.2. Civil Works .............................................................................................................23
7.2.1. Site Works, Bulk and Detail ................................................................................................ 23
7.2.2. Compaction and Backfill Requirements ............................................................................. 23
7.2.3. Pipe Installation .................................................................................................................. 23
7.2.4. Gratings and Silt Traps ....................................................................................................... 24
8. SPECIFIC TECHNICAL REQUIREMENTS - CONCRETE ..................................... 25
8.1. Design and Specification ........................................................................................25
8.1.1. Tolerances .......................................................................................................................... 25
8.1.2. Standardisation ................................................................................................................... 25
8.1.3. Standard Specifications ...................................................................................................... 25
8.2. Reinforcement ........................................................................................................25
8.2.1. Reinforcement Minimum Cover .......................................................................................... 25
8.2.2. Detailing of Reinforcement ................................................................................................. 25
8.3. Foundations ...........................................................................................................26
8.4. Slabs on Grade ......................................................................................................26
8.4.1. Slab Design ........................................................................................................................ 26
8.4.2. Joints .................................................................................................................................. 27
8.4.3. Drainage ............................................................................................................................. 27
8.5. Construction Issues ................................................................................................28
8.5.1. Curing ................................................................................................................................. 28
8.5.2. Stripping Times ................................................................................................................... 28
8.5.3. Protection of Mass Pours ................................................................................................... 28
8.5.4. Special Concrete Mixes ...................................................................................................... 28
8.5.5. Reinforcement Stools ......................................................................................................... 29
8.5.6. Blinding and Damp Proof Membrane ................................................................................. 29
8.5.7. Hold Down Bolts ................................................................................................................. 29
8.5.8. Tolerances .......................................................................................................................... 30
8.5.9. Grouting of Base Plates ...................................................................................................... 30
8.5.10. Chamfers and Fillets ........................................................................................................... 30
8.5.11. Formwork Finishes ............................................................................................................. 30
9. SPECIFIC TECHNICAL REQUIREMENTS - STEELWORK .................................. 31
9.1. Design ....................................................................................................................31
9.1.1. Minimum Connections ........................................................................................................ 31
9.1.2. Corrosion Protection ........................................................................................................... 31
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9.1.3. Ladders, Stairs and Platforms, Walkways, Handrails......................................................... 32

9.1.4. Monorails and Cranes ........................................................................................................ 32
9.1.5. Pipe Racks.......................................................................................................................... 32
9.1.6. Structural Gaps ................................................................................................................... 32
9.1.7. Avoidance of Dirt Traps and Corrosion .............................................................................. 32
9.2. Fabrication and Erection ........................................................................................33
9.2.1. Welding ............................................................................................................................... 33
9.2.2. Erection ............................................................................................................................... 33
9.2.3. Bolting Procedures ............................................................................................................. 33
9.2.4. Temporary Works ............................................................................................................... 34
9.2.5. Shop Detail Drawings ......................................................................................................... 34
10. SPECIFIC TECHNICAL REQUIREMENTS - TANKAGE .................................... 35
10.1. Approved Design Procedures .................................................................................35
10.1.1. Seismic Loads for Tanks .................................................................................................... 35
10.1.2. Maximum Stresses ............................................................................................................. 35
10.1.3. Minimum Thickness of Material .......................................................................................... 35
10.1.4. Tie Down Requirements ..................................................................................................... 36
10.1.5. Corrosion Protection ........................................................................................................... 36
10.1.6. Thermal Insulation .............................................................................................................. 36
10.1.7. Specific Requirements ........................................................................................................ 37
10.2. Caustic Embrittlement ............................................................................................38
10.3. Bunding ..................................................................................................................38
10.3.1. Process Area Bunding ........................................................................................................ 38
10.3.2. Bulk Storage Bunding ......................................................................................................... 39
10.4. Overflows ...............................................................................................................39
10.5. Special Provisions Precipitators ..........................................................................40
11. REFERENCES .................................................................................................... 41
11.1. API .........................................................................................................................41
11.2. ASTM .....................................................................................................................41
11.3. AWS.......................................................................................................................41
11.4. BS ..........................................................................................................................41
11.5. DIN.........................................................................................................................41

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1. SCOPE AND APPLICATION
1.1. APPLICATION
This Guideline sets out the minimum requirements for civil and structural
design and construction for a Bayer alumina plant project.
This Guideline also includes minimum requirements for the design of steel
tanks for Bayer refinery service.
1.2. EXCLUSIONS
This guideline does not address construction, inspection and testing of
structures, except as included in referenced standards.
Issues relating specifically to bins, silos and bunkers for bulk solid materials are
excluded.

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2. INFORMATION REQUIREMENTS
2.1. SITE ENVIRONMENTAL DATA

A comprehensive report shall be prepared addressing the following
environmental factors, prior to the commencement of Detailed Engineering
Phase. Where applicable this report shall be presented in terms of design
values associated with different return periods.
Temperature and humidity distributions
Rainfall characteristics, flood return periods and intensities
Snowfall characteristics
Wind speed characteristics
Earthquake characteristics
Soil characteristics
2.1.1. Wind
A cautionary note:
The design methods provided in the wind design codes of various authorities
are based on widely different concepts, ranging from a basic 3 second gust to
the concept of the fastest mile wind speed. Local records may have to be
interpreted for application to the approved design guide.
Wind loads shall be derived in accordance with an approved Design Standard
or Code of Practice. The basic design event shall have a probability of
occurrence which is commensurate with the choice of design method: for
example, 5% probability of exceedance in 50 years for Ultimate design wind,
and 5% in 1 year for Serviceability design wind. Working stress loads would be
intermediate between these values. Design wind pressures shall account for:
Expected future development or demolition in the vicinity
Elevation of structure above ground level
Topography
Importance of the structure (post disaster functional requirement)
Shielding by upwind structures.
Members potentially subject to dynamic excitation by wind force shall be
designed for the resultant amplified forces.
Design wind pressures shall be derived for strength as well as serviceability
factors such as deflection assessment and shut down operational wind speed.
Special requirements, such as impact resistance in cyclonic (or hurricane)
areas shall be addressed.
The most unfavourable direction of wind force shall be considered on all
structures. Pipe racks shall be designed for the unshielded wind load on the
four largest pipes at any given level of the rack.

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2.1.2. Earthquake
Earthquake loads shall be derived in accordance with the approved Design
Standard or Code of Practice. In the absence of an approved local standard,
the appropriate sections of ISO 23469 (Bases for design of structures
Seismic actions for designing geotechnical works) or of ANSI/ASCE (American
Society of Civil Engineers) 7-93, together with the relevant publications by the
SEAOC (Structural Engineers Association of California) is considered an
acceptable design standard. The basic design event shall have a probability of
occurrence which is commensurate with the choice of design method, for
example 10% probability of exceedance in 50 years for Ultimate design load,
but a shorter return period for Serviceability loads. Working stress loads shall
be intermediate between these values. Earthquake design loads shall account
for:
Location
Structure importance (post disaster functional requirement)
Soil profile
Structure type (seismic response depends on the ductility and flexibility
of the structure)
Seismic loads shall be applied in the most unfavourable direction. The design
for earthquake loads shall consider the fact that different components are
subject to greatly differing accelerations when exposed to earthquake loading.
2.1.3. Soil Properties

A detailed soils report shall be prepared prior to the commencement of any
foundation or seismic design. This report shall be prepared by an approved
suitably qualified and experienced geotechnical engineer. This report shall
address the following parameters where appropriate:
Geotechnical mapping of the area, showing major rock and soil strata
and their classification, location and levels of boreholes and sampling
points.
Borehole logs and soil sampling reports.
Soil density, internal angle of friction, cohesion, permeability.
Rankine K factors, active, passive and at rest.
Safe bearing pressures net of effective overburden pressure at
unfactored loads (long and short term).
Potential for differential settlement.
Friction factor between concrete and soil.
Effect of foundation shapes and sizes.
Dynamic and settlement characteristics (factors such as Poissons Ratio,
Young's Modulus and Shear Modulus ).
Reaction or aggression to buried concrete and steel.

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Water table levels, seasonal as well as permanent.

Compaction and excavation characteristics and recommendations to
achieve densities required. Compaction below different types of
construction, backfill requirements.
Pile design information: recommended types, construction methods,
bearing and skin friction capacities.
Seismic characteristics of each sub-area.
Susceptibility to seismic liquefaction.
Potential for environmental damage in the event of escape of process
fluids.
Recommendations on use of local materials for backfill and compaction.
2.2. PROCESS REQUIREMENTS

A detailed report shall be prepared defining all operational parameters
pertinent to structural design, prior to starting structural design. The report
would include but not be limited to, the following points:
Maximum and minimum contents of tanks and vessels
Fluid densities under all operating conditions
Class of risk and weight Equipment, contents and scale loads
Temperature ranges under all operational conditions
Special requirements for corrosion resistance
Special access, clearance and maintenance requirements
Services requirements (cranage, washdown water, compressed air)
Wear allowances
Thermal insulation
Spillage Loads
2.3. INCIDENTAL LOADS
2.3.1. Thermal Loads

Thermal expansion and contraction as a result of operational or ambient
factors can result in restraint forces acting on the structure. These restraint
forces are commonly due to the friction between the supporting structure and
equipment and piping. The frictional restraint loading shall be assessed for the
operational loads on the support, multiplied by an appropriate friction factor.
Friction factors to be adopted for design purposes shall be as follows:
Uncorroded steel to steel 0.30
Steel to concrete 0.35
Teflon to Teflon 0.10
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2.3.2. Spillage Loads

The design loading shall take account of potential spillage from conveyors and
feeders where these are installed. The design shall allow for spillage loads of
5 kPa unless a higher value is required by the approved Design Standard.
Walkways and platforms subject to spillage loads shall be designed for the live
load or the spillage load, whichever is the greater.
2.3.3. Scale Loads

Surfaces of machinery, structures and vessels exposed to Bayer process fluids
are prone to develop major growths of scale precipitated from the process.
These deposits can create a major load component, which shall be estimated
on the basis of an assumed thickness for all wetted areas, dependant on the
specific process situation.
2.3.4. Live Loads

The following minimum loads provided may be adjusted for contributory area
effects in accordance with approved Design Standards and Codes of Practice.
Specific equipment loads in excess of these loads shall take precedence.
Minor access walkways and stairs used for inspection only 2.5 kPa
Stair cases, frames and treads 5 kPa
Principal walkways and all working platforms 5 kPa
(The last item includes for incidental machinery and equipment loads that are
not major loads.)
Principal walkways (> 1.2 metres wide) and platforms subject to specific major
equipment loads shall be designed for the specific loads plus 10 kPa in the
unoccupied area around the equipment.
Roofs accessible for inspection and repair only, the larger of:
1) 1 kPa
2) 25% of roof self weight
All structural floor members shall be designed for a 10 kN point live load
applied at mid span, in addition to uniform loading from attributed area as
above.

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3. ENGINEERING REQUIREMENTS
3.1. STANDARDS AND CODES OF PRACTICE

The design shall comply in full with the requirements of approved local
standards. In the absence of approved local standards the Project Owner shall
nominate which standards are to be applied.
The specified Standards and Codes of Practice shall form a coherent,
compatible set of design guides. In particular, mixing of Standards and Codes
from different sources shall not be permitted. Approved international standards
shall include those of Australia, Great Britain, European and United States of
America.
Where this standard and or other approved documents require that several
criteria be satisfied, then the most stringent of the requirements shall apply.
Some relevant Standards and Codes are listed in Section 11.0.
3.2. DESIGN
3.2.1. Choice of Design Method

There is a worldwide trend away from working stress design in favour of limit
state design. Most recent codes of practice are in limit states design. Some
have abandoned working stress design completely.
The designer shall determine which method of design is most appropriate for
the particular structure being considered, bearing in mind the specific
requirements of the approved Design Standard. Many international standards
use working stress design and will probably continue to do so, for example,
codes for pressure vessels and tanks.
Where the code of practice does not define loads in working stress terms,
acceptable working stress loads can generally be determined by dividing the
ultimate limit state load component (for example, ultimate wind or ultimate
seismic) by 1.5, or by some other factor acceptable to the Design Authority.
3.2.2. Loads
The structural design shall consider the following unfactored loads in the
combinations provided in Table 3.4, Design Load Combinations. These are a
minimum requirement. Specific considerations may lead to more onerous
requirements in the design of the structures. Local Standards and Regulations
which require higher design loads, or more conservative load combinations,
shall take precedence over these requirements.
Structural design shall consider the potential for higher loading than initially
required in order to provide capacity for additional equipment and pipework
beyond that presently defined.

116 of 1528
3.3. LOADINGS
3.3.1. Structure Selfweight

The selfweight of the structure and permanent dead loads shall be derived
using accurate unit weights provided in the approved design standards.
3.3.2. Equipment Weight

The weight of equipment such as, vessels, tanks, pumps, piping, cable ducts,
compressors, motors, cranes and monorails shall where possible be derived
from vendors' data. A suitable allowance shall be adopted to adjust the
weights used in order to allow for the quality of the source information. In
particular cranes, monorails and their supporting structures shall be designed
for a conservative assessment of the probable safe working load required.
These loads shall be provided in a format that permits the discrete identification
of the following sub loads:
Vessel Empty weight Dead only
Vessel Operating weight Live component (for example, fluid or dry

material contents and scale allowance).
Vessel Upset load Live component (greater than normal

operating live load).
Test loads (for example, hydro-static Live Component

testing of gas-filled pipes and vessels)
Table 3.3: Design Load Components
To allow for future expansion, pipe and cable racks only partially utilised shall
be designed for larger loads based on complete occupancy of the structure, at
the load intensity of the initial design.
3.3.3. Dynamic
Structures subject to dynamic excitation from compressors, screens, large
motors, pumps and other mechanical devices shall be investigated for dynamic
response. The structure shall be "tuned" to avoid the risk of resonance
causing structural fatigue, discomfort to personnel, or other detrimental effects.
Specific dynamic factors shall be sourced from vendor data. Isolation of
structures subject to dynamic forces shall be considered during Detailed
Engineering.
In general a machine and its foundation are suitably "tuned" when the ratio of
"operating frequency" to "resonant frequency of the combined machine and
footing" is either less than 0.67 or greater than 1.5. The range less than 0.67 is
preferred, due to the lower vibration amplitudes experienced.

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The structural design shall consider suitable load combinations. These are
designed to ensure satisfactory performance under operational loads, as well
as ultimate strength, stability and serviceability conditions. Structures shall be
designed for the most onerous combinations of the component loads,
combined in all realistic potential combinations.
Specific load factors applied to Limit State ultimate strength and serviceability
and stability combinations shall be in accordance with approved Design
Standards and Codes of Practise.
Assumptions regarding the contents of each tank or vessel to be combined
with design wind for stability considerations shall be conservative. In the
absence of specific operating knowledge, stability considerations against wind
load shall be satisfied with the tank/vessel in the empty state. Stability
calculations for earthquake loads shall be considered for both full and empty
states.
The design of tanks and vessels with a free surface shall take account of the
load amplification caused by "sloshing" of the fluid under seismic conditions, as
per section 10.1 of this Guidelines.
3.3.4. Vehicle Loads

The design of slabs on grade and other structural elements shall consider the
effects of vehicle loads. Slabs on grade accessible to heavy traffic such as
large earthmoving machinery, shall as a minimum be designed for an axle load
of 450 kN. Slabs on grade where access is limited from large machines shall
be designed for an axle load of 100 kN. Construction loading shall be carefully
considered and allowed for in terms of design load as well as in considerations
of age (strength) of concrete subjected to these loads.
Bollards, fencing and other access limiting structures shall be installed for
operational security, and control of construction access. Impact loads shall be
assessed for specific risks and operational criteria. A commonly adopted
design load of 25% of vehicle weight is recommended in the absence of other
information.
3.3.5. Soil and Water Pressures

Soil pressure loads for design shall be derived from Rankine or other accepted
theory. The design loads considered shall include compaction, impact and live
loads.
Retaining walls shall be designed for all likely combinations of loading,
including (if warranted) a seismic event under saturated conditions. Drainage
to back face of walls should be considered, to relieve potential hydrostatic
pressures.
3.4. DESIGN LOAD COMBINATIONS

Actual load factors for application to Working, Ultimate Strength, Stability and
Serviceability loads respectively shall be in accordance with the approved
Standards and Codes of Practice, and sound engineering judgement.

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Design Standards are usually written for very general load situations only and
will not offer combination information for the specific loads listed below. The
designer shall assign appropriate load factors. These factors should be
determined early in the project and listed in a structural design document.
3.5. ROBUSTNESS AND RIGIDITY
3.5.1. General Design Principles

Structural designs providing alternative load paths are preferred.
Steel sections, concrete reinforcement patterns and so on shall be reasonably
rationalised. With standardised connections this contributes to overall
economy and robustness.
A limit on the ratio of Effective Length to Radius of Gyration (l/k) of 180 shall be
adopted for all members between points of lateral support.
The stiffness provided by the structural design shall be such as to avoid the
risk of excitation due to applied dynamic loads.
Floor beams may be restrained against lateral movement, where necessary, by
welding to floor plate or by shear connectors into supported concrete flooring.
3.6. DEFLECTION LIMITS

In absence of code or standard, the stiffness of structures and structural
elements shall satisfy the following limits when subjected to actual unfactored
operational loads and load combinations. The Serviceability wind load shall be
applied for deflection assessments. Actual limits shall be derived from the
most severe of the following considerations. Specific differential deflection
limits are also governed by equipment and nozzle criteria.
Total deflections of beams shall not exceed Span / 250.
Cross-falls and deflections in roofing and flooring shall be designed to minimise
the risk of ponding.
3.6.1. Pipe Racks

Sway due to wind shall not exceed the lesser of:
1) (Centre to centre frames) / 200
2) Height / 150
3.6.2. Process Buildings Clad or Unclad (without cranes)

Sway due to wind shall not exceed the lesser of:
1) (Building frame centre-to-centre of columns) / 250
2) Height / 200
Where framing is in contact with masonry or other rigid elements susceptible to
movement the allowable deflections above shall be halved.

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3.6.3. Buildings Housing Gantry Cranes

Buildings housing gantry cranes shall be designed for the specific deflection
criteria required by the approved Design Standard. Satisfactory crane
performance dictates the need for substantially greater stiffness than the
criteria above.
Monorails and cranes shall satisfy strict vertical deflection criteria. Calculations
which include effects of settling and rotation of adjacent spans and supports
should demonstrate compliance with imposed criteria. Crane rail alignment
shall be maintained under all operating conditions within tolerances specified
by the supplier.

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4. DOCUMENTATION REQUIREMENTS
4.1. UNITS
All design calculations shall be carried out in a consistent manner in full
compliance with the ISO 80000 who defines the SI System of Units.
4.2. DESIGN CALCULATIONS

To achieve uniformity of approach between designers, all calculations shall be
founded on a consistent set of design assumptions, loads and combinations as
discussed in Sections 2 and 3 above. These criteria shall be set out in a
controlled stand-alone document and made accessible to all relevant
personnel. This document shall form the basis of all structural and civil
calculations to be carried out for the project.
All calculations shall be in English and shall be catalogued and cross
referenced in a logical methodical manner in order to facilitate checking and
confirmation of compliance with referenced standards. All calculations shall be
checked and shall carry the signatures of no less than two qualified people.
Revisions after Issue for Construction shall be clearly indicated. Calculations
shall be cross referenced to the drawings to which they apply. Calculations
shall form part of the Project Archives.
4.3. COMPUTER PROGRAMS FOR DESIGN

Computer programs for design shall be written and validated by appropriately
qualified organizations. They shall comply with the requirements of the
approved Design Standard and, where possible, be accredited by the
Standards Association of the host country.
Computer input files shall be indexed and stored on disk or tape for the
duration of the project and shall form part of the Project Archives.
4.4. DRAWINGS
All drawings shall be prepared to an approved format with an approved
numbering system. All notes, titles and information included on drawings shall
be in English. Drawing sheet sizes shall be to SI standards, with scales for
work and letter size to approved standards. The use of approved standard
drawings and details is recommended.
Drawings should contain notes directly relevant to the work described in the
drawings. There should be a preference for notes on drawings instead of
including them in Specifications, which are less frequently read. Where
possible, reference should be made to the relevant approved Design Standard
rather than reproducing the standard in note form.

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5. CONSTRUCTION MATERIALS - STEELWORK AND TANKAGE

It is critical to the final integrity of structural work that the structural design
adequately defines the materials to be used, and that these materials are in
fact used in the construction stage.
5.1. HOT-ROLLED STEEL
5.1.1. Structural Steel Plate and Sections

Hot-rolled structural steel plate and sections shall be nominated and supplied
to a recognised ASTM material specification. Material supplied shall be
certified by an accredited testing authority to comply with the minimum
engineering and mechanical design values.
5.1.2. Flooring Materials

Floor plate shall possess an angular raised pattern to one surface. The pattern
and layout shall facilitate free drainage and cleaning while retaining a non-slip
surface. Minimum plate thickness shall be not less than 8 mm.
Mesh floor grating shall be nominated and supplied to a recognised material
specification. This will typically have 32 mm x 5 mm load bars at 40 mm
centres to span up to 1.2 metres with 10 kPa applied loading or 1.5 metres with
5 kPa applied loading.
5.2. OTHER MATERIALS
5.2.1. Cold Rolled Sections

Cold-rolled steel sections shall be nominated and supplied to a recognised
ASTM material specification. Material supplied shall be certified by an
accredited testing authority to comply with the minimum engineering and
mechanical design values. Approved proprietary systems shall be used strictly
in accordance with the vendor's recommendations.
5.2.2. Bolting
Bolting for structural steel, excepting minor items such as handrail, shall be
standardised to "High Strength" 20 mm diameter and larger. The minimum
strength grade of these bolts shall be in accordance with the approved Design
Standard. Preferred specifications are ASTM A325 and ISO 898 Grade C.
"Commercial" bolts shall be specified to ASTM A307 or ISO 898 Grade A.
All bolts and nuts shall be hot-dip galvanised. The coating mass shall be in
accordance with the approved Design Standard and shall generally be
between 300 and 375 grams per square metre. Threads of nuts for galvanised
bolts shall be retapped after galvanising. Nuts and bolts shall be lubricated
before assembly to prevent seizing. Tapered washers shall be specified where
connections are made to tapered flanges.

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Design shear capacities for all bolts shall be based on the threads being
included in the shear planes to simplify on-site checking and reduce the variety
of bolt lengths required.
5.2.3. Cladding
Cladding materials shall be nominated and supplied to a recognised ASTM
material specification. Material supplied shall be certified by an accredited
testing authority to comply with the minimum engineering and mechanical
design values. Approved proprietary systems including fasteners and washers
shall be used strictly in accordance with the vendor's recommendations.
Cladding shall be supplied with a coating on both outer sides and edges, which
shall be resistant to caustic attack and other corrosion agents. The cladding
system including fasteners shall be selected after due consideration of its
corrosion potential, both as a stand alone system and in conjunction with
attachments to support structures. Aluminium cladding shall not be used under
any circumstances, due to its susceptibility to caustic attack.

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6. CONSTRUCTION MATERIALS - REINFORCED CONCRETE
6.1. CONCRETE MATERIALS AND MANUFACTURE

The specification of concrete shall recognise the custom of the local industry
with respect to testing, sampling and acceptance criteria. For remote sites with
no extensive history of concrete manufacture and application, it may be
necessary to determine long term properties of local aggregates in contact with
cement and strong alkalies, by laboratory investigation. In particular, the
possibility of alkali-aggregate reactions shall be investigated.
The testing of concrete components (cement, aggregates, sand, water and
additives) and cast specimens shall generally be performed in compliance with
ASTM specifications. In particular, concrete compression testing shall be
performed in accordance with ASTM C39 and ASTM C918.
Testing shall also be carried out in compliance with ASTM standards to
determine the susceptibility of the proposed concrete mix to the full range of
Alkali-Aggregate Reactions (AAR). The tests shall include, but not be limited to
ASTM C1293, C289 and C295. The mix design shall be modified to minimise
the effects of AAR.
The specification of concrete shall recognise the custom of the local industry
with respect to testing, sampling and acceptance criteria. In specifying
concrete the following factors shall be taken into account:
Availability
Durability
Abrasion resistance of both the aggregates and the concrete
Strength criteria
Strength distribution about the mean may have to be investigated in order to
specify an achievable and reliable characteristic compressive strength for
concrete mix design. The mix design shall also take into consideration the
following factors:
Availability and quality of production and delivery facilities
Qualities of aggregates, cement and water
Site facilities for pouring, finishing and curing, and ambient temperature
range
Specific performance requirements such as strength and resistance to
caustic attack
The use of additives in concrete shall be subject to the approval of the
Engineer, who shall determine their adequacy and compliance with reputable
international standards. Local additives that do not carry the certification of
international testing authorities such as ASTM shall not be approved for
inclusion in any concrete to be used. Additives containing Chlorides shall not
be used under any circumstances.

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6.1.1. Minimum Strength Properties

Concrete 28 day Characteristic Compressive Strengths shall be as listed below
unless greater values are required by the approved Design Standard:
Blinding layers 15 MPa
Piles 40 MPa
Footings 25 MPa
Columns 40 MPa
Beams 32 MPa
Floor Slabs, Walls 32 MPa
6.2. ANCILLARY MATERIALS
6.2.1. Reinforcement
Reinforcement for inclusion in reinforced concrete shall be nominated and
supplied to a recognised international material specification. Reinforcement
generally complies with one of two groupings of world-recognised standards:
1) American Standards, principally:
ASTM A615 Grade 60 (Yield Strength 414 MPa)
ASTM A615 Grade 75 (Yield Strength 485 MPa)
2) European Standards, principally:

DIN 448 (Yield Strength 500 MPa)
BS 4449 (Yield Strength 460 Mpa)
The American steels tend to have lower ductility and lower weldability. The
above list is not exhaustive.
Material supplied shall be certified by an accredited testing authority to comply
with the minimum engineering and mechanical design values. The designer
shall specify the ductility (cold bending and rebending) and weldability
properties required of the reinforcement, and ensure that these properties are
taken fully into consideration during design, fabrication and erection.
All bar reinforcement other than ligatures and spacers shall be of a deformed
surface profile. Reinforcing mesh may have either a smooth or a deformed
surface profile. Reinforcement shall possess the mechanical properties
required by the approved Design Standard, including cold bending, rebending
and weldability requirements.
6.2.2. Embedments
Embedments and cast-ins such as hold down bolts shall be hot dip galvanised
to a coating mass of at least 375 grams per square metre

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6.2.3. Proprietary Items

Proprietary items shall be from a source that is certified, by an international
testing authority such as ASTM, to comply with the minimum engineering and
mechanical design values claimed by the supplier. Approved proprietary
systems shall be used strictly in accordance with the vendor's
recommendations. The issue of compatibility between products shall be
specifically addressed.

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7. SPECIFIC TECHNICAL REQUIREMENTS - CIVIL
7.1. ROADWAYS
7.1.1. Layouts, Widths

The roadway system including kerbs, sub-base, road base and surface course
shall be designed to provide a 15 year service life before major repairs are
needed.
Roadways shall be designed in compliance with the approved Design Standard
and any additional Statutory requirements. Road widths, vertical clearances
and kerb radii shall be proportioned to accommodate the largest and longest
vehicles (including their loads) likely to be present at any time during the life of
the plant, including construction and refit periods. Turnarounds shall be
designed to allow easy manoeuvring of laden trucks. Suitable speed limits
shall be imposed and signposted.
The sealing adopted will depend on local custom. The road seal shall be
designed to provide 15 year service life before major repairs are needed.
Sealing shall be designed to withstand the tearing effect of manoeuvring heavy
vehicles.
7.1.2. Design Loadings

As a minimum design criterion, the roadways, including bridges and culverts,
shall be designed for loads imposed by a 150 tonne wheeled crane or large
earthmoving machinery. The exact configuration of the wheel loads shall be in
accordance with a pattern provided in the approved Design Standard.
A suggested loading pattern for a Cat 992C Wheel loader is as follows:
Operating Weight - 90 tonnes
Wheelbase - 4.83 m
Width over Tires - 4.55 m
Weight distribution - Equal to both axles
7.1.3. Traffic Control, Guardrails and Kerbs

Traffic control devices shall comply with local statutory requirements.
Drive-over kerbs shall be provided only in locations where occasional access
by wheeled vehicles is required. Where more frequent vehicular access is
required, consideration shall be given to providing a permanent ramp.
Conventional kerbs shall be used elsewhere.
Guardrails shall be provided for permanent structures having less than 900 mm
horizontal clearance to the road edge.
7.1.4. Drainage
Drainage for process areas shall be made on bunded slabs in accordance with
RT standard drawings, with runoff to process sumps. Outside of these areas,
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drainage shall be provided by grading design, and installation of surface drains

and underground pipework for efficient collection and removal of stormwater.
Bayer refinery storm drains are frequently contaminated with caustic and other
substances which make the flow unsuitable for direct release. The Process
Engineer shall integrate storm water control with the plant water balance, and
specify appropriate routing and treatment processes.
Stormwater drainage installations shall comply with the approved Design
Standard and Statutory requirements. As a guide, stormwater drainage shall
be designed for a rainfall event of the following average recurrence intervals,
unless a more stringent value is required:
Major access roads, average recurrence interval 100 years.
Minor access roads, average recurrence interval 10 years.
Stormwater sewers shall be routed under footways or piperacks adjacent to
roads to provide easy access and avoid damage from wheel loads. Inclusion
of two sewers, one on each side of the roadway, avoids the need for cross-
connections. Gullies shall, where possible, be located outside the roadway to
avoid traffic loads. Paved footways shall drain towards the kerb wherever
possible.
The designer shall design the onsite drainage system to accommodate a 20
year return period flood. Pipe diameters shall be standardised to reduce the
variety of sizes. A minimum main diameter of 200 mm is recommended on the
grounds of easy maintenance. Pipe gradients shall be established with regard
to the typical ground gradients on the site, with an absolute minimum of 1:100.
7.2. CIVIL WORKS
7.2.1. Site Works, Bulk and Detail

Earthworks shall be carried out to suit the founding levels of concrete footings,
slabs and sumps etc. Where unsatisfactory or contaminated soil is
encountered it shall be removed and replaced with compacted competent
backfill, or weak mix concrete. Earthworks shall be maintained to divert
surface drainage around all excavations. Direct rainfall shall be promptly
removed from excavations, by pumping if necessary.
7.2.2. Compaction and Backfill Requirements

Compaction below various structures shall comply with the approved design
document and geotechnical report. The geotechnical report shall provide
information regarding densities to be achieved and methods of achieving these
densities using available materials.
7.2.3. Pipe Installation

Buried pipes shall be placed on approved bedding materials and backfilled in
accordance with the approved design document. Precast concrete and steel
pipe shall be laid and bedding materials shall be placed and compacted in
accordance with the manufacturers written instructions. All process pipes
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crossing beneath roadways shall be installed through sleeves or culverts

providing for monitoring and replacement.
7.2.4. Gratings and Silt Traps

All gratings and covers shall be rated to carry the appropriate loadings to suit
the location, as indicated in the approved design document.
Silt traps shall be provided to prevent the discharge of silt and other suspended
trash beyond plant boundaries, and to comply with other statutory
requirements. Traps shall be sized to handle the design run-off, and be
designed for cleanout by wheeled machinery.

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8. SPECIFIC TECHNICAL REQUIREMENTS - CONCRETE
8.1. DESIGN AND SPECIFICATION
8.1.1. Tolerances
Construction tolerances for the fabrication and erection of the structures shall
be in accordance with a single compatible source document. In particular the
construction tolerances of the concrete work shall be checked for agreement
with the fabrication tolerances specified for the structural steel work.
8.1.2. Standardisation
The design shall standardise the levels of baseplates, related pedestals and
kerbs within each area. The design shall standardise levels and depths of
concrete slabs and beams to simplify reinforcement.
8.1.3. Standard Specifications

Standard specifications should refer wherever possible to the approved Design
Standards, instead of repeating information in those documents. Drawings are
usually read more thoroughly (and more frequently) than specifications. Do not
include information in specifications that should more properly be shown on
drawings.
8.2. REINFORCEMENT
8.2.1. Reinforcement Minimum Cover

Cover to reinforcement of cast in situ concrete shall be as listed below unless a
greater value is required by the approved Design Standard. Cover shall be
measured from the outer surface of the outermost reinforcement bar (usually a
ligature) in the particular face under consideration.
Cast against and permanently exposed to earth 75 mm
Exposed to earth or weather: Slabs, walls 50 mm
Beams, columns 50 mm
Exposed to Process Fluids: Slabs, walls 65 mm

Beams, columns 65 mm
8.2.2. Detailing of Reinforcement

Minimum bar sizes shall be 12 mm, with 10 mm as a minimum for ligatures.
Lap lengths to reinforcement shall be as computed under the approved Design
Standard. Where bars of different diameter are lapped, the lap length shall
refer to the smaller bar.

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The design should consider the host country's common practices in

reinforcement detailing. If staged construction is planned the designer should
consider whether the reinforcement will be work-hardened by cold bending and
rebending. The Detail Engineer shall ascertain local dependence on the
designer for provision of reinforcement schedules, and if necessary, the
preferred format.
8.3. FOUNDATIONS
Concrete foundations shall be designed to resist all combinations of loads.
The design shall consider the mechanism of load transfer between foundation
and subsoil, and requirement for routing of new or existing underground
services (stormwater, electrical or other utilities).
For centrifugal pump foundations subject to vibrations up to 30 Hz due to out-
of-balance forces the following guidelines shall be applied:
The total mass of concrete plinth and installed equipment shall be not less than
50 times the mass of the pump impeller. For integral plinths the concrete mass
may include an apron around the plinth equal in width to the nominal slab
thickness.
For pump sets and other rotating equipment with a total equipment weight
exceeding 15 kN, and other static items with a total weight exceeding 50 kN, a
separate isolated foundation shall normally be used.
8.4. SLABS ON GRADE

It is essential that process liquors be completely prevented from leaking into
subsoil. Caustic soda reacts with subsoil, causing upward heaving, eventually
rupturing and destroying concrete paving and foundations. Even slight
movements destroy the integrity of slab joint sealing, and accelerate leakage
into the ground. The caustic liquor is highly toxic to all life forms and must be
strictly contained to prevent contamination of groundwater and natural drainage
systems.
All concrete pavement slabs and jointing detail shall be designed as liquid-
retaining structures. All joints between slabs shall be fully sealed using details
acceptable to the Project Owner, to prevent leakage of process liquors into the
ground.
8.4.1. Slab Design

Slabs on grade, shall be designed for shrinkage and expansion forces resulting
from drying and thermal effects, in addition to live loads. Slabs shall be jointed
as required to minimize the deleterious effects of these forces. The top layer of
reinforcement shall be continuous over the whole area of the slab between
joints. Reinforcement laps shall develop the full bar strength at the lap.
As a guide, the typical thickness of on-ground pavement slabs that are not
subject to heavy traffic or earthmoving machinery would be greater than 150
mm. The slab would typically be reinforced with a top layer of mesh (8 mm
diameter bar at 100 mm centres in both directions), with a lower layer of similar

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reinforcing mesh in areas subject to high heat loads (e.g. spillages of hot
liquors).
Where slabs on grade will be subject to heavy vehicular wear, the designer
shall specify materials with enhanced wear resistance, such as fibre-reinforced
concrete or an "iron aggregate" topping layer. Where ramp gradients are
sufficiently steep that traction may be limiting, the designer shall consider
appropriate surface roughening treatments. Maximum grade shall generally be
1:10.
8.4.2. Joints
The extent of construction and expansion joints in slabs for alumina refinery
areas shall be minimised by:
Providing generous steel reinforcement of slabs to permit construction of
larger monolithic areas.
Constructing machinery plinths (where practicable) integral with floor
slabs (thickened as necessary).
Wherever practical joints shall be located at the high points of slabs, and shall
cross all valleys and gutters at right angles. Standard Alcan drawings show
typical details of joints with the required integrity for containment of caustic
liquor.
8.4.3. Drainage
All concrete slabs shall be designed with continuous falls to route storm water,
process spillage and drainage to sumps with the required slopes dependant on
the extent of solids to be drained. A guide to the maximum and minimum floor
slopes considered as desirable are tabulated below:
Absolute Designed Max.

Min. Min.
Areas immediately adjacent 1:20 1:10 1:5
to process floor sumps
carrying liquors with high
solids content
Floor areas with liquors with 1:30 1:20 1:6

high solids content
Floor areas with liquors with 1:60 1:30 1:6

low solids
Table 8.4 - Typical Floor Slopes
Floor slopes shall be arranged so that the liquor collects at a low point or "Vee"
in the slab in the shortest possible distance from the discharge point so that

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wherever possible "sheet flow" is eliminated. By concentrating flows a higher

velocity can be attained which will result in more efficient cleaning of the slabs.
Process sumps shall be formed in reinforced concrete cast around a fully
welded steel liner. Connection of sump construction with adjacent paving shall
be fully detailed, as per RT Drawing N° Z02-000-3-STD-005 or other
arrangements providing equivalent integrity.
8.5. CONSTRUCTION ISSUES
8.5.1. Curing
All concrete shall be cured utilising an approved pigmented water-based curing
compound applied strictly in accordance with the manufacturer's specification.
Alternatively, curing may be accomplished by saturation with water. The curing
method shall follow international best practice regarding method and duration.
8.5.2. Stripping Times

Forms shall not be stripped until at least 70% of the 28 day Characteristic
Strength has been attained. The stripping time will usually be determined from
compression tests on test specimens. Alternatively, the concrete should have
gained sufficient strength to provide a factor of safety of 2.0 on the working
stresses to be sustained.
8.5.3. Protection of Mass Pours

The designer shall specify all necessary steps to avoid cracking of large
concrete pours. In particular:
Use cement with a low heat of hydration to avoid excessive heat build-
up
Pour in stages and make provision for construction joints
Provide adequate reinforcement
Provide adequate curing after initial set
Avoid pouring in hot weather
8.5.4. Special Concrete Mixes

Special mixes shall be designed where the normal design is inadequate for any
one of a reason, including but not limited to:
Need for high early strength
Difficulty of access for pouring
Large pours
Need to minimise subsequent working
The special mix shall be proved using test specimens following the procedures
set out in the approved Design Standard. The specification for special mixes

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shall describe the strength grade, slump, nominal aggregate size, method of
placement and other relevant parameters.
8.5.5. Reinforcement Stools

Reinforcement shall be kept in place relative to formwork by using plastic
coated stools or wired-in concrete spacers. Top reinforcement of slabs on
grade shall be supported sufficiently to ensure the reinforcement is not forced
out of position during placement of concrete.
8.5.6. Blinding and Damp Proof Membrane

Blinding is defined as a layer of concrete at least 50 mm thick which is laid on
prepared ground and worked to a smooth finish, to provide a clean dry work
surface for subsequent concreting operations. The blinding layer is normally
constructed to the finished final shape of the finished concrete including all
slopes, Vee-drain, etc. The blinding shall be sufficiently watertight that concrete
laid over it will not suffer from water loss and impaired curing by percolation
through it. The blinding layer shall generally be strong enough to provide
anchorage for formwork and temporary embedded items. Blinding may be used
as site preparation for major concrete pours. Unless otherwise specified,
blinding concrete shall normally consist of 15 parts sand to 1 part cement with
sufficient water added to give a material which has a very low slump.
Damp Proof Membrane (DPM) is defined as a thin plastic sheet which is laid on
prepared ground, and taped at the seams to prevent leakage of water.
Concrete slabs on grade may then be laid over it and the DPM retains water in
the mix so that curing is not impaired. In construction for alumina refineries
DPM also serves as a backup to concrete paving for containment of liquor, and
shall be installed with corresponding integrity. The DPM shall be sealed to all
bases, foundations, and other slab penetrations with bitumastic rubber
compound.
DPM shall be used in preparation for pouring of slabs on grade. The DPM is
normally laid over the blinding. Where stools are placed on top of DPM, the
DPM shall be adequately protected from damage.
8.5.7. Hold Down Bolts

Hold Down (HD) bolts 16 mm diameter and smaller shall be proprietary
anchors, drilled and embedded into concrete in accordance with the
manufacturer's instructions. Epoxy bonded threaded rods are preferred to
expansion type anchors.
HD bolts 24 mm diameter and larger shall be cast in place during pouring. 20
mm bolts may be cast-in or epoxy bonded anchors as appropriate to the
application. HD bolts shall be installed so that 2-5 complete threads will be
exposed after steelwork or machinery is installed and nuts are tightened up.
Cast-in hold down bolts shall comply with ASTM F1554 (Standard
Specification for Anchor Bolts). The design of hold down bolts, including
allowance for on-site adjustment, shall take into account the construction
tolerances of the supported steel structure.
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Where short slotted or oversize holes are provided in baseplates, hardened

washers or plate washers shall be used. Where long slotted holes are
provided in baseplates (that is, 2.5 diameters long), a special washer or cover
plate at least 8 mm thick shall be installed to completely cover the hole.
8.5.8. Tolerances
Concrete shall be constructed to the tolerances required by the approved
Design Standard, unless the Project Owner requires a more stringent
tolerance.
8.5.9. Grouting of Base Plates

Foundations shall be designed to allow a nominal clearance (25-50 mm)
between the top surface of the finished concrete plinth and underside of
baseplate.
The space between underside of baseplate and top of plinth shall be filled with
an approved non-shrink grout. Care shall be taken that all spaces under the
baseplate are completely filled with grout. Large baseplates shall be provided
with a central hole for feeding of flowable grout. Grouting shall be bevelled off
at the baseplate edges.
8.5.10. Chamfers and Fillets

External corners (chamfers) and internal or re-entrant corners (fillets) on
concrete shall be formed at 45 degrees to the formwork. Each leg length shall
be 20 mm minimum. On internal corners of large structural concrete items, a
larger fillet may be provided.
8.5.11. Formwork Finishes

The quality of concrete finish is dependent on the type of formwork, method of
working and curing, and the mix design. The designer shall determine the
quality of finish required in view of the Project Owners' requirements for
corrosion protection, durability, tolerances and appearance. The finish
obtained on site shall be monitored by visual comparison with sample
photographs in the approved Design Standard or with actual samples cast on
site and approved by the Project Owner.

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9. SPECIFIC TECHNICAL REQUIREMENTS - STEELWORK
9.1. DESIGN
Steelwork shall be designed and detailed with ease of fabrication and erection
and overall economy in mind. The following points shall be noted:
The lowest weight of each nominal size of universal section is the most
structurally efficient in bending.
Use repetition wherever possible. Interchangeable parts speed
erection.
Fabricate in fewer large subassemblies to simplify fabrication, transport
and erection, subject to physical constraints and lifting capacity.
For connections directly into the web of a column or beam use fin-plate
connections to facilitate assembly.
Use simple shear-type connections instead of moment-bearing
arrangements.
Detail lifting points on major items.
9.1.1. Minimum Connections

All member end connections shall be designed for the most onerous load
combinations, with a minimum (working load) of 20 kN.
The minimum permissible plate thickness for connection cleats fins and for
general structural work shall be 10 mm.
Every bolted structural connection except minor items, shall include at least
two High Strength bolts, 20 mm diameter or larger. Minor connections such as
hand-railing, shall include at least two bolts, 12-16 mm diameter (Commercial
bolts).
9.1.2. Corrosion Protection

All structural steelwork shall be adequately protected from atmospheric
corrosion and from corrosion resulting from the process itself, in accordance
with Design Standards and Codes of Practice. Corrosion protection shall take
the form of an acceptable painting system, or hot dipped galvanising, or the
use of an acceptable grade of steel with inherent resistance to corrosion. It is a
design criterion that the corrosion protection shall provide 15 year service
before requiring recoating.
Paints containing Coal Tar, Chromates or Lead are not acceptable.
Paints containing High Build Epoxies, Urethanes, and Zinc Silicate are
acceptable.
All bolts, nuts and washers used for the erection of structural steelwork shall be
hot-dipped galvanised.

136 of 1528
9.1.3. Ladders, Stairs and Platforms, Walkways, Handrails

All structures for access shall be designed in accordance with the approved
Design Standard and the Standards of the Project Owner. The minimum load
requirements of the approved Design Standard shall be used in design, unless
a higher value is required by the Project Owner.
Access ways with gradients between 45 degrees and 60 degrees to the
horizontal shall not be used, for safety reasons.
A minimum clear width of 700 mm between handrails and between kick plates
shall be provided on catwalks.
Floor grating shall be installed with 25 mm mesh beneath where there is a
possibility of small objects falling through onto personnel working below. Kick
plates shall be used on all walkways and platforms to prevent objects being
kicked over the side, and loss of personnel footing.
9.1.4. Monorails and Cranes

Monorails and cranes shall be designed in compliance with the approved
Design Standard. The designer shall conservatively assess the safe working
load and the mass of the hoist mechanism, and allow for future upgrading of
the hoist mechanism. Allowance shall be made for the transfer of all forces,
including dynamic forces, to the support structure. Travel end stops shall be
detailed on design drawings.
9.1.5. Pipe Racks

Longitudinally connected pipe racks shall be provided with movement and
thermal expansion joints at intervals not exceeding 70 metres. Pipe rack bents
shall typically be installed at 6 metre centres.
9.1.6. Structural Gaps

Where relative movement between structures (due to wind, seismic or thermal
effects) could lead to damage, a gap shall be designed between the structures.
The clearance shall be dimensioned to accommodate the two structures
moving towards each other. Walkways between these structures shall include
a sliding floor plate. In the absence of specific information, a typical gap width
of 100 mm shall be allowed.
Where structural gaps occur between a walkway or platform and the wall of
another structure, and where the walkway or platform is elevated above ground
so that objects falling from the walkway would constitute a danger to personnel
below, the walkway or platform shall be provided with a kick plate trimming the
gap.
9.1.7. Avoidance of Dirt Traps and Corrosion

All structural steelwork shall be detailed to avoid creating dirt and water traps
which may encourage corrosion. Pockets which may collect water or dirt shall
be plated over with steel plate of minimum thickness 3 mm and sealed with a
continuous weld in order to exclude dirt and water.
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Where spillage of material is likely and dirt or water traps are unavoidable,
shedder plates shall be designed to ensure that the bulk of spilled material is
deflected away from the dirt trap.
9.2. FABRICATION AND ERECTION

Structures shall be fabricated and erected to the tolerances contained in the
approved Design Standard.
9.2.1. Welding
Design of welds shall be in compliance with local standard (or AWS Standard
D1.1 if not exists). All welding procedures, consumables, joint preparations
and personnel shall be qualified for the work in compliance with this standard.
Qualified welding procedures shall be approved by the Project Owner prior to
commencement of welding.
Testing and inspection of welds, including frequencies and procedures, shall
be carried out in compliance with the approved Design Standard.
The drawings shall clearly distinguish between field welds and shop welds.
Field welds shall be used only where essential.
Generally, minimum fillet weld size for structural purpose shall be 6 mm,
measured across the gauge dimension, not the throat dimension. Smaller fillet
welds shall be acceptable where it can be shown that 6 mm fillets are
uneconomic and that a smaller weld is structurally adequate. Consideration
must be given to the closer tolerance required and the difficulty of guaranteeing
an effective weld as the weld size diminishes.
Seal welds shall be provided to all junctions that are subject to potential
corrosive influences.
9.2.2. Erection
The designer shall consider the project locality's level of technology and adapt
designs to preferred construction methods. In particular the availability of
heavy lift cranes may dictate the maximum practicable weight or outside
dimensions of individual items.
The designer shall consider the efficiency of erection in terms of on-site safety.
9.2.3. Bolting Procedures

Standard bolting procedure shall be "Snug" tightening. This is defined as "the
tightness obtained by the full effort of a man using a standard podger spanner".
It describes the level of tightening that has always been obtained in general
bolting. Slippage of the plies is required (and expected) in order to mobilise the
bearing resistance of the plies and shear strength of the bolt. They should
therefore not be used in rigid joints, which are joints where slippage cannot be
tolerated.
"Fully Tensioned" bolts shall only be specified where required, and where
permitted by the approved Design Standard. Bolts shall be fully tensioned in
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all structures subject to vibration. Tensioning shall be applied by either the

part-turn-of-nut method or by using load indicating washers.
Fully tensioned bolted connections, if permitted, shall be designed as either
bearing-type or friction-type. A bearing-type connection is expected to slip
before transferring its design load and is therefore unsuitable in a rigid joint.
Friction-type connections rely on an accurate assessment of the actual friction
coefficient between mating surfaces and their use is therefore discouraged.
Standard "commercial" bolts shall be tightened using the "Snug" procedure.
Commercial bolts shall not be used in structural situations: their use shall be
limited to handrails, stairways and similar locations. Commercial bolts shall be
used only in 12 mm and 16 mm diameters to avoid inadvertent use in place of
high strength bolts.
9.2.4. Temporary Works

Temporary Works fall into two categories.
Erection Bracing
Required to support individual members during their erection. This is solely the
erector's responsibility to design, supply and remove on completion.
Temporary Bracing
Required to maintain the structure vertical and in a safe condition after erection
is completed, until permanent bracing is completed. Design requires
knowledge of the building sequence and other factors. It should be designed
by the Engineer. Temporary Bracing and its connections shall be designed in
accordance with the approved Design Standard.
9.2.5. Shop Detail Drawings

At appropriate times, the Fabricator shall submit shop drawings to the designer
for comment.
It shall be made clear in the Contract documents that submission of shop detail
drawings to the designer in no way absolves the Fabricator from his
responsibilities.

139 of 1528
10. SPECIFIC TECHNICAL REQUIREMENTS - TANKAGE
10.1. APPROVED DESIGN PROCEDURES

Tanks for Bayer refinery service shall be designed, constructed and tested in
accordance with the latest version of American Petroleum Institute Standards
below:
API 650, for cylindrical flat-bottomed tanks.
API 620, for conical bottom and other forms.
Flat bottomed tanks up to 10 cubic metres capacity require no analysis or
engineering design beyond specification of approved materials and minimum
plate thicknesses. For flat bottomed tanks from 10 to 100 cubic metres,
calculations shall be prepared for lowest strake thickness, hold-down against
wind load, and size of top rim angle. Flat bottom tanks above 100 cubic
metres, and all cone bottom tanks, shall be subject to full engineering analysis
to the approved codes.
10.1.1. Seismic Loads for Tanks

The seismic coefficients presented in the API codes are calibrated for the
United States of America, and are unsuitable for use elsewhere. The base
acceleration factor C1 for a site outside of the United States shall be
determined (in m/s2) from the seismic response spectra for the project site.
The design horizontal seismic force (in Newtons) will then be
C1 x (Structure Mass in kg) , with the Zone Coefficient set to 1.0.
10.1.2. Maximum Stresses

The Product Design Stress applied in designs to API 650 shall be limited to the
lesser of:
1) 175 Mpa
2) Value in API 650 Table 3-2
This limitation is imposed to avoid problems with caustic embrittlement of welds
and applies to material at any level in the tank wall or base. It does not apply
to tank roofs.
10.1.3. Minimum Thickness of Material

Each tank shall undergo individual engineering assessment, however, in
general, the minimum thickness of material shall be as follows. All thickness
quoted are inclusive of corrosion/erosion allowance where applicable:
All tank walls 6 mm
All process tank roofs 6 mm
All process tank floors 8 mm
(Note: The above ruling for roof and floor thickness may not necessarily apply
to large bulk storage tanks. The API 650 code will still apply as a minimum)
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In general where tank wall thickness exceeds 6mm, API 650 will determine the
tank wall and floor thickness and the applicable erosion/corrosion allowance
will be applied. In addition the tank designer shall take into consideration loads
from scale, platforms and agitators as applicable.
Not withstanding the above, for Bayer process fluids with high solids
concentration, the designer shall ensure that the following criteria are also met:
Minimum floor and first strake wall thickness on tanks having a normal
solids concentration greater than 550 g/l shall be 10mm
Minimum floor and first strake wall thickness on tanks having a normal
solids concentration greater than 800 g/l shall be 12mm.
Where deemed necessary on tanks with high solids concentration, a
finite element analysis shall be conducted.
Corrosion allowances for specific equipment and associated structures will be

nominated on the equipment datasheets.
10.1.4. Tie Down Requirements

Tank hold-down bolts shall be designed to resist the most onerous load
combinations. Attention shall be given to the tolerance on out-of-roundness of
the column or skirt base plates and the location of cast-in HD Bolts.
10.1.5. Corrosion Protection

Corrosion protection involves many parameters, including the specific
equipment design, the specific process, the specific environment and economic
factors. The Refinery operator has a role to play in assessing the business
risks associated with the chosen method and extent of corrosion protection.
The question of whether to paint or not is driven largely by the environment and
where equipment is insulated, the effectiveness of insulation in preventing the
ingress of moisture. Where appropriate, the refinery operator may chose to
increase corrosion allowances for local economic or design reasons, or, if the
risk of failure is high and there is uncertainty regarding the effectiveness of the
cladding in the longer term then painting may be specified.
Corrosion protection is generally provided to the exterior of tankage in

compliance with Section 9.1 of this specification. Where agreed with the
Project Owner, tanks may be unpainted and shall have minimum corrosion
allowances as follows:
API 620 Tanks, 2 mm all over.
API 650 Tanks, 2 mm on floor and shell, 1 mm on roof.
10.1.6. Thermal Insulation

Thermal insulation shall be provided for tanks and vessels where specified by
the Process Engineer. As a guide, where the operating temperature of the tank
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or vessel is between 10 and 50°C, insulation is not generally required. For

temperatures between 50 and 70°C, insulation is generally only necessary in
areas for personnel protection. Where the operating temperature is above
70°C, insulation is normally required for energy conservation.
All insulation materials shall be asbestos-free. For process temperatures up to
110°C (atmospheric tanks and vessels) the insulation may be either sprayed
polyurethane foam (PUF) or Mineral fibre/Fibreglass boards (Fibre) with a
cladding of steel sheet or fibre-reinforced mastic. Above 110°C only Fibre
insulation is suitable. Insulation shall be protected from personnel traffic by
provision of walkways and platforms where access is required.
Fibre insulation shall be supported on stud-welded insulation stakes attached
prior to stress-relief and painting. All insulated tanks and vessels shall be
painted prior to insulation with a paint system rated for the operating process
temperature.
Thermal insulation shall be terminated 100 mm above the bottom of the tank to
eliminate absorption of rainwater and liquors causing subsequent corrosion.
Insulation shall be fully sealed and flashed to prevent ingress of liquid from
rainfall or spillage.
10.1.7. Specific Requirements

Loadings
The design shall take account of all special loads imposed on tanks, including:
Scale loads
Upset loads
Buoyancy effects on immersed items
Loads due to operating agitation, and maintenance machinery
Full of settled solids for tanks in slurry service
Access Provisions
All tanks exceeding 10 m3 shall include an access at least equivalent to a
600mm diameter manway at the lowest possible level to facilitate access and
cleanout. Closed tanks shall also include at least one roof hatch of equivalent
area, with mesh insert to prevent personnel falling through.
Where machinery is to be used for tank cleanout or maintenance suitable
access ways shall be provided in roof or walls as appropriate. In either location
reinforcement shall be designed at apertures to fully maintain the structural
integrity of the vessel.
Agitated Tanks
In flat-bottomed tanks with mechanical agitators a transition plate shall be
provided between walls and floor to facilitate agitation, and reduce scale build-
up. The transition shall extend inwards from the wall at least 10% of the tank

142 of 1528
diameter. For tanks with (Height x Diameter) < 50 m 2, a 45º conical section is
suitable.
Baffles shall be installed to designs and loadings specified by the agitator
supplier.
10.2. CAUSTIC EMBRITTLEMENT

The design shall take all precautions against caustic embrittlement of welds.
Carbon steel tanks to be used for storage of raw caustic or caustic cleaning
liquor shall be subject to full post-weld stress relief, carried out in accordance
with applicable API codes or as specified on the specific equipment
datasheets.
10.3. BUNDING
10.3.1. Process Area Bunding

Containment of the largest tanks within each area is generally impractical,
unsafe and expensive. Provision for bund overflow containment is incorporated
in the inherent design of the refinery with the installation of an effluent drain
system and catchments pond.
The philosophy adopted by the project for the containment and appropriate
disposal of process spillage for each individual refinery area is as noted in the
dot points below. Each area will still however require individual attention during
the Detailed Engineering phase.
The general philosophy adopted is to not fully contain area bunds
according to tank volumes in that area, but rather to control the process
excursion and direct it to the plant effluent drainage system for
containment to the environmental requirements.
In general, each area will contain its own process spillage in its sumps
and return this back to the process via the sump pumps.
Where there is excessive rainfall ending up in the sumps and the level of
contamination is low, the sump pump discharge may be manually
redirected to the effluent drain system. A 20 to 30 mm level of rainfall
over the slab is generally considered sufficient to flush away
water may be re-directed to a clean water pond once it has been

approved by the Environmental Officer.
Where the sump pump is unable to cope with the influx of rainfall, the
sump will fill and the rainwater will flood the bunded area.
The bunded area will be sloped towards the sump(s). Depending on the
specific area, the bund wall will be typically a maximum of 300mm high
(at a single elevation all round) with an overflow weir on one side
directed to the effluent drainage system.
In areas such as Precipitation where there is considerable slope on the
overall bund wall, individual attention is required. Typically, one side of

143 of 1528
the bund will be positioned adjacent to the effluent drain and will contain
a weir to direct overflow from the bund into the effluent drains.
Preliminary sizing of this weir should be based on the maximum tank
overflow that can be achieved from a tank within that particular area plus
25%. The final sizing of this weir will be conducted during Detailed
Engineering.
With regards to containment capacity, each specific area bund shall
have a storage capacity to contain 15 minutes of the single largest flow
from within that bund. The aim is to give the operators a short period of
time in which to react before the bund will overflow.
Where applicable, adjacent bunds and the operation of sump pumps in
the bunded area can be considered to minimise containment volumes.
10.3.2. Bulk Storage Bunding

Bulk Acid, Fuel Oil and Fresh Caustic storage tanks not included in the refinery
process areas will in general be bunded to comply with the applicable standard
concerning the storage and handling of corrosive substances. In general, bulk
storage shall be located within bunds for containment of spillage due to tank
failure, or any other cause. The enclosed volume of the bund (allowing a
minimum freeboard of 250 mm) shall not be less than the volume of the largest
single vessel within the bund.
Bund walls may be constructed of earth or concrete, appropriately designed for
potential hydrostatic loads. The need for impermeable lining shall be reviewed
for each installation. Piping and other services shall not be routed through any
earth bund wall. Specific provisions shall be made for adequate personnel
access over the bunds. Earth bunds shall be adequately protected against
erosion due to wind, rainfall or traffic.
Provision shall be made to capture spillage and rainfall in a sump within the
bunded area for removal by pumping as necessary. Valved gravity drains shall
not be used except for transfer into an approved disposal system.
10.4. OVERFLOWS
Every tank shall be provided with an emergency overflow arrangement to
safely discharge excess liquid. The tank wall opening shall be calculated as a
fully contracted weir with a capacity not less than 125% of the maximum
simultaneous inflow (from flowsheets), at a minimum freeboard of 300mm to
the tank rim.
Connected pipework shall be designed for the 125% flowrate above, with due
allowance for velocity head and entry losses, and without reliance on siphon
effects.
Overflow pipes shall be routed and discharged so as to prevent adverse effects
on tank foundations, and minimise hazard to personnel. Where overflows are
subject to scale formation (for example, most Bayer process tanks), ready
access shall be provided for inspection and cleaning.

144 of 1528
10.5. SPECIAL PROVISIONS PRECIPITATORS
A group of precipitators applies heavier broad-area foundation loads than any

other refinery equipment. Soil and foundation investigations must be
particularly thorough, and extend to substantial depth, to ensure foundation
integrity.
Tanks are subject to initial settlement, ongoing elastic movements between full
and empty conditions and thermal movements between operating and cleaning
cycles. Structural connections between tanks by platforms, launders and
pipework shall be sufficiently flexible to absorb relative movements without
distress.
Hydrate scale forms prolifically on all wetted surfaces. On draining the tank,
loss of buoyancy from liquor substantially increases vertical loads to be
supported by vertical tank walls, draft tubes etc. As a guide the inside of draft
tubes, and immersed mechanical agitator components, shall have a scale
allowance of 100 mm over their surface area at an SG of 2.4. All other wetted
surfaces shall be assumed to carry a scale thickness of 2.5% of tank diameter.
Discharge of settled solids from cone-bottom tanks creates a vertical drag
component which must be considered in design of support structures for
central (airlift) draft tubes.
In addition to API tank code design requirements, tank shells shall be
specifically checked at all levels against buckling due to the total vertical loads
from self-weight, scale, overhead platforms and equipment, and wind-induced
moments. Hydrostatic pressure and buoyancy effects shall not be included.
When used, Air agitated tanks shall have an included cone angle not greater
than 70°, and a draft tube diameter not less than 5% of tank diameter. For
mechanically agitated tanks, requirements of section 4.2 above shall be
applied, with the following specific adaptations:
Arrangements for maintenance shall be completely established in Basic
Engineering due to the major problems of access and cranage to be
addressed.
Drive reversal may not be a requirement for restarting settled tanks.
Draft tube design (where applicable) shall be approved by the equipment
vendor.
Proven industry experience with large-scale alumina precipitators is an
essential vendor qualification.

145 of 1528
11. REFERENCES
11.1. API
ANSI/American Petroleum Institute
620-1992 Rules for Design and Construction of Large, Welded,
Low-Pressure Storage Tanks
650-1992 Welded Steel Tanks for Oil Storage
11.2. ASTM
ANSI/American Society for Testing of Materials
A307-94 Specification for Carbon Steel Bolts and Studs, 60 000
psi Tensile Strength
A325-94 Specification for Structural Bolts, Steel, Heat-Treated,
120/105 ksi Minimum Tensile Strength
A615(M)-94 Specification for Deformed and Plain Billet-Steel Bars
for Concrete Reinforcement
C39-94 Test Method for Compressive Strength of Cylindrical
Concrete Test Specimens
C289-94 Test Method for Potential Alkali-Silica Reactivity of
Aggregates (Chemical Method)
C295-90 Guide for Petrographic Examination of Aggregates for
Concrete
C918-93 Test Method for Measuring Early-Age Compressive
Strength and Projecting Later-Age Strengths
C1293-95 Test Method for Concrete Aggregates by Determination
of Length Change of Concrete due to Alkali-Silica
Reaction
11.3. AWS
ANSI/American Welding Society
D1.1-96 Structural Welding Code - Steel
11.4. BS
British Standards Institute
BS 4449-1988 Specification for Carbon Steel Bars for Reinforcement
of Concrete
11.5. DIN

146 of 1528
1.0 MTPA ALUMINA NALCO NAL 6695-CVC-G00-EC-0002 66-6695
REFINERY STREAM-5
Technical Specifications (Construction) for

Civil / Structural / Architectural Works
Rev 00 Page 1 of 6
00 Issued for Tender 27.10.17 BHK 27.10.17 VBV 27.10.17 VBV -

Based on :
Category Code: -
Barcode
147 of 1528
REFINERY STREAM-5

Rev 00 Page 2 of 6
Contents:
1 INDEX ................................................................................................................................................... 3
2 INTRODUCTION ..................................................................................................................................... 5
3 ADDENDUM TO STANDARD TECHNICAL SPECIFICATIONS ........................................................................ 5
Enclosures :
Standard Technical Specifications $PART-II& : CI-UCH-016 $Sections 01 to 22&
148 of 1528
REFINERY STREAM-5

Rev 00 Page 3 of 6
1 INDEX
SECTION DOC. NO. DESCRIPTION LATEST NO. IF
NO. REVISION OF EXCL-
NUMBER PAGES UDED
MARK
“X“
1. INTRODUCTION
2. ADDENDUM TO R0 2
STANDARD TECHNICAL
SPECIFICATIONS
STANDARD TECHNICAL
SPECIFICATIONS
3. CI-UCH-016-01 EARTHWORK. R0 10
EXCAVATION, BACKFILL &
DISPOSAL
4. CI-UCH-016-02 CONCRETE & R1 30
FORMWORK
5. CI-UCH-016-03 BRICK WORK & R0 19
PLASTERING
6. CI-UCH-016-04 REINFORCEMENT R1 6
7. CI-UCH-016-05 FLOORING & DADO R0 18
8. CI-UCH-016-06 DOORS, WINDOWS & R0 19
PARTITIONS
9. CI-UCH-016-07 STRUCTURAL STEEL R1 24
WORK
10. CI-UCH-016-08 ROOFING & CLADDING R0 5
11. CI-UCH-016-09 PAINTING R1 13
12. CI-UCH-016-10 WATERPROOFING, R0 15
THERMAL & ACOUSTIC
INSULATION
13. CI-UCH-016-11 PLUMBING & SANITARY R0 18
14. CI-UCH-016-12 ROADS, DRAINS, PITS & R0 36
CULVERTS
15. CI-UCH-016-13 CHEMICAL RESISTANT R0 21
LINING
16. CI-UCH-016-14 EARTHWORK & LAND R0 7
DEVELOPMENT.
17. CI-UCH-016-15 FENCING & COMPOUND R0 4
WALL.
18. CI-UCH-016-16 PILING. R0 30
19. CI-UCH-016-17 STONE COLUMNS. R0 15
20. CI-UCH-016-18 FRP INSULATORS & R0 3
GRATINGS
149 of 1528
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Rev 00 Page 4 of 6
SECTION DOC. NO. DESCRIPTION LATEST NO. IF

NO. REVISION OF EXCL-
NUMBER PAGES UDED
MARK
“X“
21. CI-UCH-016-19 CAVITY FLOORING & R0 9
FALSE CEILING
22. CI-UCH-016-20 ANTI TERMITE R1 7
TREATMENT
23. CI-UCH-016-21 DISMANTLING & MISC. R0 6
WORK
24. CI-UCH-016-22 FIRE PROOFING OF R0 8
STRUCTURES
150 of 1528
REFINERY STREAM-5

Rev 00 Page 5 of 6
2 INTRODUCTION
This document contains the construction specification to be followed by the contractor.
3 ADDENDUM TO STANDARD TECHNICAL SPECIFICATIONS

This addendum is to be read in conjunction with Technical Specifications Standard Doc. No
CI-UCH-016-Sections 01 to 22
The changes are as follows:
Superseded Clause no. Revised Text as per change required Reason for Change
In Standard Doc. No
CI-UCH-016
- Wherever UHDE INDIA / UHDE/ UHDE India

Private Limited is mentioned in the
document/s, the same shall be read as tkIS –
India
Section 2, Clause 2.3.6 ADD: Client recommendation

In accordance with the guideline issued by
OSPCB (Orissa State Pollution Control
Board), use of fly ash as an admixture in
concrete is encouraged and permitted.
Contractor shall ensure that the fly ash used
as admixture meets the requirements of this
clause, IS 456 and IS 3812.
Section 3, Clause 3.1.1 ADD:
List of Codes 9) IS 12894 - Pulverized Fuel Ash-lime Bricks
Section 3, Clause 3.2 In accordance with the guidelines of OSPCB, Client recommendation
common burnt clay bricks are not allowed in
construction works. Accordingly, Only Fly Ash
Cement bricks / FALG bricks shall be used in
all the constructions.
Section 10 ADD: Client recommendation

Clause 10.3.4: Water proofing Type IV (using
Atactic Polypropylene)
The water proofing treatment of roof slabs
shall be as given below:
a) For flat roof prior to water proof treatment
grading of slope 1:80 is to be provided with
screed concrete 1:2:4 with 12 mm down
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Rev 00 Page 6 of 6
graded aggregate with minimum thickness of

25 mm near rain water drainage pipe.
b) Inaccessible Roof: Providing and laying
APP (Atactic Polypropylene Polymer) modified
pre fabricated five layer, 3-4 mm thick water
proofing membrane black finished reinforced
with polyester / glass fibre matt. The
membrane to be laid over a coat of bitumen
primer by using butane torch and finally
painted with aluminum paint. The laying of the
membrane to be done as per the
specifications provided by the manufacturer.
Approved Manufacturers: Bitumat Co. Ltd.,
Pidilite, Soprema, General Membrane,
Tamko, STP Ltd.
c) Accessible Roof: Providing and laying
APP (Atactic Polypropylene Polymer) five
layer, 3-4 mm thick water proofing membrane
black finished reinforced with polyester / glass
fibre matt. The membrane to be laid over a
coat of bitumen primer by using butane torch
and finally overlaid with 40 mm thick concrete
screed (1:2:4) with 12 mm down graded
aggregate. The laying of the membrane to be
done as per the specifications provided by the
manufacturer.
Approved Manufacturers: PIDILITE
INDUSTRIES LTD., Texsa India Ltd., STP
LTD., Bitumat Co. Ltd., SOPREMA, General
Membrane.
Section 9, Clause 9.6 The surface shall be painted with two coats of Client recommendation
exterior grade weatherproof Emulsion
paint(Acrylic smooth emulsion with silicon
additives & with Comprehensive 7 year
performance warranty) over a coat of
equivalent exterior grade primer. The paint
shall be of an approved manufacturer in
shade and colour approved by the Engineer-
in-charge.
152 of 1528
PART II DOC NO.:
CI-UCH-016-01
TECHNICAL SPECIFICATIONS
SECTION-1 Rev. :R0
Uhde India Limited EARTHWORK Page :1
Contents Page
SCOPE 2
GENERAL 2
APPLICABLE CODES 3
MATERIALS FOR BACKFILLING & SOLING 3
EXCAVATION 4
EXCAVATION IN ROCK 6
SOIL CLASSIFICATION 7
BACKFILLING 8
RUBBLE SOLING 9
MODE OF MEASUREMENT 9
Applicable Revision:
Prepared: Checked: Approved:
Date: Date: Date:

First Edition: R0
Prepared: NIRUPAMA Checked: P R KANNAN Approved: M H JOSHI
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03

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153 of 1528
PART II DOC NO.:
CI-UCH-016-01
SECTION-1 Rev. :R0
EARTH WORK: EXCAVATION, BACKFILLING & DISPOSAL
1.1 Scope
The specification covers the general requirements of earthwork in excavation in

different materials, filling in areas as shown in drawing, filling back around
foundations and in plinths, transportation and / or disposal of surplus spoils or
stacking them properly as shown on the drawings and as directed by engineer and
all other operations covered within the intent and purpose of this specification.
1.2 General
1.2.1 Contractor shall furnish all tools, plants, instruments, materials and all
consumables and every thing necessary, whether or not such items are
specifically stated herein including temporary facilities like platform, walkways, etc.
also including skilled/unskilled manpower along with supervisory personnel for
completion of the job in accordance with requirements of specifications & standard
practice.
1.2.2 The excavation shall be done to correct lines and levels. This shall also include
where required, proper shoring to maintain sides of excavations, and strutting
along with furnishing, erecting and maintaining of necessary barricades around
excavated areas and warning lamps at night for ensuring safety.
1.2.3 The rates quoted shall also include for dumping of excavated materials in regular
heaps, bunds, riprap with regular slopes as directed by Engineer, within the lead
specified and levelling the same so as to provide natural drainage. Rock/soil
excavated shall be stacked properly as directed by Engineer. As a rule all softer
material shall be laid along the centre of heaps, the harder and more weather-
resisting materials forming the casing on the sides and the top. Soft and hard
rocks shall be stacked separately.
1.2.4 Any finds of archaeological interest such as relics of antiquity, coins, fossils or
other articles of value shall be delivered to the Engineer. Any material obtained
from the excavation, which in the opinion of the Engineer is useful, shall be
stacked separately in regular stacks as directed by the Engineer.
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1.3 Applicable Codes
The following Indian Standard codes, unless otherwise specified herein, shall be
applicable. In all cases, the latest revision of the codes shall be referred to.
a. IS:783 - Code of Practice for laying of concrete pipe.
b. IS:1200 - Method of Measurement of Building work.
c. IS:3764 - Safety code for excavation work.
d. IS:4082 - Recommendation for stacking and storage of construction

materials at sites.
e. IS:3385 - Code of practice for measurement of civil Engineering
Works.
f. IS:2720
Part-II - Determination of Moisture Content.
Part-VII - Determination of Moisture Content Dry Density Relation

Using Light Compaction.
Part-XXVIII - Determination of Dry Density of Soils, in place, by the Sand

Replacement Method.
Part-XXIX - Determination of Dry Density of Soils, in place, by the Core

Cutter Method.
1.4 Materials For Back-Filling & Soling
The materials and workmanship shall conform to provisions of the following

codes and standard specifications :
IS:1200 - Method of measurement for building work.

IS:3764 - Safety code for excavation work.
Murrum - Murrum for backfilling shall be freshly excavated free from vegetation,
boulders, silt and clay and as approved by the Engineer.
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Sand - Sand for backfilling shall be medium, hard, free from organic and other
deleterious materials, silt and clay and as approved by the Engineer. It should be
suitable for attaining compaction of 90% of laboratory maximum dry density.
Rubble - Rubble for soling shall be hard, tough, durable and of approved quality. It
shall be regular in shape and size of about 200 to 230 mm or as specified in the
drawing.
All materials shall be obtained from sources approved by Engineer and shall
conform strictly to samples initially approved by Engineer prior to start of supply at
site. Change in source of materials shall be avoided. If unavoidable, the new
sample and the source shall be again approved by Engineer before actual
commencement of supply of materials at site from fresh sources.
1.5 Excavation
Excavation shall be carried out in any type of soil met at the site for items and to
the lines, levels and contours as directed by the Engineer
Excavated materials shall not be deposited within 1.5M from edge of the
excavation.
Suitable type of shoring and strutting, wherever necessary, shall be provided to

avoid any collapse of earth or cutting in slope as per site requirement and as
directed by the Engineer.
Pits shall not be excavated to final founding level unless concreting work is
imminent. Last 15 cms. shall be excavated prior to providing, blinding layer with
lean concrete (M5, unless otherwise specified in drawing). The contractor shall
not undertake any concreting in foundation until the excavated pit is approved by
the Engineer.
If any bottom of excavation is left exposed and has become deleteriously affected
by atmosphere or water, it shall be dewatered and excavated to sound base, and
shall be filled up to the required level with lean concrete of grade M-15 at the cost
of Contractor. Similarly excess excavation than the required level also to be filled
up with lean concrete at the cost of Contractor.
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Any obstacle, encountered during excavation shall be reported to the Engineer

and shall be dealt as directed. Removal of buried piping or cables shall not be
done without prior permission of Engineer and contractor shall provide all
measures to protect such lines. Cost of such protective measures are deemed to
have been included in the unit rates for excavation.
The contractor shall take adequate protective measures to ensure that the
excavation operations do not damage the adjoining structures or dislocate
underground services.
Excavated material shall be deposited within radius of 50M or as specified in the

item of work. Selected excavated material, on approval by Engineer shall be
back-filled in layers of maximum 15 cms. Watering, compacting shall be done as
specified in method of backfilling.
The Contractor shall arrange to cut or transplant any trees coming in the
alignment of the excavation or other work after obtaining prior approval and
complying with all requirements of the concerned authority and remove the same
wherever required. Unless otherwise stated no separate payment shall be made
for the same.
The Contractor shall provide suitable drainage arrangements to prevent surface

water entering foundation pits. The contractor shall engage pumps or other
approved means to keep excavation free of water.
In cases, where during excavation, side slips occur, for reasons not attributable to
the Contractor or in cases of pumping out water accumulated due to unforeseen
reasons like watermains / drains broken accidentally by other agencies, springs
etc., suitable payment shall be made separately at the rates mutually agreed.
Lowering of water table by well point system or other such special measures shall
be paid separately against relevant item in the B.O.Q. or by mutual agreement.
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1.6 Excavation In Rock:
By Blasting : Blasting shall be done by the licensed blaster approved by the

Engineer. The contractor shall obtain licence from statutory bodies for
undertaking blasting work as well as for obtaining and storing the explosive as per
prevalent rules.
Blasting shall be done by using approved blasting powder or gelatine brought

from licensed supplier.
Blasting shall be controlled blasting. Controlling shall be done by covering portion

to be blasted with steel plates or woven mesh of wire ropes, meshed at 200 x 200
mm spacing and loaded with sand bags.
Blasting shall be done with ample precaution, normally during lunch time by :
i. Evacuating the area within minimum distance of 100M from the region to
be blasted. Guarding the boundaries of the excavated area by keeping
persons, minimum four, with Red flags on the boundary to prevent entry of
personnel during blasting operation.
ii. It is preferred, if signaling system is provided to give signals before and

after blasting.
Blasting shall conform to IS:4081, IS:10081.
Chiselling as required shall be carried out to obtain correct slopes, shape and
pattern of excavation as per drawings. No extra payment will be made for
chiselling.
The other specifications for earthwork shall also apply to excavation in rock in
general.
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1.7 Soil classification for purpose of measurement and payment
All materials to be excavated shall be classified by Engineer, into one of the

following classes and shall be paid for at the rate approved for that particular class
of material. No distinction shall be made whether the material is dry, moist or wet.
The decision of Engineer regarding the classification of the material shall be final
and binding on Contractor and not be a subject matter of any appeal or
arbitration.
Any earth work shall be classified under any of the following categories; in
accordance with IS-1200 part I.
a. Ordinary soils
These shall include all kinds of soils containing kankar, sand, silt, hard and
soft murrum and/or shingle, gravel, clay, loam, peat, ash, shale, etc.. which
can generally be excavated by spade, pick axes and shovel, and which is
not classified under "soft and decomposed" and "hard rock" defined below.
This shall also include embedded rock, rubble not longer than 500 mm in
one direction and not more than 300 mm in the other two directions.
Removal of such ordinary soils by mechanical excavators, shovels,
draglines etc. shall be payable at the rate for 'Ordinary soils'.
b. Soft and Decomposed Rock
This shall include rock, boulders, slag, chalk, slate, hard mieacschist,
laterite and all other materials which in the opinion of Engineer is rock, but
does not need blasting and could be removed with picks, hammer, crow
bars, wedges and pneumatic breaking equipment. The mere fact that
Contractor resorts to blasting for reasons of his own, shall not qualify for
classification under 'hard rock'. This shall also include excavation in
macadam and tarred roads and pavements. This shall also include rock
boulders longer than 500 mm in one direction and not more than 500 mm
in any one of the other two directions.
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c. Hard Rock
This shall include all rock occurring in large continuous masses, which
cannot be removed except by blasting for loosening it. Hardened varieties
of rock with or without veins and secondary minerals, which, in the opinion
of engineer require blasting shall be considered as hard rock. Boulders of
rock occurring in such sizes and not classified under (a) and (b) above
shall also be classified as hard rock. This will also include reinforced
cement concrete (reinforcement to be cut through, but not separated from
concrete).
1.8 Backfilling
Backfill material shall be either that part of excavated material, which is specially
approved by Engineer as suitable for backfill and stacked separately for this
purpose or material brought from outside sources as approved by Engineer.
The contractor shall not fill in and around any work, until it has been approved by
the Engineer. Backfilling around liquid retaining structures shall be done only after
testing of structures against leakage is done and approval from Engineer is taken.
Back filling shall be done in layers of thickness not exceeding 15 cms. Optimum
watering shall be done to obtain maximum compaction and density free from
pockets. Compaction shall be done with mechanical equipment such as plate
vibrators, rollers. In exceptional cases hand compaction may be resorted to as
The Engineer reserves the right to order compaction test in initial stages and
whenever required during the progress of the work, to satisfy degree of
compaction upto 90% of laboratory dry density (proctor) in the case of soils other
than sand and 85% of relative density in the case of sand.
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1.9 Rubble Soling
Rubble laying shall commence on required level in proper grade and on properly
cambered sub-base. Stones shall be hand packed as close as possible and
bedded firmly on broadest base. Voids shall be filled with chips and small stones.
The interstices shall be filled up with selected (approved) earth/murrum. If
possible, this base shall be rolled with 8/10 T roller, with appropriate watering and
refilling voids with consent of the Engineer. Further activities such as laying plain
concrete will be carried out after the approval of the Engineer.
1.10 Mode of Measurement : 1200
1.10.1 Excavation Items

The payment shall be made on cubic metre basis, on the measurement of column
of pit size worked exactly as per dimensions of RCC/PCC given in drawing, (no
allowance for excess excavation). The unit rate includes setting out and line out
work, shoring / strutting, dewatering, backfilling, removal and disposal of surplus
earth within lead of 50 M radius or as specified in the item of work, after backfilling
with selected earth as specified. Any extra excavation for slopes, working space,
collapses and additional working space required for painting the sub structures
shall not be measurable / payable. The contractor may make such allowances in
his rates to provide for excavation in side slopes keeping in mind the nature of the
soil and safety of excavation.
1.10.2 Filling in plinth with material brought from outside
The payment shall be made on Cu.m. basis of the finished compacted volume.
Rate shall include cost of material, handling, transport for all leads, watering,
compaction, labour and testing etc. complete.
1.10.3 Disposal of surplus earth
The payment shall be made on Cu.m. basis on the difference of measurements of

the volumes of excavated material and the backfill. The rates shall include
loading, transporting, dumping, levelling in the area demarcated by the Engineer.
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1.10.4 Rubble Soling
The payment shall be on Sq.m. basis. The rate shall include supply of rubble,
stone chips, murrum, quarry spoil, handling, labour, watering, rolling, compaction
etc. complete.
1.10.5 Measurement of Rock Excavation - will be made by final levels and payment shall
be made on Cu.m. basis, exactly as per levels and dimensions of RCC/PCC given
in drawing. No allowance shall be added for excess excavation and the same
shall be assumed to be covered in quoted rates.
END
162 of 1528
ThyssenKrupp
Uhde India .
UAN:
TENDER FOR CIVIL AND STRUCTURAL STEEL WORK
STANDARD
PART- II : TECHNICAL SPECIFICATIONS
Document No:
CI-UCH-016-02
SECTION-2 - CONCRETE & FORMWORK
Page 1 of 30
Contents Page
0 Cover sheet: headline, codes, table of contents, check & approva) for first edition & revision .............. 1
2.1 SCOPE .......................................................................... ...... ......... ....................................... 3
2.2 LIST OF APPLICABLE IS CODES AND STANDARDS FOR REFERENCE .......................................... 3
2.3 MATERIALS .......................................... ............................................................................... 6
2.4 TRIAL MIXES ........................................................................................................................ 9
2.5 CONCRETE BATCH lNG .........................................................................................................10
2.6 MIXING ............................................................................................................................... 11
2.7 TRANSPORTATION, PLACING, COMPACTION ..................... ..................................................... 12
2.8 CURING SHALL BE DONE AS PER IS456 ................................................................................ 15
2.9 TESTS ............................................................................................................................... 15
2.10 ACCEPTANCE CRITERIA ......................................................................................................16
2.11 QUALITY CONTROL ...................................................... ............................................. .......... 16
2.12 CONSTRUCTION JOINTS ...................................................................................................... 17
2.13 ENCASING ROLLED STEEL SECTIONS .................................... ................................................18
2.14 FINISHING OF CONCRETE ................................................................................................ ..... 18
2.15 PROTECTION OF CONCRETE .................................................................................................19
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Soft File CI-U CH -016-02-R l.doc

Applicable Revision: Revision 1
RAJESH VAIDYA NIRUPAMA KARANDIKAR R.S.DESHPANDE I"
~ W'i' \_1.-CJ.~ ~p~

.2.1 · 4 · 2011
Date: fJ Date: 2. \· 0 lt · 1.--0 ' \ Date: 28·lf · 2P.Jl
First Edition: Revision 0
NIRUPAMA KARANDIKAR P.R.KANNAN M.H.JOSHI
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03

Element: Section: Rev.:
Copyright 2011 Uhde India Private Limited 1------ - -- - -+-- - - -- - - - + - ----1
ENGINEERING CIVIL 1
163 of 1528
Uhde India
Document No: CI-UCH-016-02 Page : 2 of 30
Contents Page
2.16 CRACKS .... ............ ... ................ .... ............ ......... .............................. ........................ .. ........ . 19
2.17 DEFECTIVE CONCRETE .......................... ...... ................................................................. ....... 20
2.18 EXPOSED FACES. HOLES AND FIXTURES ............................................................................... 20
2.19 APPROVAL BEFORE CONCRETING ............ ............................................. .............. ................. 20
2.20 CONCRETE FOR FLOORING ON GRADE ...... .......................... ................. ................................. 20
2.21 PRECAST CONCRETE ............................... ............................................................................ 21
2.22 PRECAST CEMENT CONCRETE JALI: .. ............................................................. ...................... 22
2.23 EXPANSION AND ISOLATION JOINTS ................... ............................. .................................. .. 23
2.24 GROUTING UNDER MACHINERY or STRUCTURAL STEEL BASES ............................................... 26
2.25 WATERPROOFING CONCRETE STRUCTURE ............. ....... ... ...................... ............................... 27
2.26 SUPPLY & SPECIFICATION OF READY MIX CONCRETE (RMC) AS PER IS 4926: .......................... 28
2.27 FORMWORK .................... .................. ......................................... .... ....... ............................. 28
2.28 EMBEDMENTS ..... ..... ........................................... ....... .................... .................................... 30
2.29 MODE OF MEASUREMENT ........................................................... .... .......................... ...... .... 30
PART-II- TECHNICAL SPECIFICATIONS 164 of 1528

SECTION-2 - N Rev. 1
ThyssenKrupp
Uhde India ~
"••'•
.

2.1 SCOPE
This specification establishes the materials, mixing, placing, curing, etc, of all types of Cast-in-
situ concrete to be used in foundation, underground and above ground structures, floors, etc.
Any special requirement as shown or noted on the drawings shall govern over the provisions of
this specification ..
This specification shall also apply to the extent it has been referred to or applicable with the
special requirements of structures covered in ~cope of IS:456.
2.2 LIST OF APPLICABLE IS CODES AND STANDARDS FOR REFERENCE
All work under this specification shall, unless specified otherwise, conform to the latest revisions
and/or repl(:)cements of the following or any other Specifications and Codes of Practice. In case
any particular aspect of work is not specifically covered by Specification, any other standard
practice, as may be specified by the Engineer, shall be followed
IS:73 Specification for Paving Bitumen

IS:216 Specification for Coal Tar Pitch
IS:269 Specification for Ordinary Portland Cement, 33 Grade.
IS:383 Specification for Coarse and Fine Aggregates from Natural Sources for
Concrete.
IS:432(Part I) - Specification for Mild steel and Medium Tensile Steel Bars for Concrete
Reinforcement.
IS:455 Specification for Portland Slag Cement
IS:456 Code of Practice for Plain and reinforced Concrete.
IS:457 Code of Practice for General Construction of Plain and Reinforced Concrete
for dams and other Massive Structures.
IS:516 Specification for Methods ofTest for Strength of Concrete.
IS:1199 Specification for Methods of Sampling and Analysis of Concrete.
IS:1200 Specification for Methods of measurement.
IS 1311) Code of Practice for Non-Destructive Testing of Concrete.
(Part I & II
IS:1322 Specification for Bitumen felts for Waterproofing and Damp-Proofing
IS:1489 Specification for Portland pozzolona Cement.
Part I Fly ash based
Part II Calcined clay based.
IS:1566 Specification for Hard drawn steel wire fabric for Concrete Reinforcement.
PART-II - TECHNICAL SPECIFICATIONS 165 of 1528

SECTION-2- CONCRETE & FORMWORK
Rev. 1
Uhde India
I
Document No: CI-UCH-016-02 Page: 4 of 30

IS:1609 Code of Practice for Laying Damp-proof Treatment using Bitumen Felts.
IS:1786 Specification for High Strength Deformed Steel bars and wires for Concrete
Reinforcement.
IS:1791 Specification for Batch Type Concrete Mixers.
IS:2062 Steel for general structural purposes.
IS:2185 Specification for Hollow Cement Concrete Blocks.
IS:2210 Specification for Design of Reinforced Concrete shell Structures and Folded
Plates.
IS:2386 Specification for Methods of Test for Aggregates for Concrete- Part-1 to VIII.
IS:2502 Code of Practice for Bending and Fixing of Bars for Concrete Reinforcement.
IS:2505 General Requirements for Concrete Vibrators, Immersion Type.
IS:2506 General Requirements for Screed Board Concrete Vibrators.
IS:2514 General Requirements for Concrete Vibrating Tables.
IS:2645 Specification for Integral Waterproofing compounds for
Cement mortar and Concrete.
IS:2722 Specification for portable Swing Weight Batchers for Concrete (Single and
Double Bucket type).
IS:2750 Specification for Steel Scaffoldings.
IS:2751 Code of Practice for Welding of Mild steel Bars used for Reinforced Concrete
Construction.
IS:2770 Specification for Method ofTesting Bond in Reinforced Concrete.
IS:3025 Specification for Methods of Sampling and Test (Physical and Chemical) for
Water used in Industry.
IS:3201 Specification for Design and Construction of Precast Concrete Trusses.
IS:3366 Specification for Pan vibrators.
IS:3370 Specification for Code of Practice for Concrete Structures for Storage of
Liquids - Parts I to IV
IS:3550 Specification for Method of Test for Routine Control for Water used in
Industry.
IS:3558 Code of Practice for use of Immersion Vibrators for Consolidating Concrete.
IS:3590 Specification for Load Bearing Light Weight Concrete Blocks
IS:3696 Safety Code for Scaffolding and Ladders.
IS:3812 Specification for Fly Ash for Use as Admixture for Concrete.
IS:4014 Code of Practice for Steel tubular scaffolding.
IS:4031 Specification for Method ofTests for hydraulic Cement.
IS:4082 Specification for Recommendation on Stacking and Storage of Construction
Materials at site.
IS:4090 Specification for Design of Reinforced Concrete Arches.

Rev. 1
SE Tl N- - F
Uhde India
IS:4634 Specification for Method of Testing Performance of Batch-type Concrete
Mixes.
IS:4656 Specification for Form Vibrators for Concrete.
IS:4925 Specification for Concrete Batching and Mixing Plant.
IS:4926 Ready Mixed Concrete- Code of Practice
IS:4990 Specification for Plywood for Concrete Shuttering work.
IS:4991 Specification for Blast Resistant Design of Structure for Explosion above
ground.
IS:4995 Specification for Design of Part-1&11 Reinforced Concrete Bins for the
Storage of Granular and Powdery Materials.
IS:4998 Specification for Design of Reinforced Concrete Chimneys.
IS:5512 Specification for Flow Table for use in Tests of hydraulic Cement and
Pozzolanic Materials.
IS:5513 Specification for Vicat Apparatus.
IS:5515 Specification for Compaction Factor Apparatus.
IS:5751 Specification for Precast Concrete Coping Blocks.
IS:5816 Specification for Method of Test for Splitting Tensile Strength of Concrete
Cylinders.
IS:5891 Specification for Hand Operated Concrete Mixers.
IS:6452 Specification for high Alumina Cement for Structural Use.
IS:6461 Glossary of terms relating to cement concrete.
IS:6909 Specification for Supersulphated cement.
IS:7251 Specification for Concrete Finishes.
IS:7320 Specification for Concrete Slump Test Apparatus.
IS:7861 Specification for Recommended Part-1 & II - Practice for Extreme Weather
Concreting.
IS:7969 Safety Code for Storage and Handling of Building materials.
IS:8041 Specification for Rapid Hardening Portland Cement.
IS:8043 Hydrophobic Portland cement.
IS:8112 43 Grade Ordinary Portland Cement- Specification.
IS:8142 Specification for Determining Setting time of Concrete by Penetration
Resistance.
IS:8989 Safety Code for Erection of Concrete Framed Structures.
IS:9013 Specification for Method of Making, Curing and Determining Compressive
Strength of Accelerated-cured Concrete Test Specimens.
IS:9077 Code of Practice for Corrosion Protection of Steel Rails in RB and RCC
Construction.
IS:9103 Specification for Admixtures for Concrete.

Rev. 1
Uhde India
IS:10262 Specification for Concrete Mix Design
IS 12269 Specification for 53 Grade Ordinary Portland Cement
(Part I & II)
IS 12330 Sulphate resisting Portland cement.
IS 12600 Low heat Portland cement.
IS:13920 Code of Practice for Ductile detailing of Reinforced Concrete Structures
subjected to seismic forces.
SP 23 Handbook on Concrete Mixes (based on Indian Standards).
2.3 MATERIALS
2.3.1 Cement
IS:269 Ordinary Portland cement, 33 Grade

IS:1489 Portland pozzolona Cement.
IS:455 Portland Slag Cement.
IS:8041 Rapid hardening Cement.
IS:8112 High strength Cement.
IS: 12330 - Sulphate resisting portland cement.
IS:8043 - Hydropholic Cement
IS:12600 - Low Heat Portland Cement
Generally cement shall be obtained from approved suppliers and shall be stored in a
waterproof/weatherproof shed in a manner approved by the Engineer. No cement that has been
allowed to deteriorate in quality or that has become caked or has perished by dampness or
otherwise shall under any circumstances be used on the works. The concrete mix proportions
shall be used on the weight of cement bags as delivered at the mixer and not on their theoretical
weight. The contractor should allow in his rates for losses in weight of cement bags in transit
and handling.
2.3.1.1 Storage
The Contractor shall follow accepted good practice in handling and storing cement. Cement may
be stored on site in moisture proof bulk containers which shall be equipped with venting
arrangements.
Cement delivered in bags shall be stored off the ground (at least 15 ems.) in dry, well ventilated ,
weather-proof/waterproof sheds, arranged in separate consignments as received from the
manufacturer so that consumption of cement is insured in the order of receipt, i.e. 'First in First
Rev. 1
Uhde India
Out' rule. The stacks of cement shall be such that there is easy access for proper inspection and
identification. The bags shall be piled not more than 10 bags per pile and placed close together
in the pile to reduce circulation of air. Each stack of cement shall be covered with good
waterproof tarpaulin or thick polyethylene sheets.
Different types of cement shall be stacked and stored separately.
2.3.1.2 Use
Cement shall be used in the order in which it is received . Cement in bags in storage for more
than 3 months shall be retested before use.
2.3.1.3 Testing
In addition to verification of manufacturer's test certificates , the Engineer may opt to carry out
following tests :
Tests shall be carried out on cement delivered to the site for fineness, initial and final setting
time, and compressive strength (IS:4031) and the results should be approved by the Engineer
before use of the cement in permanent works. Samples shall be taken immediately on receipt of
cement at site. The methods and procedure of sampling shall be in accordance with IS:3535.
The Engineer may specify other forms of sampling and tests, if in his opinion the cement is of
doubtful quality, the costs of such additional tests, shall be borne by the Contractor, if supplied
by him.
The decision of the Engineer will be final and binding on the contractor.
2.3.2 Fine Aggregate (sand) (IS:383)
2.3.2.1 It shall be river or pit sand or, if permitted by the Engineer, crushed stone sand (Produced from
crushing stone suitable for concrete aggregates) and all fine aggregates shall be sharp, free
from excess fines, loam, earth, vegetable matter, soluble salts and other harmful
chemical/organic impurities and shall be clean. If considered by the Engineer as necessary, the
same shall be washed. Washing shall be done at least one day before using it in concrete . The
aggregate should be stored in such a manner as to avoid contamination.
2.3.2.2 Fine aggregates acceptable for the works shall normally be in a grading which falls within the
GRADING LIMITS as specified in IS:383 .

Rev. 1
ThyssenKrupp
Uhde India .·"1

If grading of fine aggregates can be improved by mixing two varieties of sand, the Engineer may
at his discretion specify such mixing, and may permit the use of crushed sand as one of the two
sands forming the mixture. The provisions of two types of sand and their mixing in the specified
proportions shall be done at Contractor's cost.
2.3.3. Coarse Aggregate
Coarse aggregate for the works shall be river gravel or crushed stone obtained from sources
approved by the Engineer and shall conform to IS:383
Aggregates shall be properly screened and if necessary washed and cleaned before use.
Coarse aggregates containing flat or flaky pieces or mica shall be cleaned of such impurities
before use.
2.3.3.1 The grading shall conform to IS:383 for Grading Limits for Single Sized Coarse Aggregate
Limits for use of single sized coarse Aggregate in various type of structures shall be as follows:
Use Size
Ordinary plain concrete/ Reinforced concrete 40mm
foundation.
Slabs and Walls 200mm or more in thickness. 20mm to
10mm
Columns and Girders with least dimension under 20mm to
300mm 10mm
Very narrow space 10mm
Mass concrete 80mm
2.3.4 Tests of Aggregates
Before commencing the trial mix design, and in course of the work, whenever the apparent
quality I source of the aggregates changes, the Engineer may ask for tests on aggregates to be
conducted in an approved laboratory and test results to be submitted to Engineer and approved
by him. The tests may generally include determination of particle size and shape, organic
impurities, surface moisture and 10% fine value.
2.3.5 Water
PART-II- TECHNICAL SPECIFICATIONS 170 of 1528 Rev. 1

Thyssen Krupp
Uhde India
Before commencing the trial mix design, and in course of the work whenever the source of water
changes, or whenever there is in the opinion of the Engineer reason to suspect a change in
water quality, the contractor shall get the water to be used for mixing, tested in an approved
laboratory. The water in general shall comply with the requirements as specified in IS:456
2.3.6 Mineral Admixtures
The engineer may permit the use of Mineral Admixtures as specified in IS:456. This may be
permitted only if
a. the concrete is manufactured in batching plant OR
b. Ready mix concrete is used.
and provided that uniform blending with cement is ensured
2.4 TRIAL MIXES

The contractor shall be entirely responsible for the design of the concrete mixes. The design is
however to be approved by the Engineer before commencing any concreting in the works. The
contractor shall make trial mixes using samples of coarse aggregates; sand, water and cement,
typical of those to be used (discarding the first batch).
2.4.1 Design mix concrete is preferred to nominal mix. If design mix concrete can not be used for the
work for grades of M20 or lower, nominal mixes may be used with permission of the Engineer.
Grade Volume (Cement : Sand : Aggregate)
M-10 (1:3:6)
M-15 (1:2:4)
M-20 (1:Ph:3)
M-25 -
M-30
M-35
M-40
} Not recommended
2.4.2 Concrete Mix design

Concrete mixes for various specified design strengths shall be worked out by the contractor,
generally as per the requirements of IS:456 I IS:10262.
a) The mixes designed by the contractor shall be used on works only after obtaining
a written approval of the Engineer. It is to be understood that the mix design shall be
entirely the responsibility of the contractor and such approval by the Engineer shall not
relieve the contractor of his responsibility in respect thereof.
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b) The contractor shall prepare all calculations, tabulation, graphs, etc. pertaining
to concrete mix designs and I or test results and supply copies of such
calculations, tabulations , graphs etc. as required by the Engineer.
c) Either Ordinary Portland or Portland Pozzolana Cement or Sulphate resistant

Cement will be supplied /used. No deviation either in rate or schedule of work will be
entertained on this account. The mix design should be based on the
use of Ordinary Portland Cement/Portland pozzolana Cement/sulphate
resistant cement. Due regard should also be taken regarding minimum
cement specified as above.
d) Contractor shall furnish the cement content assumed for various mixes for
approval by the Engineer within one {1) week after award of contract. In case
it becomes necessary to use Portland Pozzolana Cement during the course of
the work, the contractor shall design fresh mixes and the difference in the
consumption of cement due to use of pozzolana cement shall be taken
into account for reconciliation purpose also.
In all cases the contractor shall make trial cubes from each consignment of
cement and test the same before actually using in the work.
2.4.3 Whenever there is a significant change in the quality of any of the ingredients of concrete, the
Engineer may at his discretion order the carrying out of fresh trial mixes. All costs for trial mixes
and tests shall be to the Contractor's account & to be included in the contract rates.
2.4.4 Before commencing the works the contractors shall submit to the engineer,
for approval full details of all preliminary trial mixes and tests.
2.4.5 When the proportions of the concrete mix have been approved by the Engineer, the Contractor
shall not vary the quality or source of the materials or the mix without the written approval of the
Engineer.
2.5 CONCRETE BATCHING
Concrete batching shall be as per IS456
PART-II- TECH NICAL SPECIFICATIONS 172 of 1528

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All tests shall be carried out at regular intervals and records of the results shall be kept at site.
Copies of records shall be sent to the Engineer for reference.
To ensure that the grading of the aggregate remain the same as the grading to
which the mix design is based, sieve analysis shall be carried out regularly and
charts showing the results shall be prepared. Copies of these information shall be kept a site
and supplied by the contractor as instructed. If a change in grading is unavoidable the mix shall
be redesigned and got approved.
Record of theoretical and actual consumption of cement shall be maintained by the

contractor for each work separately and regularly.
2.6 MIXING
Concrete mixing shall be as per IS456
Each time the work stops, the mixer shall be thoroughly cleaned & when the next mixing
commences, the first batch shall have 10% additional cement at no extra cost to the Owner to
allow for loss in the drum.
Regular checks on mixer efficiency shall be carried out as directed by the Engineer as per
IS: 1791. Should any mixer at any time produce unsatisfactory results, leak mortar or cause
waste of materials, its use shall be promptly discontinued until it is repaired. Blades shall be
replaced on showing signs of wearing down~
Hand Mixing:
Normally hand mixing shall not be permitted except in special cases such as far away isolated
places, if allowed by the engineer.
When hand mixing is authorised by the Engineers subject to adding 10% extra cement, it shall
be done on a water tight platform. The materials shall be turned at least three times after the
water is added and until the batch is homogeneous in appearance and colour.
Batching Plant where used shall conform to IS:4925.

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Concrete shall be poured and consolidated in its final position within half an hour of mixing.
Tampering with concrete which has partially hardened, i.e. remixing with or without additional
cement, aggregate or water, shall not be permitted.
2.7 TRANSPORTATION, PLACING, COMPACTION
2. 7.1 Transportation:-
Concrete shall be transported from place of mixing to the place of laying as rapidly as possible
by methods which will prevent segregation or loss of any of the ingredients and maintaining the
required workability. Buckets, containers or conveyors which are leak proof shall be used for this
purpose. During hot or cold weather, concrete shall be transported in deep containers or other
suitable methods to reduce loss of water by evaporation in hot weather and heat loss in cold
weather.
2.7.2 Placing:-
Transportation, placing, compaction of concrete shall be as per IS456
Before depositing the concrete, all debris and dirt shall be removed from the space to be
occupied by concrete. Concrete shall not be placed until the· formwork, placement of
reinforcement; embedment's etc. have been checked and approved by Engineer The formwork
shall be sufficiently rigid. During the placing and compaction of concrete, care shall be taken to
ensure that there is no loss of water from concrete and no segregation takes place. The method
of placing and compaction employed in any particular section of the work shall be
to the entire satisfaction of the Engineer.
To ensure bond and water tightness between old concrete surface and the concrete to be
placed, the surface should be cleaned and roughened . The bonding old and new concrete
should be done by applying the cement slurry after thoroughly watering the old concrete surface
and removing all loose particles.
Unless otherwise approved, concrete shall be placed in single operation to the full thickness of
slabs, beams and similar members and shall be placed in horizontal layers not exceeding 1 M.
deep in walls, columns and similar members. Concrete shall be placed continuously until
completion of the part of the work between construction joints or as directed by Engineer.
Concreting shall not be started unless the Electrical conduits or any other piping
wherever required are laid by the concerned agency. The Civil Contractor shall
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provide all the facilities, and maintain coordination of work with other agencies
engaged in electrical and such other works as directed by the Engineer.
Where concrete is placed on soil, it shall be placed only on firm undisturbed

ground. Any concrete that is placed on a well compacted fill shall have the prior
approval of the Engineer. Concrete shall not be placed in standing water on
subgrade or in foundation excavation.
2.7.3 Compaction:-
The concrete after being laid shall be compacted by means vibrators of approved type under
proper supervision as directed by the Engineer. Vibration shall not be confined only to the top
surface, but the whole mass of concrete shall be well vibrated until the dense mass assumes
jelly like appearance and consistency. Water just appearing on surface shall be avoided. Care
should be taken to avoid segregation and formation of air bubbles. Vibration shall be
accomplished by means of "spud" type internal vibrators with flexible shaft of 6000 vibration I
min. The vibrator shall not be left in any position for more than 5 sec. The Immersion type
vibrators shall be inserted in a vertical position at intervals of about 600 mm and fully worked
around reinforcement, embedded fixtures and into corners of formwork without directly coming
in contact with reinforcement steel and formwork. Over vibration shall not be permitted.
After concrete has been placed, it shall be spread, if necessary and thoroughly
compacted by approved mechanical vibration to maximum subsidence without
segregation and thoroughly worked around shape. Vibrators shall not be used for pushing
concrete into adjoining areas. Vibrators must be operated by experienced persons. In thin
members with heavy congestion of reinforcement or other embedments, where effective use of
internal vibrator is, in opinion of the Engineer, doubtful, in addition to immersion vibrators the
contractor may have to employ form vibrators the contractor will additionally employ screed
vibrator as per IS:2506. Hand tamping may be allowed in rare cases, subject to the approval of
the Engineer. Care must be taken to ensure that the inserts, fixtures, reinforcement and
formwork are not displaced or distorted during placing and consolidation of concrete.
The rate of placement of concrete shall be such that no cold joint is formed and fresh concrete is
placed always against green concrete which is still plastic and workable. No concrete shall be
placed in open, during rains. During rainy season, no placement in the open is to be attempted
unless sufficient tarpaulins or other similar protective arrangement for completely
covering the still green concrete from rain is kept at the site of placement. If there
has been any sign of washing of cement and sand , the entire affected concrete
shall be removed immediately. Suitable precautions shall be taken in advance to guard against

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rains before leaving the fresh concrete unattended. No accumulation of water shall be permitted
on or around freshly laid concrete.
The whole process starting from the mixing of concrete to the placing and
compaction shall not take more than 20 min. The process shall be completed
before the initial setting takes place.
All chutes, pipes and other placing equipment shall be kept clean and free from
coatings of hardened concrete by cleaning and thoroughly flushing, with water after each run,
and water used from flushing shall be discharged clear of the concrete already in place.
No concrete shall be deposited until the Engineer has inspected the forms,
reinforcing steel, inserts, hollow clay tile units, sleeves, etc, and given permission
to place. Concrete, shall be deposited only in the presence of representative of the Engineer.
2.7.4 Extreme weather concreting-

In very hot weather precaution shall be taken to see that temperature of wet
concrete does not exceed 38 deg.C while placing. During cold weather, concreting shall not be
done when the temperature falls below 4.5 deg.C. During hot weather (atmospheric
temperatures above 40 deg.C) or cold weather (atmospheric temperatures below 5 deg.C), the
concreting shall be done as per the procedure set out in IS 7861.
Rock at foundation level or construction joint of concrete kept moist for at least 72 hours prior to
placement. Concrete will be placed always against moist surface but never on pools of water. In
case the foundation cannot be dewatered completely, special procedure and precaution, as
directed by the Engineer will have to be adopted.
2.7.5 Underwater Concreting:-
Concreting shall not be deposited under water if it is practicable to de-water the area and place
concrete in the regular manner. The concrete shall contain at least 10% more cement than that
required for the same mix placed in dry conditions, the quantity of extra cement varying with
conditions of placing with prior written permission of the Engineer. Such extra cement will be
paid extra. The volume of coarse aggregate shall not be less than 11/2 times nor more than
twice the fine aggregate and slump not less than 100 mm nor more than 180 mm. Where found
necessary to deposit any concrete under water, the method, equipment, materials and mix shall
first be got approved by the Engineer. Concrete shall be deposited continuously until it is

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brought to required height. While depositing, the top surface shall be kept as nearly level as
possible and the formation of heaps shall be avoided. The concrete shall be deposited under
water by one of the approved methods such as tremie method, drop buckets, bags, groutings
etc. as per details given in 15:456. If it is necessary to raise the water after placing the concrete ,
the level shall be brought up slowly without creating any waves or commotion tending to wash
away cement or to disturb the fresh concrete in any way.
2.8 CURING SHALL BE DONE AS PER IS456
Following methods shall be employed for effective prevention of loss of moisture from concrete:-
2.8.1 Moist Curing:-

Exposed surfaces of concrete shall be kept continuously in a 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 seven days from date of placing concrete in case of ordinary Portland cement
and at least 10 days where mineral admixtures or blended cements are used.
The period of curing shall not be less than 10 days for concrete exposed to dry and hot weather
conditions . In case of mineral admixtures or blended cements are used, it is recommended that
above minimum periods may be extended to 14 days.
2.8.2 Membrane curing:-
Approved curing compounds may be used in lieu of moist curing with the permission of the
engineer-in-charge. Such compounds shall be applied to all exposed surfaces of the concrete as
soon as possible after the concrete has set. Impermeable membranes such as polyethylene
sheeting covering closely the concrete surface may also be used to provide effective barrier
against evaporation.
2.9 TESTS:-
2.9.1 Slump test:-
This test shall be carried out for every compressive strength test (cube test)
2.9.2 Cube test:-

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The quality of hardened concrete will be verified by the following procedure:
The Engineer shall select random batches of concrete for examination without warning the
contractor and sampling will generally be done at the point of discharge from the mixer.
2.10 ACCEPTANCE CRITERIA
The sampling, testing and "Criteria of Acceptance" for concrete shall be as per IS:456.
2.10.1 If the concrete produced at site does not satisfy the above strength requirements, the Engineer
will reserve the right to require the contractor to improve the methods of batching, the quality of
the ingredients and redesign the mix with increased cement content if necessary. The contractor
shall not be entitled to claim any extra cost for the extra cement used for the modifications
stipulated by the Engineer for fulfilling the strength requirements specified.
2.10.2 If from the test results it appears that some portion of the works has not attained the required
strength, the Engineer may order the testing of the suspected as well as adjacent portions of the
structure. Such testing shall be at the Contractors cost. The Engineer may also reject the work
and order its demolition and reconstruction at the contractor's cost.
2.10.3 If the strength of concrete in any portion of the structure is lower than the
required strength, but in the opinion of the engineer demolition is not necessary, the Contractor
shall be paid a lower rate for such lower strength concrete as determined by the Engineer.
2.11 QUALITY CONTROL
Contractor shall exert proper quality control at the various stages of concrete production and
placement.
As frequently as Engineer may require, testing shall be carried out in the field for:
1) Moisture content of sand
2) Moisture content of aggregates.
3) Silt content of sand
4) Grading of sand
The contractor shall provide and maintain all items, (until the works are completed) equipment
and staff required for carrying out these tests.

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The Contractor shall grant the Engineer or his representative full access to this laboratory at all
times and shall produce on demand complete records of all tests carried out in site.
Alternatively, the Contractor may also avail of the services of the local testing laboratory with
prior approval of the engineer.
2.12 CONSTRUCTION JOINTS
Construction joints shall in general conform to the relevant clauses of IS:456.
When the placing of concrete is interrupted and a construction joint is formed, provision shall be
made for interlocking with the succeeding layer by the embedment or saturated wooden blocks
or strips, smoothened on four sides to facilitate their removal. Prior to the next pour the wooden
pieces shall be loosened and removed in such a manner as to avoid damage to the concrete.
Such construction joints shall be approved by the Engineer and shall be so located and formed
as to least impair the strength and the appearance of the structure.
They shall be made in the positions as specified or as approved. Such joints shall be truly
vertical or horizontal as the case may be except that in an inclined or curved member the joints
shall be strictly at right angles to the axis of the member.
Construction joints shall be rebated to an approved profile and an approved water stop shall be
placed in the joints when specified.
Construction joints shall be made horizontally in the foundations and 75mm below the lowest
beams soffit at the head of columns. Concrete in the ribs and slab of small tee and other beams
shall be placed in one operation but for large beams concrete in the rib upto a level 25mm below
the slab, soffit shall be placed first. Concrete in haunches or splays on beams. or braces and
concrete in the head of adjoining position of the column shall be placed at the same time and at
junction of walls and slabs shall be placed at the same time as that in the slab. Construction
joints in slab and beams shall be located at one third span and keyed and dowelled as specified.
2.12.1 Cold Joint
An advancing face of a concrete pour, which could not be covered by fresh concrete before
expiry of initial setting time (due to an unscheduled stoppage or delay on account of breakdown
in plant, inclement weather, low rate of placement or any other reason), is called a cold joint.
The Contractor should always remain vigilant to avoid cold joints.

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If, however, a cold joint is formed due to unavoidable reasons , the following
procedure shall be adopted for treating it:-
a) If concrete is so green that it can be removed manually and if vibrators can penetrate the
surface without much effort, fresh concrete can be placed directly against the old surface.
The old concrete should be covered by fresh concrete as quickly as possible and the joint
thoroughly and systematically vibrated.
b) In case concrete has hardened a bit more than (a) but can still be easily removed by a light
hand pick, the surface will be raked thoroughly and the loose concrete removed
completely without disturbing the rest of the concrete in depth. A rich mortar layer 12
mm in thickness, will be placed on the cold joint fresh concrete shall be placed on the
mortar layer and the joint will be thoroughly and systematically vibrated penetrating the
vibrator deep into the old layer of concrete.
c) In case the concrete at the joint has become so stiff that it cannot be remoulded and
mortar or slurry does not rise inspite of extensive vibration, the joint will be left to harden
for at least 12 - 24 hrs. It will then be treated as a regular construction joint, after cutting
the concrete to required shape and preparing the surface.
2.13 ENCASING ROLLED STEEL SECTIONS
Before concrete work is started, the Engineer shall check that all rolled steel sections to be
encased, have been erected truly in position. The sections shall be unpainted and shall be wire
brushed to remove the loose rust I scales etc. Where so specified, ungalvanised metal, having
mesh or perforations large enough to permit the free passage of 12.5 mm nominal size
aggregate through them, shall be wrapped round the section to be encased in concrete and
paid for separately.
2.14 FINISHING OF CONCRETE
On stripping the formwork, all blowholes and honey combing observed shall be brought to the
notice of Engineer. The Engineer may, at his discretion allow such honeycombing or blowholes
to be rectified by necessary chipping and packing or grouting with concrete or cement mortar. If
mortar is used, it shall be 1:3 mix, or as specified by Engineer. However, if honeycombing or
blowholes are of such extent as being undesirable, the Engineer may reject the work totally and

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his decision shall be final and binding. No extra payment shall be made for rectifying these
defects. All humps and uneven faces shall be rubbed smooth with the help of carborundum
stone.
The surface of non-shuttered faces shall be smoothened with a wooden float to give a finish
equal to that of the rubbed down shuttered faces. Concealed concrete faces shall be left as from
the shuttering except that honeycombed surface shall be made as detailed above. The top faces
of slabs not intended to be surfaced shall be leveled and floated to a smooth finish as the levels
or falls shown in the drawings or elsewhere. The floating shall not be executed to the extent of
bringing excess fine materials to the surface.
The top faces or slabs intended to be covered with screed, granolithic or similar finishes, shall be
made rough when wet with wire brush. Faces of concrete intended to be plastered shall be
roughened by approved means to form a key.
2.15 PROTECTION OF CONCRETE
Care shall be exercised to protect the completed concrete from damage by subsequent
construction operation. No equipment shall be run over the complete slabs until they are at least
two weeks old, special case shall be taken on concreting in hot weather. The forms must be
thoroughly wetted first before the concrete is placed and the exposed surface of the concrete
shall be kept continually damp, by sprinkling for two days.
Heavy loads shall not be placed on or moved across floor slabs until curing is complete. Care
shall be taken to prevent floor surface from being marred during curing period. For freshly laid
concrete, formwork shall not be jarred. Concrete placed under water shall be protected from
falling earth during and after placing.
Walking on concrete shall not be permitted for at least twenty four hours after it has been placed
in the forms and for such additional length of time as the Engineer may direct.
2.16 CRACKS
If cracks, which in the opinion of the Engineer may be deterimental to the strength of the
structure, developed in concrete construction, the contractor at his own expense shall test the
slab or other construction as specified in Special Conditions. If under such test loads the cracks
develop further, the contractor shall dismantle the construction, carry away the debris, replace
the construction and carry out all consequential work thereto, at his cost.

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If any cracks develop in the concrete construction, which in the opinion of the Engineer have
suffered damage either in appearance or stability owing to such cracks. The Engineer's decision
as to the extent of the liability of the Contractor in the above matter shall be final and binding.
2.17 DEFECTIVE CONCRETE
Should any concrete be found honeycombed or in any way defective, such concrete shall on the
instruction of the Engineer be cut out by the Contractor and made good at his own expenses.
2.18 EXPOSED FACES. HOLES AND FIXTURES
On no account shall concrete surface be patched or covered up or damaged concrete rectified or

replaced until The Engineer or his representative has inspected the works and issued written
instructions for rectification. Further to observe this procedure will under that portion of the
works liable to rejection; in which case it will be treated as rejection which has failed to meet
specified strength requirements.
2.19 APPROVAL BEFORE CONCRETING
Pour card system to be followed. No concreting shall be carried out by the Contractor until the
Engineer or his representative has inspected formwork and reinforcement and certified in writing
that concreting may proceed. Any concrete poured without such prior written approval shall be
cut out and removed by the Contractor at his own cost.
2.20 CONCRETE FOR FLOORING ON GRADE
Concrete for flooring on grade shall be over well packed stone metal /pee levelling course or on
earth as specified with or without reinforcement, placed in alternate bays not exceeding more
than 6M x 3M or as specified including hacking the joints or adjacent bays. The water cement
ratio shall not exceed 0.4 and cement content shall not be less than 320 kg/m"3 of finished
concrete. The stiff mix shall be thoroughly vibrated and finished to receive the floor finish.

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2.21 PRECAST CONCRETE
2.21.1 General Requirements:-
Precast reinforcement concrete units such as columns, fencing posts, door and window frames,
lintels, chajjas, copings, sills, shelves, slabs, louvers etc. shall be of grade of mix as specified
and cast in forms or moulds. The forms/ moulds shall be of fiber glass or of steel sections for
better finish. Provision shall be made in the forms and moulds to accommodate fixing devices
such as nibs, clips, hooks, bolts and forming of notches and holes. The contractor may precast
the units on cement or steel platform which shall be adequately oiled provided the surface finish
is of the same standard as obtained in form. Each unit shall be cast in one operation.
2.21.2 Concrete used for precasting the units should be well proportioned, mixed, placed and
thoroughly compacted by vibrations or tamping to give a dense concrete free from voids and
honey combing.
2.21.3 Precast articles shall have a dense surface finish showing no coarse aggregate and shall have
no cracks or crevices likely to assist in disintegration of concrete or rusting of steel or other
defects that would interfere with the proper placing of the units. All angle of the precast units
with the exception of the angles resulting from the splayed or chamfered faces shall be true right
an·gles. The arises shall be clean and sharp except those specified or shown to be rounded. The
wearing surface shall be true to the lines. On being fractured, the interior or the units should
present a clean homogeneous appearance.
2.21.4 The longitudinal reinforcement shall have a minimum cover of 12 mm or twice the diameter of
the main bar, whichever is more, unless otherwise directed in respect of all items except fencing
posts or electric posts where the minimum cover shall be 25 mm.
2.21.5 Curing:-
After having been cast in the mould or form the concrete shall be adequately protected during
setting in the first stages of hardening from shocks and from harmful effects of frost, sunshine,
drying winds and cold. The concrete shall be cured at least for 7 days from the date of casting.
2.21.6 The precast articles shall be matured for 28 days before erection or being built in so that the
concrete shall have sufficient strength to prevent damage to units when first handled.

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2.21.7 Marking:-
Precast units shall be clearly marked to indicate the top of member and its location and
orientation in the structure.
2.21.8 Precast units shall be stored, transported and placed in position in such as manner that they will
not be overstressed or damaged.
2.22 PRECAST CEMENT CONCRETE JALI:
The jali shall be of cement concrete 1:2:4 (1 cement 2 coarse sand:4 stone aggregate 6 mm
nominal size) reinforced with 1.6mm thick mild steel wire, unless otherwise specified.
2.22.1 Fixing:-
The jali shall be set in position true to plumb and level before the joints sills and soffits of the
openings are plastered. It shall then be properly grouted with cement mortar 1:3 (1 cement :3
coarse sand) and rechecked for levels. Finally the jambs, sills and soffits shall be plastered
embedding the jail uniformly on all sides.
2.22.2 Measurements:-
The jali shall be measured for its gross superficial area. The length and breadth shall be
measured correct to a em. The thickness shall not be less than that specified.
2.22.3 Rate:-
The rate shall be inclusive of materials and labour involved in all the operations described above
except plastering of jambs, sills and soffits, which will be paid for under relevant items of
plastering.
PART-II - TECHNICAL SPECIFICAT,IONS 184 of 1528

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2.23 EXPANSION AND ISOLATION JOINTS
Expansion and isolation joints in concrete structures shall be provided at specific places as per
details indicated on the drawings. The materials and types of joints shall be as specified herein
after, if not, otherwise mentioned in the drawings. In case of liquid retaining structures,
Contractor is responsible for achieving watertight concrete. All materials are to be procured from
reliable manufactures and must have the approval of the Engineer. Where it is the responsibility
of the Contractor to supply the material, the Engineer may demand test certificates for the
materials and/or instruct the Contractor to get them tested in an approved laboratory free of cost
to the Owner. Joints shall be formed true to line, level, shape, dimension and quality as per
drawings and specifications.
Prior approval of the method of forming the joints should be obtained from the Engineer before
starting the work.
2.23.1 Bitumen Board/Expanded Polystyrene Board.
Bitumen impregnated fibre board of approved manufacturer as per IS:1838 may be used as
fillers for expansion joints. It must be durable and waterproof. It shall be compressible and
possess a high degree of rebound. The dimensions of the board should be equal to that of the
joint being formed. It should, preferably be manufactured in one piece, matching the dimension
of the joint and not prepared by cutting to size smaller pieces from larger boards at site. At the
exposed end, the joint shall be sealed with approved sealing compound to a depth of atleast
25mm after application of an approved primer.
The sealing compound and the primer shall be applied as specified by the manufacturer.
2.23.2 Metal Sealing Strips I water stops
Metal sealing strips shall be either G.l, Aluminium or Copper and formed straight, U shaped, Z
shaped or any other shape and of thickness as indicated in the drawing and schedule of items
and/or as instructed by the Engineer.
The transverse joints will be gas welded using brass rods and approved flux and will be tested by
an approved method to establish that it is leakproof, longer lap lengths and different method of
PART-II - TECH NICAL SPECIFICATIONS 185 of 1528

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brazing which will render it leakproof, will be adopted by the contractor without any additional
cost to the Owner.
The edges shall be neatly crimped and bent to ensure proper bond with the concrete.
a) G.l Strips
G.l strip shall be minimum 1.5mm thick and 150 mm in width unless specified otherwise.
The standard of Galvanizing shall be as per relevant India Standards for heavy duty work.
At the joints, the overlapping should be for a minimum length of 50mm.
b) Aluminium strips shall be minimum 18 SWG thick and 300 mm wide unless specified
otherwise and shall conform to IS:737 of 19000 grade or 31000 grade (Designation as
per IS:6051). A minimum lap of 50mm length is required at the joints.
2.22.3 Non-metallic Sealing Strips I water stops
These will be normally in rubber or P.V.C can be of shape having any combination of the
following features:-
a) Plain
b) Central bulb
c) Dumb-bell or flattened ends
d) Ribbed and Corrugated Wings
e) V shaped
As these types of seals can be easily handled in very large lengths unlike metal strips,
transverse joints will be allowed only under unavoidable circumstances and with the specific
approval of the Engineer.
The method of forming these joints, laps etc. shall be as specified by the Manufacturer and/or
as approved by the Engineer taking particular care to match the central bulbs and the edges
accurately.
2.22.3.11nstallation & Jointing Techniques of non metallic sealing strips.
One of the main advantages of PVC water-stops is that they can be installed very easily. The
jointing can be carried out by simple heat fusion/welding process. The installation consists of
embedding one half of he water-stop across its width in concrete leaving the second half open.

Rev. 1
Uhde India
Page: 25 of
30
After completion of the first half, the concrete would be poured and the second half would also
be embedded leaving the centre bulb free for expansion and contraction.
It is important that during pouring of concrete the water-stops should not be deformed due to
impact. The concrete should be properly vibrated so that it develops intimate contact with the
water-stops Care should be taken so as not to reduce effective cross section of the water-
stops.
It is necessary that PVC water-stops are placed near the centre of the concrete walls. During
installation, PVC water-stops are often required to be jointed. there are essentially two types of
joints:
1) Straight Joints
2) Mitred Joints
Straight joints are very simple and can easily be carried out at the site.
Fabrication of PVC water-stops can be carried out by means of simple tools; they are:
1. Hand saw or sharp knife for cutting.
2. Heating source like blow lamp or any other means.
3. A metal strip plate of suitable width and about 500- 600 mm length with simple holding
device like a wooden handle.
4. Metal or wooden templates with suitable marking/grooves for 45 Deg.C and 90 deg.C
angle cuttings.
The following jointing method is recommended :

1. Water-stops are cut by means of cutting device. Clean cuts provide the best results.
2. The metal strip is heated to about 200 Deg.C which would be adequate to melt the water-
stops material. The strip should not be overheated so as to prevent charring of PVC
material.
3. Two ends of PVC water-stops to be joined are pressed uniformly against the hot metal
strip. When sufficient fusing of PVC is attained, the metal strip removed and both the
ends are pressed together. It is necessary to ensure that the entire cross section is
uniformly heated and fused. It also essential to attain alignments of the complete cross
section and particularly of centre bulbs both the ends are well pressed until the joint cools
down to ambient temperature.

Rev. 1
ThyssenKrupp
Uhde India .
Page : 26 of
30
4. The metal strip should be cleaned by means of wire brush and cotton
waste before the next welding is carried out.
2.23.4 Rubber Pad
Hard foundation quality rubber pads of required thickness and shapes shall be put below
machine or other foundations as shown on the drawings or as directed by the Engineer. The
rubber shall have a unit weight of 1500 kg/Cu.m, a shore hardness- 65A to 70A and be of best
quality of approved manufacture, durable, free from moist or dry earth or any other deleterious
material.
2.24 GROUTING UNDER MACHINERY or STRUCTURAL STEEL BASES.
If required, grouting under base plates of machines or structural steel etc. shall be carried out
by the Contractor.
2.24.1 Cement Sand Grout:-
In general, the mix shall be 1 (one) part cement and 1 (one) part sand and just enough water to
make it flow as required. The areas to be grouted shall be cleaned thoroughly with compressed
air jet and/or with water in locations where accumulated surplus water can be removed. Where
directed by the Engineer, 6 mm down stone-chips may have to be used in the mix. Surface to
be grouted shall be kept moist for at least 24 hours in advance. The grout shall be placed
under expert supervision, so that there is no locked up air. Edges shall be finished properly.
2.24.2 Cementitious Non shrink grout:-
Non-shrink type grout using cementitious base material shall be from approved manufacturer
and shall be free flow type. The minimum compressive strength of the grout shall not be less
than 650 kg/cm 2 . The grout material shall be expansive to ensure the full contact between the
base plate and grout. It should not shrink during setting process. Necessary formwork shall be
used around the portion to be grouted. The water cement ratio shall be as per manufacturer's
specification and in no case shall be more than 0.18. To achieve the workability for the
minimum horizontal flow of 1000 mm, when the grout is poured from one end, necessary
plasticizers may be added as recommended by the manufacturer. These additives I
admixtures shall be added by the manufacturer only and shall not be added by the contractor at
site in the ready mix grout.

Rev. 1
Uhde India
Page: 2 7 of
30
2.24.3 Non-Shrink Epoxy Grout:-
Grout shall be a 100% solids system with the ability to be placed in flowable state. Non shrink
Epoxy shall have a minimum allowable compressive strength of 800 kg/cm2 at 7 days as
determined by tests on 50 mm cubes as per ASTM C579, Method B. Epoxy grouts whose resin
component has an SPI rating higher than II shall not be used, due to potential local
atmospheric contamination making the installation area hazardous.
The grout surfaces shall be made completely dry prior to grouting. Epoxy grout component
ratios shall not be changed from that recommended by the manufacturer. No solvents or
thinners shall be added to the mi~ . The grouts are usually supplied in a 3-pack form consisting
of: Resin , Hardener, Aggregate (Filler).
2.25 WATERPROOFING CONCRETE STRUCTURE
2.25.1 General:-
Water proofing of concrete structures shall be done by either suitable extraneous treatments like
applying paints, fixing bitumen felts etc. or internally by suitable design of the concrete mix,
· addition of suitable admixtures in the concrete or mortar at the time of mixing and/or installing
water bars at the joints .
. The design, material and workmanship shall conform to the relevant IS Codes where applicable.
The Engineer's approval of the materials shall be obtained by the Contractor before
procurement. If desired by the Engineer, test certificates for the materials and samples shall be
of best quality available indigenously, fresh clean and suitable for the duties called upon.
If it is found that water I liquid is leaking, the contractor shall carry out rectification work by
injection grout method or any other method as directed by the Engineer at no additional cost to
the Owner.
2.25.2 Waterproofing Admixtures:-
In-concrete: The admixtures shall be procured from reliable and reputed manufacturers and
approved by the Engineer. The method of application and other details shall conform to the
manufacturer's specification and/or as instructed by the Engineer. The Contractor shall have the

SECTION-2 - C N R
Rev. 1
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Uhde India ~.' ....
Page: 28 of
30
services of the manufacturer's supervisor at no extra cost to the Owner to supervise the work, if
desired by the Engineer.
2.26 SUPPLY & SPECIFICATION OF READY MIX CONCRETE (RMC) AS PER IS 4926:
2.26.1 Ready Mix concrete (RMC) generally be supplied to the Contractor in grades as required at site
by the Owner. In such cases the contractor shall inform the Owner well in advance and inform
the Engineer in writing I prescribed form his requirement time, date and quantity so that the
Engineer I Owner can organise such supplies. If the total quantity asked for could not be
poured at site, the contractor shall pay for such excess quantity as per mutually agreed rates.
It is to be noted that RMC, on arrival at site, shall be immediately pumped to the location of
pouring. Pumps and hoses to be supplied by RMC vendor. In case of any delay occurring
because of site of pouring being not ready, thus resulting in rejection of RMC because of initial
set or otherwise, the entire cost of the rejected batch at mutually agreed rates shall be borne by
the Contractor.
2.26.2 In case, RMC is supplied by the Contractor as per contract, the same shall be supplied from
Mls. ACC or any other reputed approved supplier. Approval for such supplies shall be given by
the Engineer after contractor supplies all information about the supplier as required by the
Engineer.
2.26.3 Contractor shall obtain from the manufacturer the test certificates for all materials forming RMC
including details of concrete mix design and submit for Engineer's approval.
2.27 FORMWORK
2.27 .1 If it is desired by the Engineer, the contractor shall prepare, before commencement of actual
work design and drawings for formwork and get them approved by the Engineer.
2.27 .2 The arrangement and alignment of formwork, shall be approved by the Engineer prior to
concreting. However, this shall not relieve the Contractor from his responsibility of doing
accurate work and rectifying the same if required.
2.27.3 Formwork for concrete shall be of plywood, steel, good seasoned timber of other approved
materials, properly designed easy to remove and clean and shall give smooth and even surface
after removal thereof. It shall be sufficiently tight to prevent loss of cement slurry from the
concrete.

Rev. 1
SECTION-2- CONCRETE FORMW RK
Uhde India
Page: 29 of
30
As far as practicable, clamps shall be used to hold the forms together. Where use of nails is
unavoidable, minimum no. of nails shall be used.
All joints and holes in the formwork shall be caulked with putty, jute cloth or other approved
materials to the satisfaction of the Engineer. The inner face of the shuttering shall be cleaned
and thoroughly wetted or greased with approved material. Care shall be taken that such coating
is kept free from contact with the reinforcements. All formwork shall be levelled and aligned and
all rubbish, particularly, chippings , wood shavings, saw dust and adhering grout shall be
removed from the interior of the forms by compressed air or any other approved method before
the concrete is placed. Good quality shuttering oil to be used. Burnt black oil will not be
permitted.
The contr9ctor shall obtain approval of the Engineer as to the design, fabrication, and erection of
the formwork. Form and false work shall be designed as per IS 14687.
Wherev.er it is specified on the drawings that concrete surface will be left untreated, the pattern
of joints in the formwork shall be subject to the approval of the Engineer, and no extra will be
paid for special care in shuttering.
Temporary openings shall be provided at columns and wall forms and other places to facilitate
inspection and cleaning. Before concrete is placed, all forms shall be carefully inspected to
ensure they are properly placed sufficiently rigid and tight and approved by the engineer before
the reinforcement bars are placed in position. When forms appear. to be unsatisfactory in any
way, either before or during the placing of concrete, the work shall be stopped until the defects
have been corrected.
All corners and angles shall be formed with 45 deg. mouldings to form chambers or fillets on the
finished concrete as directed by the Engineer. Formwork shall be cambered at centre (at free
end for cantilevers) as specified in the drawings and as per instructions of engineer in charge.
2.27 .4 Tolerance shall be as per IS 456 unless the values are specifically mentioned on design
drawings.
2.27 .5 The contractor shall submit his design and detailing of formwork before starting the work for the
approval of the Engineer. The number of props, their sizes and location shall be such as to be
able to safely carry the full dead load and construction loads. However, approval of the

Rev. 1
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Page: 30 of
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Engineer to this effect shall not relieve the contractor of his responsibility for proper work and
safety.
2.27 .6 All formwork for beams, slabs and similar members shall be so designed and erected that the
sides can be removed without disturbing the soffit and its supports. Vertical props shall be
supported on wedges or sole plates or by any other suitable means whereby the props can be
gently lowered while commencing the removal of shuttering. Column shuttering shall not be
more than 2.5 Min height per piece if not otherwise approved by the Engineer.
2.27. 7 The stripping time for the shuttering and formwork shall in general conform to the provisions in
the relevant clauses of IS:456.
2.28 EMBEDMENTS
Contractor shall not do concreting unless Electrical conduits, pipes, fixtures etc. wherever
required, are laid by the concerned agency. Embedded items shall be placed and maintained in
correct position while concreting. Embedded items shall be properly anchored to develop
required strength.
2.29 MODE OF MEASUREMENT
2.29.1 Mode of Measurement for Concrete Work
Payment for all concrete work shall be made on cubic metre basis. The pre-cast members shall
be measured on Sq.Metre basis. The measurements shall be as per relevant part of IS:1200.
The rates shall be inclusive of taxes, levies, labour, equipments, material, curing, pouring at
different heights, working platforms etc. all complete.
Reinforcement and formwork shall be paid separately, if not otherwise mentioned in the
Contract.
2.29.2 Formwork
The payment for formwork items shall be on Sq.m. basis of the actual area in contact with
concrete cast unless noted. The rate shall be inclusive of all props, struts, bracings, centering
and shall be for all heights, with camber, chamfering etc. and keeping formwork for full period as
required including all false shuttering and staging for high structures and all taxes and levies.

Rev. 1
PART – II DOC NO.:
CI-UCH-016-03
SECTION-3
TECHNICAL SPECIFICATIONS Rev. :R0
Uhde India Limited MASONRY, PLASTER, POINTING Page :1
Contents Page
SCOPE 2
LIST OF I.S. CODES 2
BRICK MASONRY 3
RUBBLE MASONRY 6
CONCRETE BLOCK MASONRY 7
MASONRY WITH AUTOCLAVED CELLULAR BLOCKS 13
PLASTERING 14
POINTING 18
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03

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3.0 MASONRY
3.1.1 Scope
The Work under this section consists of providing and constructing all masonry
true to lines & levels as shown on the drawings and as specified herein.
The work shall be co-ordinated in such a manner that built-in items such as
flashing, dowels, anchor bolts, doors/window, frames, conduits and outlet boxes
etc. are furnished and installed as the masonry work progresses.
It includes supply by the Contractor of all materials, labour, plant, tools,

scaffolding, curing etc. complete in all respect as required for the work.
List of IS Codes.
1) IS:1661 - Code of practice for cement lime plaster finish on walls

& ceilings
2) IS:4101 - Code of practice for external facings & veneers
3) IS:1597 - Code of practice for construction of stone masonry

(Parts 1 & 2)
4) IS:1609 - Code of practice for laying damp proofing treatment

using bitumen felts.
5) IS:2212 - Code of practice for Brick work
6) IS:2250 - Code of practice for preparation and use of masonry
mortar
7) IS:2185 - Specification for concrete masonry units
IS:2185 - Hollow & Solid concrete blocks of normal weight
(Part 1)
IS:2185 - Hollow & Solid light weight concrete blocks
(Part 2)
IS:2185 - Autoclaved Cellular (aerated) concrete blocks
(Part 3)
8) IS:2572 - Code of Practice for construction of Hollow Concrete
Block Masonry
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3.2 Brick Masonry

3.2.1 Material
3.2.1.1 First Class Bricks
These shall be sound, hard tough, rectangular in shape and size, well burnt of
uniform deep red, cherry or copper colour and shall conform to IS:1077. No
overburnt or underburnt bricks shall be used.
The bricks shall be of approved make and free from modules of tree lime, cracks,
flaws, chips, stone or humps of any kind. These shall not show any sign of
efflorescence. The nominal size shall be 23 x 11.5 x 7.5 cm. These shall have
sharp and square sides and parallel faces to ensure uniformity in the thickness of
the course of brick work. All bricks shall be machine moulded and kiln burnt if not
otherwise approved by the Engineer. The bricks shall be homogeneous in texture
and give a clear ringing sound on being struck, and shall have minimum
compressive strength of 50 kg/sq.cm or as specified and shall not absorb water
more than 20% of its dry weight when soaked in cold water at room temp. for 24
hours.
3.2.1.2 Second Class Bricks
These shall conform to specifications for 1st class bricks except that some surface
cracks are allowable. these shall have minimum compressive strength of 35
kg/sq.cm
3.2.1.3 Locally Available Bricks
In case 1st class bricks are not available, then locally available best quality brick
samples will be submitted for the approval of Engineer. However, the
Compressive strength of locally available bricks shall not be less than 35
kg/sq.cm.
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Bricks to be used shall be approved by the Engineer. Samples of such approved

bricks shall be deposited with Engineer and all the bricks brought subsequently
therein after for construction shall be as per approved samples. All the bricks
should be unloaded by hand. Bricks shall be carefully and systematically stacked
at locations as directed by the Engineer. Such stack shall contain equal number
of bricks preferably not more than 3000 Nos.
Engineer may order the following tests on bricks: Dimensional tolerance, Water
absorption, Efflorescence, Compressive strength. The contractor shall arrange for
tests as required without extra payment.
3.2.1.4 Sand
This shall be dry coarse sand of approved quality conforming to IS:383. 100% of
the sand shall pass through I.S. sieve No. 240 and not more than 15% to 35%
through Sieve No.30. Sand shall have a fineness modulus between 2.1 to 2.
Sand shall be clean angular free from dust, clay or any other impurities.
Percentage of clay or total impurities shall not be more than 5% by weight.
Sand for use in masonry mortar shall conform to IS:2116 including grading. Sand
for use in plaster shall conform to IS:1542 including grading.
3.2.1.5 Mortar
Brick work shall be laid with specified Mortar to be prepared in accordance with
IS:2250. It shall be made of cement and sharp coarse sand and shall be made in
small quantities so as to be used within 30 minutes. The cement and sand in the
required proportion., and classification shall be first mixed dry thoroughly and then
water added and mixed to a sufficiently thick consistency as required by the
Engineer. No left over mortar shall be used. Mortar which has partially set shall
not be retempered by mixing additional material or water.
The unit of measurement for cement shall be of a bag of cement weighing 50 Kg.
and shall be taken as 0.035 cu.m. Other ingredients in specified proportion shall
be measured in boxes of 25 x 35 x 40 cm size. Sand shall be measured on the
basis of dry volume. In case of damp sand, its quantities shall be increased
suitably to allow for bulkage.
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Mortar proportions will be as follows : [If not otherwise mentioned]
1) One cement and 6 sand for all brickwork in foundation.

2) One cement and 5 sand for all brickwork in superstructure.
3) One cement and 4 sand for 115 mm thk. partition walls.
3.2.2 Soaking of Bricks
Bricks required for masonry shall be thoroughly soaked in clean water before use
for at least six hours until air bubbles cease to come out. The practice of dipping
the bricks in water just before use shall not be allowed. The soaked bricks shall
be kept on wooden planks or brick platform to avoid earth being smeared on
them.
3.2.3 Laying
Brick work shall be laid in English Bond unless otherwise specified. Half or cut
bricks shall not be used except where needed to complete the bond. Each course
shall be perfectly straight horizontally and transversely. The walls shall be taken
up truly plumb; if battered, the batter is to be truly maintained. The level of the
brick work in vertical walls shall be checked up at every one metre interval.
Bricks shall be laid with frogs upward. While laying, bricks shall be thoroughly
bedded and flushed in mortar and tapped into position with a wooden mallet and
the superfluous mortar removed.
Walls of all structures shall be carried up regularly in all cases, leaving no part,
one metre lower than another. If this cannot be adhered to the brick work shall be
racked back at an angle not more than 45°, so as to maintain a uniform and
effectual bond, but racking back should not start within 60 cm of a corner.
Partially or totally set exposed surface of the masonry shall be cleaned, roughened
and lightly wetted so as to obtain the best possible bond with new work. All loose
bricks and mortar shall be removed. All masonry walls shall be bonded. Each
course at corners and intersections and shall be bonded or anchored to
connecting work.
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No deductions or additions in measurement shall be made on any account for the

following:
a) ends of dissimilar materials(i.e joints, beams, lintels, posts,girders, rafters,

trusses, corbels, steps etc.) upto 500 sq.cm. in section and
b) opening upto 0.1 sq.m in section. However, full deduction from masonry
work shall be made for notches kept in the wall for pipeline.
At all angles forming the junction of any two walls, the brick shall, at each alternate
course, be carried into each of the respective walls so as to thoroughly unite the
work. The brick work shall not be raised more than 14 courses per day.
All iron fixtures, pipes, conduits, drains, sleeves, bolts, hold fasts for doors and
windows etc. which are required to be built in walls, shall be embedded in cement
mortar or cement concrete as specified as the work proceeds.
All uneven, irregular and disturbed brick work shall be pulled down and rebuilt with
fresh bricks at the contractor's expenses.
3.2.4 Joints
Thickness of joints shall be restricted to 6mm in first class brick work and 10mm
in second class brick work (unless any wider vertical joints upto 13mm are
necessary to give the required thickness of the wall).
All bed joints shall be normal to the pressure acting upto them i.e. horizontal in
vertical walls, radial in arches and at right angles to the face in battered relating
walls. The vertical joints in alternate course shall come directly one over the other
and shall be truly vertical. Care shall be taken that all joints are fully mortared
(proportion as specified Schedule of Items) well flushed up and in case where no
pointing is to be done neatly struck as the work proceeds. The joints in faces
which are to plastered or pointed shall be squarely raked out to a depth of 12 mm
while the mortar is still green. The raked joint shall be well brushed to remove the
loose particles. At the junction of concrete and masonry wall, G.I. Chicken wire
mesh, 150 mm wide and 22 SWG shall be provided, prior to plastering. After the
work, the faces of brick work shall be cleaned with wire brush so as to remove
any splashes of mortar during the course of raising the brick work.
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3.2.5 Curing
Green work shall be protected from rain by suitable covering. Masonry work as it
progresses be kept thoroughly well watered on all faces for atleast 7 days after
completion. Proper watering can with nozzles must be used for this purpose. The
top of masonry work shall be kept flooded at the close of the day by forming fillet
or mortar 40mm high round the edges of top course and filled with water.
3.2.6 Scaffolding
Double scaffolding sufficiently strong so as to withstand all loads likely to come

upon it and having two sets of vertical supports shall be provided. Where two sets
of supports are not possible the inner end of the horizontal scaffolding pole shall
rest in a hole provided in the header course only.
Only one header for each pole shall be left out. Such holes however shall not be
allowed in pillars under one metre in width or immediately near the skew backs of
arches. Such holes shall be filled up immediately after removal of scaffolding.
3.2.7 Brick work in partition walls
It will be carried out as detailed in brickwork above, except concrete band of 115 x
75 mm in M-15 grade concrete and 8 dia. tor steel bars tied with 8 dia. tor steel
stirrup @300 c/c to be provided at 90 cm. interval. Suitable dowels shall be left
from RC columns or shall be welded with steel stanchions. Half brick walls shall
have bricks laid in stretcher bond.
3.3 RUBBLE MASONRY
3.3.1 Stone
The stone for the works except where otherwise described shall be of the best
quality procurable complying with IS:1597 (Part 1). No stone with flaws, or
traversed with seams of perishable materials or quarry faced, or otherwise in any
way defective shall be allowed to be used and the Engineer may reject and refuse
to permit the use of any stone which, in his opinion, is unfit for the work.
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3.3.2 Method of laying

Stone Masonry, wherever required, shall conform to the requirements of IS:1597
and shall be composed generally of large stone weighing about 25 kgs. The
corner stones shall be squared on all joints and beds, and shall be hammer and
chisel dressed, true and square for atleast 75 mm back from the corner face, and
the joints for atleast 40 mm. The faces of the stones to be hammer dressed, and
“bushing” shall not project more than 40 mm. The stone shall be clean, flat
bedded, properly selected for their places and carefully laid with a suitable
proportion of smaller stones and chips to fill up the interstices. The mortar
including the constituents shall conform to the requirements of IS:2250.
The Masonry work shall be done in C.M. (1:6) or as directed by Engineer. The
masonry shall be uncoursed or brought to courses as specified. The whole
masonry shall be hand set solidly bedded and surrounded with mortar on every
side except the face. There shall be no hollows or dry portions in work nor pinning
in the face and no joint shall be more than 10mm thick. The face stone shall be
flat bedded. Through stones covering the whole width or thickness of the walls, or
600 mm long where the walls are thicker than 600 mm are to be provided. At
least one bond stone or a set of bond stones shall be provided for every 0.5 sq.m.
of area of wall surface. The faces of the walls shall be strictly straight. The
masonry shall be shaded from the sun, and kept wet for not less than 7 days after
completion.
All fixtures plugs, frames shall be placed securely as the work proceeds and not
after completion of the masonry.
3.4 CONCRETE BLOCK MASONRY
3.4.1 Hollow and solid concrete blocks:

These shall conform to the requirements of IS:2185 - Specification for hollow and
solid concrete blocks except with regard to the mix of cement concrete and sizes
of aggregates which shall be as indicated. Hollow blocks shall be sound, free
from cracks, broken edges, honey combing and other defects that would interfere
with the proper placing of block.
3.4.1.1 The concrete mix used for blocks shall not be richer than 1 part by volume of
cement to 6 parts by volume of combined aggregate before mixing.
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3.4.2 Dimensions and Tolerances

3.4.2.1 Concrete masonry building units shall be made in sizes and shapes to fit different
construction needs. They include stretcher, corner, double corner or pier, jamb,
header, bull noise, and partition block.
3.4.2.2 Concrete Block-hollow (open or closed cavity) or solid shall be referred to by its
nominal dimensions.
The nominal dimensions of concrete block shall be as follows:

Length : 400, 500 or 600 mm
Height : 200 or 100 mm
Width : 50, 75, 100, 150, 200, 250 or 300 mm
In addition, block shall be manufactured in half lengths of 200, 250 or 300 mm to

correspond to the full lengths.
The maximum variation in the length of the units shall be not more than ± 5 mm
and maximum variation in height and width of unit, not more than ± 3 mm.
3.4.3 Classification
3.4.3.1 Hollow (open and closed cavity) Concrete Blocks:

The hollow (open and closed cavity) concrete blocks shall conform to the following
three grades:
(a) Grade ‘A’ – These are used as load bearing units and shall have a minimum
block-density of 1500 kg/cu.m. These shall be manufactured for minimum
2
average compressive strengths of 3.5, 4.5, 5.5 and 7.0 N/mm respectively at
28 days (See Table below).
(b) Grade ‘B’ – These are also used as load bearing units and shall have a block
density less than 1500 kg/cu.m but not less than 1000 kg/cu.m. These shall
be manufactured for minimum average compressive strengths of 2.0, 3.0 and
2
5.0 N/mm respectively at 28 days (See Table below).
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(c) Grade ‘C’ – These are used as non-load bearing units and shall have a block
density less than 1500 kg/cu.m. but not less than 1000 kg/cu.m. These shall
2
be manufactured for minimum average compressive strength of 1.5 N/mm
at 28 days (see Table below).
Solid Concrete blocks shall conform to:

(d) Grade ‘D’ – The solid concrete blocks are used as load bearing units and
shall have a block density not less than 1800 kg/cu.m. These shall be
manufactured for minimum average compressive strengths of 4.0 and 5.0
2
N/mm respectively (See Table below).
3.4.4 Physical Requirements

3.4.4.1 Compressive Strength – The average crushing strength of eight blocks, when
determined in accordance with IS:2185 shall be not less than as specified in table
given below.
TABLE
Type Grade Density of Min. Average Min. Strength

Block Compressive of Individual
3 2
Kg/mm Strength of Units Units N/mm
2
N/mm
(1) (2) (3) (4) (5)
Hollow A(3.5) Not less than 3.5 2.8
(open & A(4.5) 1500 4.5 3.6
closed A(5.5) 5.5 4.4
cavity) A(7.0) 7.0 5.6
load
bearing B(2.0) Less than 2.0 1.6
unit B(3.0) 1500 but 3.0 2.4
B(5.0) not less 5.0 4.0
than 1000
Hollow C(1.5) Less than 1.5 1.2

(open and 1500 but not
closed less than 1000
cavity)
non-load
bearing
units
Solid load D(5.0) Not less than 5.0 4.0
bearing D(4.0) 1800 4.0 3.2
units
3.4.4.2 Drying Shrinkage – The drying shrinkage of the blocks (average of three blocks),
when unrestrained, shall be determined in accordance with IS:2185 and shall not
exceed 0.1 percent.
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3.4.4.3 Moisture Movement – The moisture movement (average of three blocks), when
determined in the manner described in IS:2185, shall not exceed 0.09 percent.
3.4.4.4 Water Absorption – The water absorption (average of three blocks), when
determined in the manner described in IS-2185 shall not be more than 10 percent
by mass.
3.4.4.5 Face shells and webs shall increase in thickness from the bottom to the top of the
unit. Depending upon the core moulds used, the face shells and webs shall be
flared and tapered or straight tapered, the former providing a wider surface for
mortar. The thickness of the face shell and web shell be not less than the values
given in Table below.
TABLE
Nominal Block Face shell Thickness, Thickness Total Web

Width Minimum of Web. Thickness
Min. per Course in
any 200 mm
length of
Walling Min.
(1) (2) (3) (4)
100 or less 25 25 25
Over 100 to 150 25 25 30
Over 150 to 200 30 25 30
Over 200 35 30 38
3.4.5 Curing and Drying
The blocks shall be cured in an immersion tank or in a curing yard and shall be
kept continuously moist for at least 14 days. When the blocks are cured in an
immersion tank, the water of tank shall be changed at least every four days.
After curing, the blocks shall be dried in shade before being used on the work.
They shall be stacked with voids horizontal to facilitate through passage of air.
The blocks shall be allowed to complete their initial shrinkage, before they are laid
in wall.
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3.4.6 Construction of Masonry
If hollow blocks are used, their hollows shall be filled up with cement concrete
1:3:6 using 12.5 mm nominal size aggregates, where required by Engineer.
3.4.7 Wetting of Blocks

Blocks need not be wetted before or during laying in the walls. In case the climate
conditions so require, the top and the sides of the blocks may only be slightly
moistened so as to prevent absorption of water from the mortar and ensure the
development of the required bond with the mortar.
3.4.8 Laying
Blocks shall be laid in mortar, as indicated and thoroughly bedded in mortar,
spread over the entire top surface of the previous course of blocks to a uniform
layer of not more than 10 mm thickness.
All courses shall be laid truly horizontal and all vertical joints made truly vertical.
Blocks, shall break joints with those above and below for not less than quarter of
their length. Precast half length closers (and not cut from full size blocks) shall be
used. For battered faces, bedding shall be at right angles to the face unless
otherwise directed. Care shall be taken during construction to see that edges of
blocks are not damaged.
3.4.9 Provision for Door and Window Frames

A course of solid concrete block masonry shall be provided under door and
window openings (or a 10 cm thick precast concrete sill block under windows).
The solid course shall extend for atleast 20 cm beyond the opening on either side.
For jambs of very large doors and windows either solid units are used, or the
hollows shall be filled in with concrete of mix 1:3:6 using 12.5 mm nominal size
aggregates.
3.4.10 Provisions for Roof

The course immediately below the roof slab shall be built with solid blocks. The
top of the roof course shall be finished smooth with a layer of cement and coarse
sand mortar 1:3, 10 mm thick and covered with a thick coat of white wash or crude
oil, to ensure free movement of slab.
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3.4.11 Intersecting Walls

When two walls meet or intersect and the course are to be laid up at the same
time, a true masonry bond between at least 50% of the units at the intersection is
necessary. When such intersecting walls are laid up separately, pockets with 20
mm maximum vertical spacing shall be left in the first wall laid. The corresponding
course of the second wall shall be built into these pockets.
3.4.12 Fixtures, fittings, etc. shall be built into the masonry in cement and coarse sand
mortar 1:3 while laying the blocks where possible. Hold fasts shall be built into the
joints of the masonry during laying.
Holes, chases, sleeves, openings etc. of the required size and shape shall be
formed in the masonry with special blocks while laying, for fixing pipes, service
lines, passage of water etc. After service lines, pipes etc. are fixed, voids, left, if
any, shall be filled up with cement concrete 1:3:6 (1 cement : 3 coarse sand : 6
stone aggregate 20 mm nominal size) and neatly finished.
3.4.13 Finishes
Rendering shall not be done to the walls when walls are wet. Joints for plastering
or pointing as specified shall be raked to a depth of 12 mm.
3.5 MASONRY WITH AUTOCLAVED CELLULAR BLOCKS
3.5.1 Autoclaved cellular blocks for masonry shall conform to IS:2185 Part 3 and shall
be procured from approved manufacturer. Manufacturer’s literature and samples
shall be approved by Engineer prior to ordering the blocks at site.
3.5.2 The blocks shall be stacked in dry, well-ventilated areas. These blocks shall not
be used below ground or in plinth. Damp proof course shall be provided before
starting superstructure masonry.
3.5.3 Construction of Masonry

Cement mortar 1:6 using portland cement shall be used in masonry. It is not
necessary to soak the blocks before their use in masonry. Their surfaces shall be
wetted sparingly and afterwards water shall be sprinkled for curing of masonry
joints especially in hot weather. As to breaking of joints, specifications for brick
masonry work shall be adopted for guidance. It is essential to avoid future cracks
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in plaster at opening corners. For this purpose, door and window openings should
be provided with 2 Nos. 6 mm bars extending to 0.6 M on either side. The bars
should be placed in the joints just below the opening for windows. Similar
reinforcement should also be provided at the top of the opening (doors and
windows) in the course immediately above the lintel.
Inter-locking shall not be done at junctions of load bearing and non-load bearing
partition walls. Connections between these walls can be achieved by:
a) Nailing galvanised strips across every third joint with 12 mm galvanised or

aluminium nails, or
b) 125 mm cut nails in every third joint
c) 6 mm dia. Bars 200 mm long or
d) Chicken mesh
Inter locking at junction of two load bearing walls shall be done as in brick
masonry. At junction between conventional and cellular block masonry, chicken
mesh shall be provided in the plaster to avoid future cracking at the corners and
junctions.
Unsupported walling shall not exceed in height 18 times the thickness of wall and
horizontally 24 times the thickness of wall for load bearing walls. For partition or
non-load bearing walls, the unsupported length and height shall not be more than
36 times the thickness of wall. The wall shall be wetted sparingly before plaster.
3.6 PLASTERING
3.6.1 Preparing of surface

The surface to be plastered shall be thoroughly cleaned so that it is free from dust,
dirt, salts, etc. The joints of masonry work shall be raked out to the depth of
atleast 12 mm. Cement concrete surfaces shall be cleaned with wire brush. The
surface in both cases shall be washed properly and kept wet for 4 hours before
plastering is commerced.
3.6.2 Mortar
Cement and sand shall be thoroughly mixed in the proportion specified and water
shall be added to form an easily workable paste. In no case shall mortar which
has been allowed to stand for more than an hour after mixing to be used.
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3.6.3 Application of Plaster
Plaster, when more than 12 mm thick, shall be applied in two coats a base coat
followed by the finishing coat. Thickness of the base coat shall be sufficient to fill
up all unevenness in the surface, no single coat, however, shall exceed 12 mm in
thickness. The lower coat shall be thicker than the upper coat, the overall
thickness of the coats shall not be less than the minimum thickness shown on the
drawings. The undercoat shall be allowed to dry and shrink before applying the
second coat of plaster. The undercoat shall be scratched or roughened before it
is fully hardened to form a mechanical key. The method of application shall be
‘thrown on’ rather than ‘applied by trowel’.
The entire plastering job inside and outside shall be a thoroughly sound and
workmanlike job. All corners and angles shall be true to plumb or level. All plane
surface shall be levelled or plumbed and shall contact a 3 m straight edge in its
entire length with not more than 3 mm variation either way.
The plastering shall start from top and gradually worked down towards floor. It
shall not, at any place, be thinner than specified. To ensure even thickness,
plaster in about 15 cm wide strip shall be first applied horizontally and vertically at
not more than 2 meter interval over the entire surface to serve as gauge. The
surface of these gauged areas shall be truly in the plumb and plane of finished
plaster surface. The mortar shall then be applied on the wall or other surface
between the gauges and finished even. All corners shall be rounded to a radius of
12 mm unless otherwise specified. Rounding or chamfering corners, junctions
etc. where required shall be done without extra payment. The contractor shall not
be paid for any extra thickness of plaster than as specified.
In case of sand-faced and rough cast plaster, specific instructions in the

specification of the same shall be followed for coats and finishing techniques. In
case of neat cement and neeru finish plaster specific instructions in the
specification of the same shall be followed.
Any cracks which appear in the surface and all portions which sound hollow when
tapped or are found to be soft or other defects shall be cut out in rectangular
shape and redone as directed to match smooth and even with the original surface.
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3.6.4 Curing
Curing shall start 24 hours after the plaster is laid. It shall be kept wet for 7 days.
During this period it shall be suitably protected from all damages at the
contractor’s expense as directed.
3.6.5 Scaffolding
As described in brick masonry work.
3.6.6 13 mm Neeru Cement Finished Plaster in CM as specified

Plaster shall be smooth finished with neat cement slurry.
3.6.7 13mm Neeru Plaster in CM 1:4
After completion of plaster for the panel in hand. Neeru shall be applied as given
below:
1. Preparation
Fat lime of best quality shall be slaked and mixed with sufficient water to form
a thick paste. It shall then be passed through a fine 3 mm mesh to remove
all unslaked particles and foreign matter and allowed to mellow under water
for atleast 10 days. The surplus water on top shall then be allowed to run off
and the top layer of lime formed into putty shall be skimmed off and well
mixed sand and jute. The proportion of sand shall be of 1 cu.m. fine washed
sand (passing through I.S. sieve No.60) to 4 cu.m. of lime putty. The jute
shall be finely chopped and shall be used in the proportion of 1 kg. per cu.m.
of mortar.
2. The mixture shall be properly ground to fine paste between two stones or in a
mill. The ‘neeru’ thus prepared shall be kept moist until used and no more
than what can be consumed in 15 days shall be prepared at a time.
3. The ‘Neeru’ as prepared above shall be applied to the prepared surface with
a steel trowel to a thickness not exceeding 3 mm and rubbed and polished to
perfectly smooth and even finish working from top to bottom. While
trowelling is going on, soap stone powder contained in thin muslim bags shall
be dusted over the surface and worked in.
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4. Ready mix Neeru, if used, shall be obtained from approved manufacturer. A

sample plaster finish shall be carried out at site and approved by Engineer
prior to ordering the material at site. Manufacturer’s instructions shall be
followed in the sample as well as in the actual work.
3.6.8 13 mm Water-proof Plaster in CM 1:4
Water proof-cement plaster shall be specified herein before for cement plaster work
except for the following.
In the preparation of cement and sand mortar, cement shall be mixed with 2%
approved waterproofing compound or as per manufacturer’s instructions and as
directly by the Engineer.
3.6.9 20 mm Sand-face Plaster

Sand face plaster shall consist of two layers. The first layer shall be generally 12 mm
average thick cement plaster with cement sand of 1:4 mix (1 cement : 4 sand) and
shall be rough finished carried out by wire brush scarifying on wet plaster. Over this a
second layer, average 8 mm thick, of cement sand plaster in the proportion of 1:2 mix
shall be applied. The second layer of plaster shall be laid only after the first layer has
sufficiently dried. The surface of the sand face plaster shall be finished rough with
sponge or as directed by the Engineer.
3.6.10 Rough Cast Cement Plaster

The cement shall be thoroughly mixed with sand and gravel in the proportion of 1
cement : 2 sand : 1 aggregate. The gravel shall be of a size passing through 6 mm
mesh but retained completely on 2 mm mesh. The constituents shall be thoroughly
mixed dry until the mix is homogeneous. Water shall then be added gradually to the
required extent and the material turned over sufficiently to give a homogeneous mass
of uniform colour. Mortar shall be applied to the wall in 2 coats with force to a
thickness of 20 mm and finished to a uniform surface. No more mortar shall be
prepared than can be used up with half an hour.
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3.7 POINTING
3.7.1 Scope
Work includes providing, mixing CM 1:3 and applying cement pointing on masonry
surfaces indicated in the item, including all materials, labour, plants, tools, equipment,
scaffolding racking etc. required to complete the job in all respects.
3.7.2 Type of pointing

Pointing shall be of the type specified such as “flush”, “recessed” (weathered, keyed,
ruled etc.), “tuck” etc.
3.7.3 Preparation of surface

All joints in masonry shall be raked out at least 12 mm deep when the mortar is firm
but not wet. The joints shall be brushed clean of dust with wire brush and wetted
thoroughly for 6 hours before pointing is commenced.
3.7.4 Application & Finishing

The mortar shall be pressed into raked out joints with a point trowel and finished
either flush, sunk or raised according to type of pointing specified in the drawings or
as directed. The superfluous mortar shall be cut off from the edges of the lines and
the surfaces of masonry shall be cleaned of all mortar. Finish shall be free of slick
spots, cut faces and other blemishes.
Finished work of pointing shall be to exact size and shape stipulated with edges
straight, neat and clean. No smearing of cement mortar shall be allowed and the
entire work shall be carried out in most workmanlike manner.
3.8 Drip Mould

Drip mould shall be provided on underside and not more than 50 mm from outer edge
in chajjas and projection of roof slab and at places indicated by the Engineer and
shall be of minimum 10 mm in depth and 20 mm in width and well rounded from
either in plaster or concrete while casing. It shall be neat finished. The size and
shape shall have to be approved by the Engineer.
3.9 Damp Proof Course

Unless otherwise specified Damp-proof course shall be 40 mm thick ‘artificial stone’
in proportion 1:1½3 cement, sand, stone chips (10 mm down) with admixture of a
waterproofing compound as approved by the Engineer.
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3.10 Mode of Measurement
1. Brick and stone Masonry shall be measured on Cu.m. basis. The rate shall
be inclusive of material supply, labour, tools and tackles, raking of joints,
providing recesses and openings, embedding fixtures, laying, curing, double
scaffolding, cleaning area etc. complete including all taxes and levies.
2. Brick work in partition walls will be measured on sq.m. basis. The area will
be inclusive of material supply, labour, tools and tackles, laying, providing
R.C. band as specified, curing, double scaffolding, cleaning area etc.
complete and including all taxes and levies. Providing and laying
reinforcement shall be measured and paid separately.
3. Plastering
The payment for plastering shall be made on square metre basis. Deduction
shall not be made for opening less than 0.5 sq.m. and Jambs, sills and soffits
etc. shall not be measured. For opening of area between 0.5 sq.m. and 3.0
sq.m. each, deduction shall be made at 50% of the opening area and no
payment made jambs, soffits, sills, etc. For opening of area above 3 sq.m.
each, deduction shall be made for full area of opening but jambs, soffits, and
sills shall be measured. All measurements shall be separately made for
each face. The rate shall include the cost of scaffolding and swing needed
for the work with labour and materials and all complete including all taxes
and levies.
4. Pointing
The payment shall be made on sq.m. basis. Deductions for voids shall be as
per plastering item. The rate shall include cost of all materials, labour,
scaffolding, curing, cleaning the masonry faces etc. complete.
5. Damp proof course
The payment shall be made on sq.m. basis inclusive of all materials, labour,
shuttering if required.
END
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Uhde India Limited FLOORING / DADO Page :1
Contents Page
APPLICABLE CODES AND SPECIFICATION 2
IPS FLOORING 2
ABRASION RESISTANT FLOORS 3
TERRAZO TILE FLOORING 4
PVC TILE FLOORING 6
GLAZE TILE FLOORING 7
KOTA STONE FLOORING 8
TREMIX CONCRETE 8
MAGNESIUM OXYCHLORIDE FLOOR 13
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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5.1 APPLICABLE CODES AND SPECIFICATIONS
The following codes, standards and specifications are made a part of this
specification. All standards, specifications, codes of practices referred to herein
shall be the latest edition including all applicable official amendments and
revisions.
In case of discrepancy between this specification and those referred to herein,

this specification shall govern.
1) IS:777 - Glazed Earthenware tiles.
2) IS:2114 - Code of Practice for laying in situ terrazzo floor finish.
3) IS:2571 - Code of Practice for laying in situ concrete flooring.
4) IS:4860 - Specification for acid resistant bricks
5) IS:5491 - Code of Practice for laying in siitu granolithic floor topping
5.2 Granolithic (IPS) Flooring
Granolithic finish of the thickness as indicated in drawings or as specified in

schedule of items shall consist of 2 layers of M-15/M-20 grade (as in B.O.Q.)
cement concrete. The first layer of machine mixed concrete of 30 mm thick shall
be laid with 10 mm to 6 mm graded aggregate and well compacted. Within 15
minutes of laying this course, the second layer of minimum 10 mm thk. with 6
mm down aggregate shall be laid. the cement and aggregates for the top layer
shall be mixed dry. After mixing, sufficient quantity of washed sand and water
shall be added to make the mix plastic but not flowing. The mixtures shall be laid
on the under-layer so that the two layers firmly grip together. The top layer shall
be well tampered, trowelled and finished with a neat cement punning or with non-
skid finish as required. At the junction of adjoining panels a thin string shall be
given.
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The castings of the granolithic finish layer shall be done in rectangular or square
panels not exceeding 1.2m on any side, using wooden strips of height equal to
the specified thickness of the floor finish. Required slope in the floor shall be
given in the base course concrete without reduction in thickness. The work shall
be in true plumb free from any unevenness, cracks, etc. Curing shall be done for
a period of 7 days by ponding the finished area.
5.3 Abrasion Resistant Floors.
5.3.1 Floors using metallic Hardeners.
Unless otherwise specified one part of Ironite and four parts of ordinary portland
cement by weight shall be mixed dry thoroughly on a clean and dry platform.
This dry mixture shall be mixed with stone grit 6 mm and down size in the ratio of
1:2 (1 Ironite cement mixture:2 stone grit) by volume and well mixed over, just
enough water shall be added to this dry mix before laying.
Laying
Over first layer of 38 mm thick M-15/M-20 grade (as in B.O.Q.) concrete 12 mm

thick Ironite topping shall be laid. The topping shall be laid true to line to provide
uniform and even surface. It shall be firmly pressed into bottom concrete so as to
have a good bond with it. After the starting of initial setting the surface shall be
finished smooth and true with steel floats. The laying as usual shall be done in
rectangular or square panels, using wooden strips of height equal to the specified
thickness of the floor finish. No dimension of a panel shall exceed 2M and the
area of panel shall not be more than 2 sq.m.
Curing shall be done for period of 7 days by ponding the finished area.
5.3.2 Floors using Non metallic Hardener
5.3.2.1 Where ever industrial flooring using non metallic hardner is specified, the same
shall essentially composed of thermo setting polymers reinforced with minerals
and fibres suitably coupled and compounded with organo functional sealants.
(Refer to Data Sheet ‘B’ for recommended Vendor / brand information).
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5.3.2.2 Laying
The standard thickness shall be 12.mm 15mm, and 20mm. The thermal rating
shall be 60°C continuous with max. permissible operating temperature of 110°C.
The material chosen shall withstand acidic, alkaline or a combination of acidic &
alkaline conditions and shall be laid as per manufactures specification.
5.3.2.3 Physical properties:
Typical physical properties of the material used shall be as per following details:
Compressive strength = 1100 to 1500 kg/cm sq.

Tensile strength = 220 to 350 "
Coeff of thermal = 0.8 to 2 Kcal/mh °.c
Conductivity
Imperviousness = 0.05
Laboratory or field tests in order to check conformity with above specifications, if

ordered by the Engineer, shall be performed by the Contractor without any extra
payment.
5.4 Terrazzo (Mosaic) Tile flooring
Terrazzo title shall be 20 mm thick of approved shade, and size, conforming in

all respect to IS:1237. (Refer to Data Sheet ‘B’ for Vendor / brand information).
Laying
The bedding for the tiles shall be of cement mortar 1:3 (1 cement : 3 sand) mix.
The average thickness of bedding mortar shall be 20mm and the thickness at
any place shall not be less than 13 mm. Cement mortar bedding shall be spread,
tamped and corrected to proper levels and allowed to harden for a day before the
tiles are set.
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Over this bedding neat cement slurry of honey like consistency shall be spread at
the rate of 5 kg. of cement per square metre. Tiles shall be soaked in water for
20 minutes and allowed to drain out for 20 minutes before laying. Tiles shall be
laid in the mortar bedding from centre to outwards to obtain a symmetrical
pattern, each tile being gently tapped with wooden mallet till it is properly bedded
and is in level. Laying shall be frequently checked with a straight edge at least 2m
long so as to obtain true surface with required slope. Fractional tiles shall be
used where full tiles cannot be used. If the extra space left out is less than 25mm
it shall be filled with coloured terrazzo to match the tile pattern and finished to
match tiled floor.
Joints.
The joints shall be uniform and as thin as possible and run in straight lines or to
suit the required pattern.
Tiles which are fixed in the floor adjoining the wall shall enter not less than 13mm
under the plaster, skirting or dado. The junction between wall plaster and tile
work shall be finished neatly and without wavings.
After the tiles have been laid, surplus cement grout that may have come out of
the joints shall be cleaned off.
Curing, Polishing and finishing
The day after the tiles are laid, all joints shall be cleaned with wire brush to the
depth of 5mm and all dust and loose mortar removed. Joints shall then be
grouted with grey or white cement, mixed with or without pigment to match the
shade of the topping of the wearing layer of the tiles. Pigment shall conform to
IS:59.
However this may be noted that the properties may vary slightly depending upon
the individual manufactures. Manufacturer's specifications, after prior approval
from Engineer shall be followed.
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The floor shall then be kept wet for minimum period of 7 days. The surface
thereafter be ground evenly to the satisfaction of the engineer with machine
grinders in 3 phase with grade stones from coarse to fine grade. The surface
shall receive wash of neat cement mixed with or without pigment and cured
before every grinding operation. After final polish, surface shall be cleaned and
oxalic acid shall be dusted over the surface @ 35 gms. per sq.m sprinkled with
water and rubbed hard with pad of wooden fags and wiped and dried with soft
cloth. Finally the finished Terrazo surface is to be rendered with turpentine or
similar approved material. The surface after polishing shall be hand polished. In
all other respects the process shall be similar as per machine polishing.
Tests to determine Transverse strength, water absorption, Abrasion etc. may be

ordered by Engineer for checking with IS requirements. Contractor shall perform
all tests without any extra payment.
5.5 PVC TILE FLOORING
PVC (vinyl) tiles shall be 3mm thick. These shall be of approved make
conforming to IS:3461 or 3462.
Laying
A course of approved base binding agent shall be applied evenly over the
bedding which shall be finished even and smooth. The tiles shall be sufficiently
dried before fixing to the floor. The tiles shall be jointed with binding agent. After
allowing it to become sufficiently dry, the tiles shall be pressed down with even
pressure until it adheres well to the bed material. In case the binding agent rises
from the joints it shall be removed. The tile floor shall be cleaned with the tile
finish wax and polished with the muslin cloth. The binding material shall be from
approved manufacturer.
The pattern and colour arrangement for the flooring and dado shall be as
indicated on the drawings or as specified by the Engineer. The contractor shall
assume full responsibility for any failures and defects in the tile finish work.
The tiles shall be laid in accordance with approved manufacturer's directions.
All flooring shall be thoroughly cleaned upto full satisfaction of the Engineer.
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5.6 White/coloured Glazed tiles
Tiles shall conform to IS:777 in all respect and shall be of approved quality and
make.
These shall be flat, true to shape and of uniform shade. These shall also be free
from cracks, spots, chipped edges and corner. Thickness of tiles shall be 6mm,
unless otherwise specifically mentioned in drawings or schedule of items.
Preparation of Surface and Laying
Base course concrete or RCC slab on which tiles are to be laid shall be well
cleaned, wetted and mopped. The bedding for the tiles shall be with cement
mortar 1:3 or as specified. The average thickness of the bedding shall be not
less than 10 mm.
Mortar shall be spread, tamped and corrected to proper levels and allowed to
harden sufficiently to offer a fairly rigid cushion for the tiles to be set and also to
enable the mason to place wooden plank across and to sit on it for the work.
Over this mortar bedding neat grey cement slurry of honey like consistency shall
be spread, at the rate of 3.3 kg per square metre, over and area such that
approximately 20 tiles can be accommodated. Tiles shall be washed cleaned
and fixed on this mortar one after another, each tile being gently tapped with a
wooden mallet till it is properly bedded in level with adjoining tiles.
Joints shall be uniform and as thin as possible.
Curing, Pointing and finishing
The joints shall be cleaned off the grey cement grout with a wire brush or trowel
to a depth of 5 mm and all dust and loose mortar removed. Joints shall then be
pointed with white cement.
Flooring shall be kept wet for 7 days. The tiled surface shall then be finished with
a 3% solution of Oxalic Acid duly waxed and polished as directed by the
Engineer.
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Tests to determine water absorption, crazing, impact strength, chemical

resistance etc. may be ordered by Engineer for checking with IS requirements.
Contractor shall perform all tests without any extra payment.
5.7 Kotah stone flooring:
Kotah stone shall be obtained from reputed suppliers as approved by the

Engineer.
The stone shall have natural split non slip surface and non porous. As the stones
are natural riven material supplies may not be in a particular thickness, The range
of thickness shall be 12-15 mm, 16-24 mm and 25-37 mm. The standard size
shall be 600 mm x 600 mm. The bedding mortar will be either 1:2 cement sand
or chemically resistant mortar as per duty conditions shown on the drawing. The
tiles will have hand pitched edges.
5.8 TREMIX CONCRETE FLOORS.
5.8.1 GENERAL
The contractor shall improve the quality of all concrete floor slabs by placing the
concrete according to the Tremix system as indicated on the contract drawings
and as specified herein.
5.8.2 TECHNICAL ASSISTANCE/TRAINING OF LABOUR
During the placement of concrete, the Contractor shall have a minimum of one
person present at all times who has been adequately trained by a representative
of the equipment and shall direct all concrete dewatering work performed. The
contractor shall provide the services of a representative from the manufacturer of
the vacuum dewatering equipment on site. The manufacturer's representative
shall provide technical assistance for the vacuum dewatering process on the
initial day of operation. (Refer to Data Sheet ‘B’ for Vendor / brand information).
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5.8.3 EQUIPMENT FOR COMPACTING, PLACING, VACUUM

PROCESSING AND FINISHING OF SLAB
All process equipment to be used shall be of proven design, and shall be subject
to the approval of the engineer. Equipment shall be Tremix or approved equal.
The system shall have demonstrated five years history of performing such work.
The vacuum pumps shall be able to generate a minimum vacuum of 609 mm(24
inches) of mercury(0.80 atmospheres) in actual operation using the maximum
number and size of suction mats required for this work.
The contractor shall have at the job site sufficient equipment(vacuum pumps,
mats, filter pads and accessories) to ensure that the vacuum dewatering process
continues uninterrupted till completion.
5.8.4 MIX DESIGN
The contractor will be responsible for the mix design of the class as called for on
the Contract Drawings and must submit the mix proposed for use in the Contract
before any work is started. All mix parameters must conform to the values
specified in Tremix recommendations and preferably be tested with Trevac
Meter.
The contractor shall utilize knowledgeable and experienced concrete technicians

for the design and production of mix mixes meeting all the requirements of the
specifications.
5.8.5 QUALITY CONTROL
The contractor has the responsibility for achieving the quality of concrete
specified by controlling the concrete mixes, placing, vacuum process finishing
and curing. The concrete technician in charge must be present at the site when
work is in progress.
The contractor shall be responsible for mix adjustments, performing necessary

tests, correcting deficiencies and trouble shooting in general.
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The contractor shall be required to maintain control charts showing individual

test results for aggregate gradation, slump, air content, cement content and
compressive strength.
5.8.6 PLANNING OF PLACING
The contractor shall submit for review shop drawings for floor slabs detailing the
location of all construction joints and the sequence of slab placement, and
manufacturer's literature describing the equipment to be used. In addition to the
shop drawings, the Contractor shall indicate the quantity of each dewatering
equipment that will be located at the construction site and shall include the
dimensions of all suction mats.
Before concreting, the work should be planned with a view to determine areas to
be placed daily, the required amount of equipment, size of vacuum mats, length
of vacuum hoses, arrangement of rails, if any, or screeds etc. Placing, vibration,
vacuum treatment and floating to follow immediately behind each other. The
planning shall be approved by the Engineer.
5.8.7 Cement
Portland cement of normal grinding fineness, which corresponds to a specific

surface of 2600 - 3500 cm.sq/g is required in Tremix concrete. Cement of higher
grinding fineness, e.g.rapid-hardening Portland cement of larger specific
surface/g shall be avoided.
5.8.8 EQUIPMENT SPECIFICATION TREMIX SYSTEM
Poker vibrator with frequency preferably 335 hz(20,000 vibr/min) dia. 25 to

40mm.
Surface vibrator type double beam with beam spacing 300 mm.
Preferably one piece beam in full length exceeding bay width within 20 to 60cm.
Beam should easily be adjusted to absolute straightness and controlled every
morning before placing of concrete starts.
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Suction mat 100% light plastic material weight 650 gram/sq.m. Width same as
bay size and length 6 M for capacity and flexibility.
Filter pad weight 600 g/sq.m. width 1.2 M, length-bay width minus 20 cm.
Vacuum pump with 10 HP engine and specially designed pump unit with heavy
duty chrome housing and sealing, Adjustable vacuum by valve on top of tank for
ease of operation with different mix designs.
Skimfloater with disc which allows direct floating of dewatered concrete. Weight
maximum 90 kg for 1000 mm. Finishing is done with blades only and is normally
done with 30 minutes intervals between passes.
The above equipment specified should be used for the production of quality
concrete floors according to the Tremix System. Interchangeability of equipment
is not recommended.
5.8.9 EXECUTION TREMIX SYSTEM
5.8.9.1 General
The work shall be planned and executed so that there is no delay between the
placement, screeding, dewatering and floating of the concrete. Concrete to be
vacuum dewatered shall be handled and placed so as to prevent segregation.
The concrete shall be properly vibrated prior to screeding.
5.8.9.2 Levelling
Immediately following placement, the concrete shall be levelled with a vibrating

screed running on a true surface, set at the proper elevation required to provide
the specified finished elevation. The concrete surface shall be screeded high by
2% of the slab's thickness to compensate for the compaction caused by the
vacuum dewatering process. The vibrating screed shall be moved forward as
rapidly as proper consolidation allows. The proper surcharge of concrete must
be maintained in front of the leading edge of the screed.
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5.8.9.3 Vacuum
Immediately after levelling, the concrete shall be covered with filter pads and
suction mats in strict accordance with the recommendation of the manufacturer
to have slab fully dewatered. The suction mat shall extend 10 cm beyond the
edge of the filter pad on all sides. The pads shall extend to within 10 cm of the
edge of concrete slab, and the mats shall cover entire slab. Before connecting
the hose on the suction mat to the vacuum pump, the edges of the mat shall be
smoothed to enable an airtight seal to be created. Vacuum shall then be applied
to the mat.
The vacuum shall be maintained for at least 12 minutes per 10 cm of concrete

thickness at 0.80 atmospheres. (Where aggregate hardeners are specified,
sufficient moisture shall be maintained to meet manufacturer's requirements).
The suction mats and filter pads shall then be removed and moved to the next
section in a leapfrog manner.
Stop the vacuum dewatering when light foot prints only are left in the concrete
when stepped upon. A suitable suction time can also be checked with a Proctor-
apparatus which should show 1.5-2 kg/sq.cm pressure.
5.8.10 Floating
Upon removal of the suction mats and filter pads the concrete surface shall be
power-floated without delay until all imprints from the vacuum process are
removed. If crusting occurs, the floating operation must be delayed.
Higher speed is recommended for the floating operation. Two passes with the
floating disc should be made in the junction of two mats in order to avoid risk for
cracking.
5.8.11 Finishing
The waiting time after the floating operation depends on concrete temperature
and humidity and varies from 10 minutes to 2 hours.
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The trowelling operation should not take place before the concrete has hardened
enough to carry the machine. i.e the trowelling blades will not leave any marks on
the concrete. Repeated trowelling, with intervals between the passes should be
adopted.
At least two passes are recommended for floors which are not to be covered.
5.8.12 Curing
Vacuum dewatered concrete should be cured like any other quality concrete in
order to achieve a good final result. Use curing compounds, plastic sheets or wet
burlap.
5.9 Magnesium Oxychloride Floors
5.9.1 Magnesium oxychloride flooring shall be laid generally as per recommendation of

IS:657 and IS:658.
5.9.2 Application
Preparation of the base shall be sound, rigid, free from rising damp and not
unduly porous. The base may be of cement concrete, or timber. Highly
absorbent materials such as pumice concrete, breeze or clinker concrete and
aerated concrete shall not be used unless a layer of damp proof course is laid
between the base and the main floor.
New cement concrete Base

The base or screed should have a true and even surface which has been slightly
coarsened by means of a stiff broom or wire brush and should be free from
ridges and hollows. A steel trowelled finish is not desirable.
The levels of the base should be such that the specified thickness of magnesium
oxychloride can be applied uniformly. It is of particular importance to ensure that
there is a minimum cover of at least 25 mm of impervious uncracked dense
concrete or a screeded bed over any base containing reinforcement either as
rods or in filler joints. Any magnesium chloride solution gaining access to the
reinforcement may cause serious damage. New concrete to which oxychloride
composition is to be applied directly should be allowed to age for at least 28 days
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before the application of oxychloride composition. No hardening agent other

than water shall be used in the concrete. No lime admixture shall be allowed in
the concrete where oxychloride is to be applied directly to the concrete.
Existing concrete Base
This should be checked for absorption. The existing cement concrete base
should be roughened to suitable degree by tooth chiselling, picking or by any
other suitable process before oxychloride composition is laid.
Timber base
A suitable mechanical key should be provided between the timber base and the
floor finish such as dove tailed wooden battens or galvanised wire nettintg firmly
secured to the base at approximately 200 m centres with galvanised clout nails
driven home at joints of the mesh. An equal number of galvanised clout nails
should be used at 200 mm centres and be left proud of the base.
The moisture content of the timber base shall not exceed the limits specified for
the corresponding zones given in IS:287.
5.9.3 Preparation of Floor Finish Mixture

Magnesium Chloride Solution – Magnesium chloride both before and after it has
been dissolved should not be allowed to come into contact with any floors or
walls. Whenever possible, the work of breaking up and dissolving the solid
material or diluting the solution should be performed outside the building. Where
the work has to be done inside, adequate protection should be provided under
and around all vessels containing the chloride by means of tarpaulins, trays or
other suitable devices. The solid chloride should be broken up and dissolved in a
watertight vessel by covering the same with clean water, that is, clean and free
from deleterious acids, alkalies, salts organic material and stirring the same from
time to time. The solution should be allowed to stand over night so that residue,
dust, impurities, etc. may settle to the bottom. The clean concentrated solution
should be well stirred after each dilution before determining the specific gravity.
The solution shall be prepared sufficiently early so that it is cooled to room
temperature before use. The specific gravity of the chloride solution should be
maintained at a selected value within the limits in Table 1. This value will depend
on the type of work, the nature of the base and ambient temperature conditions.
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TABLE 1 : SPECIFIC GRAVITY OF MAGNESIUM CHLORIDE SOLUTION
Flooring finish mix (1) Baume (be)-conc. Scale (2) Specific gravity (3)
Single coat and top 20° to 24° 1.16 to 1.20
coat
Bottom coat, loves and 18° to 20° 1.14 to 1.16
Skirtings
5.9.4 Final mixing

The mixing of the chloride solution with the dry mix should be carried out in
trough or box or on a bunker and in no case directly on the floor. The quantity of
material mixed in any one batch should be such as can be laid easily before initial
set begins. The addition of further quantities of chloride solution during laying
should not be permitted. If the mix becomes too stiff to be worked, it should be
discarded.
5.9.5 Laying the Floor Finish

If the floor finish is to be laid on a concrete base, this should be thoroughly dry
before commencement of laying.
The floor finish should not be laid over or near any localised source of heat.
Size of Bay
The floor finish should be laid between battens trued and levelled to ensure that
the thickness of each coat complies with the requirements. The optimum size of
bay will depend upon the temperature conditions at the time of laying and,
generally, the controlling factor would be the time taken to obtain adequate
compaction of the floor finish.
Jointing
Where a dimension of floor surface in either direction is 7.5 M or more, joint shall
be provided at interval of not more than 5M. These may be in the form of mastic
insertions or may consist of strips 5 mm in width of hard wood, vulcanite,
nonferrous metal or other suitable material bedded flush with the surface of the
flooring materials. Where the flooring is laid over concrete sub-floor, it is
important that any joint in the flooring should be made not to coincide with joint in
the sub-floor.
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Laying
A concrete base or screed should be damped before laying the floor, finish, but
excessive wetting or flooding should be avoided. The damping should be carried
out with either:
a) A solution of magnesium chloride which should be not weaker than 12° –
nor stronger than 14°C or
b) A wash composed of a 14°C. Magnesium chloride solution and magnesia
mixed to the consistency of cream and brushed over the base.
5.9.6 Curing
Rapid drying of the floor finish should be avoided for atleast the first 24 hours
after laying . It should be allowed to set and harden, undisturbed for at least
three days before being opened to traffic. The setting and hardening process is
affected by the surrounding temperature conditions and in cold weather it may be
advisable to allow a longer period before the floor is put into use. In any case,
some weeks should necessarily elapse before the floor finish is fully dried and
hardened and, for this reason, it should not be exposed to abnormally havy traffic
during this period.
Protection of the Surface
During laying and until the floor finish has hardened, It should not be exposed to
extremes of heat or cold. The surface should be protected from the direct rays of
the sun and rain.
5.9.7 Magnesium Chloride
5.9.8 Chemical Requirements
The composition of calcined magnesite when tested in accordance with the

method given in IS:10032 shall be as specified in Table 2
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TABLE 2 : CHEMICAL REQUIREMENTS OF CALCINED MAGNESITE
Sr. No. Characteristic Requirements

(1) (2) (3)
i) Magnesium oxide (Mgo) percent by mass 87 Min.

ii) Calcium oxide (CaO), percent by mass 2.5 max.
iii) Carbon dioxide (Co2), percent by mass 2.5 max.
iv) Loss on ignition (Carbon dioxide and water), 8 max.
percent by mass.
v) Total contents of MgO, CaO, Al2O3, SiO2 99.5 min.
and loss on ignition, percent by mass.
5.9.9 Physical requirements
The physical requirements of calcined magnesite when tested in accordance with

the method given in IS:10032 shall be as specified in Table 3.
TABLE 3 : PHYSICAL REQUIREMENTS OF CALCINED MAGNESITE
Sr. No. Characteristic Requirements

(1) (2) (3)
1 Bulk density, Kg/1 0.65 to 0.85
2 Fineness
a) Percent by mass passing through 97 (min).
150 micron IS Sieve.
b) Percent by mass passing through 75 95 (min).
micron IS Sieve.
3 Setting time, hours
a) Initial 3 to 6 hrs.
b) Final 7 to 15 hrs.
4 Modules of rupture N/sq.m.
At 7 days 7 (min).
At 28 days 10.5 (min).
5 Linear change, percent :
The average change in length
Duration expansion 0.15 (max).
Duration contraction 0.25 (max).
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5.10 MODE OF MEASUREMENT (IS:1200)

5.10.1 Flooring and Dado finishes
The payment shall be made on sq.m. basis of finished area. The rate shall include
all materials, labour, tools and tackles, curing, cleaning, wastages etc. complete as
specified.
5.10.2 Skirting
The payment shall be in RM basis. The rate shall include all materials, labour,
curing etc. complete as specified.
END
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Uhde India Limited DOORS, WINDOWS & PARTITIONS Page :1
Contents Page
SCOPE 2
APPLICABLE CODES AND SPECIFICATIONS 2
WOODWORK IN DOORS AND WINDOWS 3
STEEL, ALUMINIUM DOORS & WINDOWS 5
AIR TIGHT & SOUND INSULATED DOORS 6
FIRE RESISTANT DOORS 6
BLAST PROOF DOORS 6
FABRICATION 7
ROLLING SHUTTER 11
HANDLING & STORAGE OF FABRICATED MATERIALS 12
ASSEMBLY & ERECTION 12
ACCEPTANCE CRITERIA 13
GLASS & GLAZING 15
METHOD OF MEASUREMENT 18
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03

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6.1 SCOPE
The work in general shall consist of supplying assembling and/or erecting and
installing of all doors, windows, ventilators, louvers, rolling shutters, glazed
partitions, etc. as shown on drawings with all materials complete including supply
and fixing of glass and glazing.
6.2 APPLICABLE CODES AND SPECIFICATIONS:
The following codes, standards and specifications are a part of this specification.
All standards, tentative specification, specifications, codes of practices referred to
herein shall be the latest edition including all applicable official amendments and
revisions.
In case of discrepancy between this specification and those mentioned elsewhere,

this specification shall prevail.
IS : 4021 - Timber doors, window and ventilator frames.
IS : 2202 - Wooden flush door shutters (Solid core Type)

(Part I & II)
IS : 1003 - Timber panelled and glazed shutters.
(Part I & II)
IS:4020 - Methods of tests for wooden flush doors: Type tests.

IS:2835 - Flat Transparent sheet glass
IS:4351 - Steel door frames
IS:1038 - Steel doors, windows and ventilators
IS:1361 - Steel windows for industrial buildings
IS:1081 - Code of practice for fixing and glazing of metal (Steel and
aluminium) doors, windows and ventilators.
IS:5807 - Method of test for clear finishes for wooden furniture (Part I &
III)
IS:1477 - Code of practice for painting of ferrous metals in buildings and
allied finishes (Part I & III)
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IS:2338 - Code of practice for finishing of wood and wood-based

materials (Part I)
IS:1948 - Aluminium doors, windows and ventilators
IS:1949 - Aluminium windows for industrial buildings

IS:3548 - Code of practice for glazing in buildings
IS:6248 - Metal Rolling Shutters and Rolling grills
6.3 INSTALLATION
6.3.1 Materials:
6.3.1.1 Woodwork in doors & windows:
Wood used for all work shall be the best of the respective class specified, and
properly seasoned by at least 6 months air drying, suitable for joiner's work,
should be of natural growth, uniform in texture, straight grained, free from
sapwood, dead knots, open shakes, boreholes, rot, decay and any and all other
defects and blemishes.
The thickness specified for joiner's wrought timbers are, unless otherwise
specified, values prior to planning and 3 mm will be allowed from the thickness
stated for each wrought face.
All joints shall be wrought on all faces and finished off by hand with sand paper,
with slightly rounded corners.
The joints shall be pinned with hard wood pins and put together with white lead.
Jointing shall be by means of mortice and tenon or dovetailed joints as approved.
Any joiner's work which shall split, fracture, shrink, or show flaws or other defects
due to unsoundness, inadequate seasoning or workmanship, shall be removed
and replaced with sound material at the CONTRACTOR's expense.
Doors, windows and ventilator frames, transomes and mullions shall rebated. All
dimensions shall be as per drawings. The top framing member of doors and top
and bottom framing of windows and ventilators shall be embedded 150mm in brick
work. The verticals of door frames shall be embedded 50mm below finished floor.
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Surface coming in contact with brick / concrete work shall be painted with bitumen
as directed by the Engineer. Each of the door and window frames shall be
provided with 3 Nos. M.S. 25x6 flat split, 225 mm long holdfasts with split ends
and these shall be embedded in masonry or concrete work. Each of the window
frames shall be provided with 2 Nos. 25 x 6 flat, 150 mm long holdfasts with split
ends. The work shall conform to IS : 4021.
The doors shall be panelled or solid flush doors as described in the item of work.
All flush doors shall be supplied with approved fittings such as hinges, mortice lock
of approved make with handles on both sides, oxidized brass tower bolts and latch
arrangements, door stops etc. as shown in drawings but exclusive of door
closures. Door closers, where separately specified shall be of heavy duty
hydraulic type to be approved by Engineer. Panelled doors shall have the same
fittings except that in place of union lock, aldrop shall be provided. Each door leaf
shall have two 250 mm tower bolts, two aluminium or oxidized brass handles, and
one door stopper mounted near the bottom of door. External flush doors shall be
made of weatherproof plywood. Flush doors shall conform to IS:2202 (Part - I)
(Refer to Data Sheet ‘B’ for recommended vendor / brand information).
Doors will generally have no sills but if a few have to be provided, the Contractor
shall do so at no extra cost to the Owner.
The type of window shall be as specified. Each shutter shall have one pair of
hinges, two tower bolts one 225 mm long and another 150 mm long, one handle
and one hook with eye and pegstay. Ventilators shall have two m.s. hold fasts and
hinges, one handle and one hook and eye at each end and one small tower bolt in
the centre. Where so directed by the Engineer, the doors and windows shall be
provided with parliamentary type hinges at no extra cost.
The workmanship of all door and window shutters shall conform to the
requirements of IS:1003 (Part I & II) and IS:2202 (Part I). If required, flush door
panels shall be got tested as per IS:4020.
The finish expected is of a very high order and the work shall be all inclusive
whether or not all detailed specifications have been spelt out and the work shall be
free from blemish.
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No iron bars or grills are proposed to be provided in the windows or ventilators.

Glass louvered ventilators where specified shall be provided.
Woodwork shall not be painted, oiled or otherwise treated before it has been
approved by the Engineer.
6.3.1.2 Steel doors & windows and aluminium doors & windows
Steel section used for fabrication of doors, windows etc. shall be standard rolled
steel sections specified in IS : 1038 and IS : 1361 or as specified in drawing and
schedules.
Steel sheets for frames, shutters, louvers blades etc. shall be of a gauge
mentioned in drawings and schedules.
Aluminium sections for fabricating doors, windows, partitions etc. shall be

extruded sections conforming to IS : 1948 and 1949 or as manufactured by
approved manufacturer. (Refer Data Sheet ‘B’ for recommended vendor / brand
information). The alloy used shall conform to IS Designation HE 9-WP of IS : 733.
Hardware and fixtures shall be as specified in "Schedule of Fixtures" and the best
quality from approved manufacturers (Refer to Data Sheet ‘B’ for recommended
vendor / brand information) shall only be used. The tenderer shall specifically
state the particular manufacturer's material he proposes to use. "Schedule of
Fixtures" is for the purpose of stating the minimum requirement and improper
alignment or faulty operation due to inadequate strength of hardware or fixture
shall entirely be the Contractor's responsibility. All hardware and fixtures shall be
able to withstand repeated use. Door closers shall conform to IS : 3564 and shall
be suitable for doors weighing 61-80 kg. unless otherwise stated in schedule.
Each closer shall be guaranteed against manufacturing defect for one year and
any defect found within this period shall be rectified or the closer replaced free of
charge. Concealed door closers shall be either floor mounted or transom
mounted, and suitable for installation with metal doors. It shall conform to the
performance requirements and endurance test stated in IS : 3564 - Appendix A.
The contractor shall submit samples of each type of hardware to the Engineer.
The approved samples shall be retained by the Engineer for comparison of bulk
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supply. The samples shall be returned to the Contractor towards the end for
incorporation in the job.
The mastic for caulking shall be of best quality from a manufacturer approved by
the Engineer. In general, the mastic for fixing of metal frames shall be as per
IS:1081 and/or as approved by the Engineer.
6.3.1.3 Air tight and sound insulated doors.
The air tight and sound insulated doors shall be supplied by manufacturers (Refer
to Data Sheet ‘B’ for recommended vendor / brand information). The doors shall
be made from 16 g.MS sheets sandwiched with 50 mm thick insulation. Sturdy
hinges of shaft and barrel type shall be provided to withstand heavy and repeated
industrial use. Sealing gasket shall be provided all round the door frame. The
arrangement of the gasket shall be such as to allow easy replacement. The
handles shall be made of brass and chromium plated. The design of handles shall
be such as to ensure effective sealing. Alternatively design drawings will be
furnished by UIL for the supply, fabrication, erecting and fixing the door.
6.3.1.4 Fire resistant doors.
The fire resistant doors shall be plate type, complete with door frames etc. made
with 6 mm thick MS plate, angles & flats. Styles shall be rivetted. These doors
shall be supplied by approved manufacturer and shal lbe as per IS:3614 (Part I).
Alternatively design drawings will be furnished by UIL for the supply, fabrication,
erecting and fixing the door.
6.3.1.5 Blast proof doors.
The blast proof shall be specifically designed to resist, the design blast pressure.
These shall be plate type made from 6 mm thick (min.) MS plates. Hollow MS,
Rolled Sections or 'Z' Sections shall be used as stiffners. Hinges shall be made
from roller thrust bearings. The contractor shall furnish the detailed drawings to
the Engineer for approval. Alternatively design drawings will be furnished by UIL.
The contractor shall supply / erect / fix in position including all fittings.
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6.3.2 Fabrication:
6.3.2.1 Steel Doors, Windows, Ventilators, Louvers etc. :
a) Door Frames:
Frames shall be fabricated from 16g sheets. They shall be mortised,

reinforced, drilled and tapped for hinges and lock and bolt strikes. Where
necessary, frames shall be reinforced for door closers, Welded
construction with mitered corners shall be used. Rubber door silencers
shall be furnished for the striking jamb. Loose "T" masonry anchors shall
be provided.
Frames shall finish flush with floor and adjustable floor anchors shall be
supplied. Frames shall be brought to site with floor ties/weather bars
installed in place.
b) Double Plate Flush Door Shutters:
Door shutters shall be 45mm thick, completely flush design and shall
comprise of two outer 18G steel sheets, rigidly connected and reinforced
inside with continuous vertical 20G stiffeners, spot welded in position at not
more than 150mm on centres.
c. Sliding doors:
Shall be either double plate or single plate construction as called for in

drawings and schedules made out of 18 gauge steel sheets with adequate
stiffeners. The Contractor shall specify the weight of the door in his shop
drawing and submit the manufacturer's catalogue of the sliding gear he
proposes to use. Where shown on drawings or called for in the Schedule
of Items, the Contractor shall make provisions for openings in the door for
monorail beams etc. Doors shall close positively to exclude rain water from
seeping in. When called for in schedule, sliding doors shall withstand
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specified wind loads without buckling of jamming. The door shall slide
freely under all ambient conditions.
d) Door Threshold:
Door thresholds shall be provided as shown on drawing. Door without

threshold shall have bottom tie of approved type.
e) Steel Windows, Sashes, Ventilators etc.
These shall conform in all respects to IS:1038 and IS:1361 latest editions
and as shown on drawings. The details as called for in the above codes
shall be applicable for coupling mullions, transoms, weather bars, pivot
arrangements for ventilators, etc. or as shown on drawings or called for in
the Schedule of Items.
All welds shall be dressed flush on all exposed and contact surfaces.
Where composite unit openings are shown on drawings, the individual

window units shall be joined together with requisite transoms and mullions
as shown on drawings. All windows shall be outside glazed, fixed with
putty or metal glazing beads as shown on drawings and/or specified under
Schedule of Items.
Where aluminium glazing beads are specified, they shall be extruded

aluminium channel 9.5 mm x 9.5 mm x 1.6 mm (Indian Section No. 2209)
unless otherwise shown on drawings. Aluminium beads shall be given one
coat of zinc chromate primer before fixing to windows. Both edges of
doors shall be jointed and reinforced full height by steel channels placed
immediately inside and welded to the door faces. Top and Bottom of doors
shall be reinforced horizontally as shown on drawing by steel channels
running full width of door. Doors shall not have more than 2.5 mm
clearance at jambs and heads shall have proper bevel on lock stiles and
rails to operate without binding, and shall be reinforced at corners to
prevent sagging or twisting. Pairs or double doors shall have meeting stile
edges bevelled or rebated. Where shown or drawing, or called for in the
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schedule of items, the doors shall be sound insulated by filling the inside
voids with mineral wool or other suitable approved materials.
Doors shall be morticed, reinforced, drilled and tapped in shop for hinges,
hooks and bolts. They shall also be reinforced for closers, push plates and
other surface hardware where necessary. Any drilling and tapping required
for surface hardware shall be done at site. Where shown in drawing,
provision shall be made for fixing glazing, vision panels, louvers etc.
Glazing mouldings shall be of 18g steel or extruded aluminium sections
with profiles shown in drawing and suitable for fixing glass. Louvers blades
shall be V or Z shaped and made out of 16g sheets.
f) Single Sheet Door Shutters :
Single sheet doors shall be made from best quality 18g mild steel sheets,
and shall present a flush surface on the outside. The inside shall be
stiffened with semitubular edge and central stiffening rail which shall hold
the lock and other furniture. The frames shall be made from best quality
16g mild steel sheets.
Wherever required as shown on drawing, provisions for fixing glass panes,

louvers etc. shall be made.
The manufacturing shall be done as specified in (e) "Double Plate Flush

door shutters".
6.3.2.2 Aluminium Doors, Windows and Frames:
Extruded sections shall have a minimum 3mm wall thickness. All sections shall be
approved by the Engineer before fabrication is taken up. Doors, frames mullions,
transomes etc. shall be anodized in bath of sulphuric acid to provide a clear
coating. The anodized materials shall then be sealed by immersing in boiling
water for 15 minutes. A protective transparent coating shall be applied to the
sections before shipment from the factory.
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All work shall be fitted and shop assembled to a first class job, and ready for
erection. Shop joints shall be made to hair lines and then welded or braced by
such method as will produce a uniform colour throughout the work. Work on the
above, other than described, shall be carefully fitted and assembled with neat
joints with concealed fasteners. Whenever possible, joints shall be made in
concealed locations and on edges of doors. Field connections of all work may be
made with concealed screws or other approved type of fasteners. Glazing beads
shall be snap fit type without visible screws and shall be of sizes to accommodate
6mm thick glazing. All work shall be adequately braced and reinforced as
necessary for strength and rigidity.
6.3.2.3 Aluminium Partitions
Aluminium partitions shall be made out of framing and adequate stiffeners of

standard Aluminium sections of approved make, heavy or medium duty
conforming to IS:733 IS:1285, having 3 mm minimum wall thickness. The
aluminium sections shall be anodised in natural matt finish and thickness of
anodic film shall be 15 microns (± 3 microns). The top portion of the partition shall
be fitted with 4/5.5 mm thick clear transparent or translucent sheet glass with
ethylene / propylene / rubber / PVC gaskets. The bottom portion shall be of
panels of double aluminium sheeting, suitably framed with the interspace being
filled with thermal / sound insulation. Sliding / hinged openable shutters with
glazing at top shall be provided as required and all work shall be carried out as
detailed in drawings.
6.3.2.4 PVC Partitions

Partitions shall have robust frames and stiffeners all of plastic made out of UV-
stabilised special compounds / grades of PVC of approved make, reinforced with
steel sections concealed inside the cavity of PVC sections with EDPM weather
sealing strips, along with fixed PVC sheets and sliding / (brass) hinged openable
PVC shutters with or without glazing at top. PVC partitions including doors shall
be obtained from reputed and approved manufacture.
6.3.2.5 FRP door shutters

Fibre Glass Reinforced Plastic (FRP) door shutters shall be obtained from reputed
and approved manufacturer. The door shutters shall exhibit qualities of being
waterproof, weatherproof, chemical resistant, abrasion resistant, light weight, non-
porous and U.V. stabilised.
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6.3.2.6 Rolling Shutters:
Rolling shutters shall conform to IS:6248.
Rolling shutter shall be of the size to suit the openings and shall be positioned as
shown on the drawing and/or as directed by the Engineer.
The rolling shutter shall be fabricated from 0.9 mm thick steel for shutters upto 3.5
M width and 1.2 mm thick sheet for shutters over 3.5M width. The shutter shall be
rolled with lath sections of effective bridge depth 12mm at 75 mm rolling centres,
interlocked with each other and ends locked with malleable cast iron or mild clips.
The guide shall either be rolled or pressed deep channel sections, fitted with
necessary fittings and fixtures. The width of the channel shall be 25 mm and the
depth 75 mm upto 8 M wide shutter. The depth shall be 100 mm for shutters
above 8 M width.
The hood covers shall be made of 20 gauge G.I sheets with necessary stiffeners
and frame work to prevent sag. The bottom lock plate shall be made of 3mm thick
M.S. plate and 95 mm wide reinforced with angle iron of suitable section with 6mm
dia. M.S rivets interlocked with stride of curtain.
Unless otherwise specified for overall area of rolling shutters up to 8 Sq.m pull and
push type hand operated shutters shall be used. For area between 8 and 10
Sq.metre, push and pull type shutters shall be provided with ball bearings.
For area larger than 10 Sq. meter mechanical gear type or electrically operated
shutters shall be used. Operation of shutters shall be by means of worm and
worm wheel and shaft arrangement and it shall be possible to operate the door
either from inside or from outside. The shutter shall be capable of withstanding
horizontal forces up to 100 kg/m² without any appreciable deflection.
6.3.3 SHOP COAT OF PAINT
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The shop paint for steel doors, windows etc. shall be best lead or zinc chromate
primer paint from approved manufacturer. All surfaces shall be thoroughly
cleaned of rust, grease, loose mill scales etc. and given one coat of shop paint.
Portions like mullions, transoms etc. which will be inaccessible after assembly of
units shall be given an extra coat of paint before assembly.
Where called for in the Schedule of Items, all steel doors, Windows etc. shall be
hot dip galvanized to give a coating weight of 1.5 to 2 oz. per sft. One coat zinc
chromate primer coat shall then be applied as shop paint.
Portions of aluminium frame which come in contact with masonry construction,

shall, before shipment from workshop, be protected with a heavy coat of alkali
resistant paint. Aluminium coming in contact with other incompatible metals shall
be coated with zinc chromate primer.
6.4 HANDLING & STORAGE OF FABRICATED MATERIALS:
All doors windows, etc. shall be packed and crated properly before despatch, to
ensure that there will be no damage to the fabricated materials. Loading into
wagons and trucks shall be done with all care to ensure safe arrival of materials at
site in undamaged condition.
When taking delivery of items supplied by Owner, the Contractor shall satisfy
himself that the items supplied are up to the specified standard. Any defect
detected shall promptly be brought to the notice of the Engineer.
All doors, widows etc. shall be stored under cover in a way to prevent damage or
distortion. Special care shall be taken to prevent staining of aluminium products
by rust, mortar etc.
6.5 ASSEMBLY & ERECTION AT SITE:
In general, the fixing of steel doors, windows, ventilators, louvers, etc. shall
conform to IS:1081 and as shown on drawings. The contractor shall assemble
and install all steel doors, windows, sashes, fixed metal louvers, etc. including
transoms and millions for composite units in respective places as shown on
drawings, keeping proper lines and levels, and in approved workmanship manner,
to give trouble free and leak-proof installations. The installation shall be done
according to the instructions of the manufacturer, and/or as approved by the
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Engineer. If required by the Engineer, the installation shall have to be carried out
under the supervision of the manufacturer's staff. The contractor shall take every
precaution against damage of the components during installation. Necessary
holes, chases, etc. required for fixing shall be made by the Contractor and made
good again as per original, after installation, without any extra charge.
After installation of steel doors, windows, etc. all abrasions to shop-coat of paint
shall be retouched and made good with the same quality of paint used in shop
coat.
All coupling mullions, transoms, frames etc. in contact with adjacent steel and
other members, shall be well bedded in mastic. The Contractor shall bring to the
site the mastic cement in original sealed containers of manufacturer and shall
apply it as per the instructions. For all frames supplied by either the Owner or the
contractor, mastic shall be supplied by the Contractor and caulking done properly
as per drawings, specifications and as per instructions of the Engineer. Door
shutters partitions hardware fixtures etc. shall be fixed only after major equipments
have been installed in rooms.
Wherever required, nylon cords of approved quality shall be supplied along with
pivoted sashes and shall be of adequate length to terminate one meter from the
floor. Loose ends of cords shall end in metal or plastic pull as approved by the
Engineer.
6.6 ACCEPTANCE CRITERIA:
6.6.1 For Fabricated Items:
a) Overall dimensions shall be within ± 1.5mm of the size shown on drawings.
b) Mullions, transoms etc. shall be in one length and permissible deviations

from straightness shall be limited to ± 1.5 mm from the axis of the member.
c) Door and windows shutters shall open without jamming. The clearance at
head and jamb for door shutters shall not exceed 1.5 mm. For double leaf
doors, the gap at the meeting stiles shall not be more than 1.5 mm.
d) Door leaves shall be undercut where shown on drawings.
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e) Doors, windows, frames, etc. shall be on a true plane, free from warp of
buckle.
f) All welds shall be dressed flush on exposed and contact surfaces.
g) Correctness of location and smoothness of operation of all shop installed

hardware and fixtures.
h) Provision for hardware and fixtures to be installed at site.
i) Glazing beads shall be cut with mitered corners.
j) Glazing clips, fixing devices etc. shall be supplied in adequate numbers.
k) Shop coats shall be properly applied.
I) Exposed aluminium surfaces shall be free from scratches, stains and

discolouration. Anodised surfaces shall present a uniform and pleasing
look.
6.6.2 For Installed Items :
a) Installations shall be at correct location, elevation and in general on a true

vertical plane.
b) Fixing details shall be strictly as shown on drawings.
c) Assembly of composite units shall be strictly as per drawings, with mastic

caulking at transoms and mullions, gaskets, weather strips etc. complete.
d) All frames on external walls shall be mastic caulked to prevent leakage

through joint between frames and masonry.
e) All openable sections shall operate smoothly without jamming.
f) Locks, fasteners etc. shall engage positively, Keys shall be non-

interchangeable.
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g) Cutting to concrete or masonry shall be made good and all abrasions to

shop paint shall be touched up with paint of same quality as shop paint.
h) Aluminium doors, windows etc. shall be free from scratches, stain or

discolouration.
6.7 INFORMATION TO BE SUBMITTED:
6.7.1 With Tender :
a) Names of manufacturers for doors, windows etc.
b) Manufacturer's catalogue for all hardware and fixtures proposed to be used.
6.7.2 After Award :
a) Before starting fabrication of all metal doors, windows, etc. the Contractor
shall submit detailed fabrication drawings to the Engineer for approval. The
fabrication shall be started only after approval of drawings.
b) Before bulk supply, he shall submit for the approval of the Engineer samples
of all bought out items and samples of each type of fabricated item. The
samples shall be retained by the Engineer for comparison of bulk supply
and returned to the Contractor towards the end for the final incorporation in
the job.
6.8 GLASS AND GLAZING
6.8.1 Scope
The work in general shall consist of supplying and fixing all glass and glazing
including all clips, putty, mastic cement etc., wherever required as shown on
drawings and specifications.
6.8.2 Applicable codes and specifications
specification. All standards, codes of practices referred to herein shall be the
latest edition including all applicable official amendments and revisions.
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In case of discrepancy between this specification and those referred to here, this
specification shall govern:
IS:3548 Code of practice for glazing in building
IS 1081 Code of practice for fixing and glazing metal doors, windows and
ventilators.
6.8.3 Installation
General
The Contractor shall supply and install all glass and glazing as required for various
doors, windows, ventilators and fixed louvers, miscellaneous glazing and
partitions, having uniform refractive index and free from flows, specks and
bubbles. Glass shall be obtained from approved manufacturer. (Refer to Data
Sheet ‘B’ for recommended vendor / brand information).
The glass shall be brought to site in the original packing from the manufacturer
and cut to size at site. The cut edge shall be straight and free from chips, spalls or
any other damage.
Materials
a) Glare reducing or heat absorbing glass shall be of approved make and
special care shall be taken to grind smooth and round off the edges before
mixing.
b) Clear glass shall be flat drawn sheet glass and shall be at least 4 mm thick,
unless specified in drawings. Sheet glass for doors shall be minimum 5.5
mm thick.
c) Wired glass shall be thick rolled glass with centrally embedded 24 g wire
mesh of Georgian type. This may be of clear or coloured glass, as shown in
drawings or schedules.
d) Obscure glass shall have a cast surface on one side.
e) Coloured and figured glass shall be as per approved sample.
f) In general, the putty shall conform to IS:400 and be of best quality from
approved manufacturer. It shall be brought to site in the manufacturer’s
original packing. Quick setting putty shall be used for windows and sashes
except when glare reducing glass is used where it shall be of non-setting
type.
g) Neoprene gasket with snap-fit glazing beads shall be fixed as per
manufacturer’s instructions and shall sit snugly against glass to give a
leakproof installation.
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6.8.4 Glazing, setting and finish

All glazing clips, bolts, nuts, putty, mastic cement etc. as required shall be
supplied by the Contractor.
All glass shall be thoroughly cleaned before putting in position. Each glass pane
shall be held in place by special glazing clips of approved type. As specified in
relevant I.S. Codes, four glazing clips shall be provided per glass pane, except for
large panes where six or more clips shall be used as per Engineer’s instruction.
All holes that may be necessary for holding the clips, glazing beads and all other
attachments shall be drilled by the Contractor.
Glass panes shall be set without springing and shall be bedded in putty and
putted, except where moulding or gaskets are specified. Putty, mastic cement
etc. shall be smoothly finished to a true even line. Obscure and figured glass shall
be set with smooth side out.
Where glass will be supplied by Owner, the Contractor shall cut it to size and fix
them in the same way as specified above.
Glazing clips, putty, mastic cement etc. shall be supplied by the Contractor. The
Contractor shall be responsible for damage of glass supplied by the Owner, during
handling, transportation, fixing etc. Maximum wastage allowance shall be 5%.
After completion of glazing work, the Contractor shall remove all dirt, stains,
excess putty etc. clean the glass panes and leave the work in perfectly acceptable
condition. All broken cracked or damaged glass shall be replaced by new ones at
the Contractor’s own cost.
6.8.5 Acceptance criteria
a) All installations shall be free from cracked, broken or damaged glass. Edges
of large panes of thicker glass and heat absorbing glass shall be inspected
carefully for chipped, cracked or unground edges.
b) Glazing shall be carefully done to avoid direct contact with metal frames.
c) All glass shall be embedded in mastic or fixed by neoprene gaskets to give a
leak-proof installation.
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d) At completion the panes shall be free from dirt, stains, excess putty etc. to
the complete satisfaction of the Engineer.
6.9 RATES :
a) Rates shall be unit rates for items described in the schedule.
b) Rates for supply and / or installation of different kinds of glass are to be

included in the rates as mentioned in the Schedule of Items.
c) No separate payment shall be made for glazing clips, mastic cement, putty,
nails etc. for drilling holes in frames for inserting glazing clips.
d) No separate payment shall be made for cutting of glass to required size,

edge finishing etc., if the glass is supplied by the Contractor.
e) No separate payment shall be made for cleaning the glass after installation.
6.10 METHOD OF MEASUREMENTS:
a) Supply and installation of doors, windows, ventilators and rolling shutters

shall be measured in square metre for each type used. The types shall be
as shown on drawings and described in Schedule of Items. The actual size
shall be measured to the outside of the framework.
b) Supply and installation of louvers shall be measured for area of opening in

which the louvers is to be installed.
c) Glazing beads, weather stripping, fixing devices locks, keys, bolts, hinges
etc. shall not be measured separately but shall be included in the supply
rate of respective items.
d) Any curing or grouting to concrete and masonry or welding and drilling to

steel required for installation shall be included in the installation rate. No
separate payment shall be made for caulking and jamming of frames or
making good to concrete or masonry.
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e) The rate shall also include cost of painting. Painting shall be as described in
the respective specification.
f) Glass and glazing shall be measured and paid under relevant items.
END
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DOC NO.:
CI-UCH-016-08
SECTION-8
Uhde India Limited ROOFING & CLADDING Page :1
Contents Page
SCOPE 2
A.C.SHEETING AND ACCESSORIES 2
A.C. RAINWATER PIPES & FITTINGS 3
G.I. SHEET WORK 3
FRP SHEETING 4
COLOUR COATED SHEETS 5
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03

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SECTION-8
8.1 SCOPE OF WORK
The Contractor shall furnish all labour, materials, tools and services necessary to
complete all work in Roof Sheeting, louvers, side cladding etc. in accordance with
the drawings and as specified therein.
8.1.1 Applicable Codes & Specifications
specification. All specifications, standards, codes of practices referred to herein
shall be the latest edition including all applicable official amendments and
revisions. In case of discrepancy between this specification and those referred to
herein, this specification shall govern:
1. IS:3007 : Code of Practice for laying of asbestos cement sheets.
2. IS:2527 : Code of Practice for fixing rain water gutters and down
pipes for roof drainage.
3. IS:1626 : Specification for asbestos cement building pipes,

gutters and fittings.
4. IS:277 : Specification for galvanised steel sheets (plain and

corrugated).
5. IS:459 : Corrugated and semi-corrugated asbestos cement

sheets.
8.2 A.C. Sheeting & Accessories

8.2.1 Workmanship
1) A.C. sheets shall be installed by experienced workmen as shown on the

drawings and in a workmanlike manner, whether in Roofing or side
cladding. The maximum spacing of roof purlins / side runners as
recommended by manufacturer shall not be exceeded.
2) The completed surface shall be leakproof against rainwater and rigidly

attached to the structural frame of the building.
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3) Final coat of paint on steel members shall have dried for at least 24 hours
before the erection is started. All holes shall be accurately drilled as
specified by the manufacturer, and laps shall be made over the structural
members and sheeting shall be bolted at spacing not greater than those
specified by the manufacturer or as directed by the Engineer.
8.2.2 Asbestos Cement Rainwater Pipes & Fittings
These shall comply with IS:1626 - Specification for asbestos cement building
pipes, gutters and fittings (spigot and socket type). The pipes shall be straight, and
the end of the pipes, gutters and fittings shall be finished square to their axes.
Pipes, gutters and fittings shall be true and smooth: their inner and outer surfaces
shall be as nearly as practicable concentric, and shall be in all respects sound,
homogeneous and free from impurities, other imperfections and defects.
8.2.3 North Light Glazing - Material shall be 6 mm thick reinforced with G.I. mesh. The
glass shall be fixed using Standard Aluminium vertical sections and aluminium
press-fit clips all as per drawings and manufacturer's spec. Suppliers Ajit India,
Alumilite or equivalent approved vendor.
8.3 G.I. SHEETING & ACCESSORIES
Roofing and accessories wherever indicated shall be of galvanised iron sheets,

corrugated or plain confirming to IS:277, with thickness specified hereinafter or as
indicated in bill of quantities. The Contractor shall supply, fabricate and erect all
sheets and accessories complete as specified and as shown on the drawings.
The G.I. sheeting shall, unless otherwise indicated, be of the following type and
thickness:
1) G.I. coating will be confirming to IS:1367 and shall be of 750 grade.

2) Roofing sheets along with 22/24 gauge corrugated Northlight Curves &
ridges..
3) The G.I. sheets shall be laid with a minimum end lap of 150 mm and 2
corrugation at each side. For flatter slopes of more than 1 vertical to 2
horizontal the min. end laps shall be 200 mm for ridge, hip and valley.
4) The laying operation shall include all scaffolding work.
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5) The roofing. sheets shall be laid and fixed to roof structurals by ‘J’ or ‘L’
G.I. hook bolts, 25 x 6 mm nuts and 8 mm bitumen and limpet washers as
per best practice. At the side lap of 2 corrugations, the bolts shall be
placed zig-zag to hold the sheets tightly, with the spacing of bolts not
exceeding 600 mm along each of the staggered rows. The holes in the
sheets for the fixing of bolts shall be drilled and not punched from the
northern ridges of the corrugations from the underside, while the sheets
are on the ground.
6) Gutters shall be of the design and size specified in on the drawings. Such
gutters shall be made of 16 gauge plain G.I. sheets or epoxy painted M.S.
sheets as specified in the drawings and with seal-welded joints.
7) Hanging gutters shall be constructed of galvanised iron unless otherwise

specified or shown on the drawings. Hanging shall be provided in sections
not less than 2.5M long, jointed by 25mm soldered laps in the direction of
flow.
8) Supports shall be of galvanised iron stock gutter hangers of the adjustable

strap type, with spacer attachments to maintain gutter alignment and shall
be secured by screws or bolts at spacings not greater than 60 cm on
centres.
9) End pieces, caps, outlet tubes, miters and reinforcing members shall be
provided wherever indicated or required. Slip joints, wherever required,
shall have grooves filled with whitelead paste.
10) Wind Tie : Wind ties shall be of 40 x 6 mm flat or other M.S. sections as
specified. These shall be fixed at the eaves of the sheets. The fixing
shall be done with the same hook bolts which secure the sheets to the
roof purlins. The ties shall be paid for separately as per relevant structural
steelwork item.
8.4 Fibre Glass Reinforced Plastic Sheeting and Polycarbonate

Sheeting
This shall be of thickness and profile as mentioned in the Schedule of Items.

(Refer to Data Sheet ‘B’ for recommended vendor / brand information). Colour
and light transmittance shall be as mentioned in drawings and or schedules.
Where used in conjunction with C.G.I. or asbestos sheeting, the end and side laps
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and fixing device shall be same as used for general sheeting. Where used in lieu
of glass, the fixing shall be by means of timber or metal glazing beads as
mentioned in Schedule of Items. In all cases, the installation shall be completely
watertight and able to withstand the designed wind pressure as mentioned in
Schedule. The mode of measurement shall be similar to A.C. sheeting.
8.5 Colour Coated Galvanised Sheets
Colour Coated Galvanised Sheets shall be supplied by reputed manufacturers like

(Refer to Data Sheet ‘B’ for recommended vendor / brand information). These
sheets shall be manufactured by Roller Coating process using polyester based
paints and Galvanised Sheets as base substrate. The galvanising shall be as per
IS : 277 normally to Grade 175 giving minimum average coating of 120 gm/sq.m.
The mode of measurement shall be similar to G.I. sheeting.
a. The payment for A.C. sheeting and cladding, glazing for natural light shall
be on Sq.m basis on finished plan area without allowances for (end and
side) laps and corrugations and overlapping at ridge or hip, valley etc.
b. The payment for other A.C. materials like Ridge pieces, apron pieces, etc.
shall be on R.M. basis on finished area.
c. The payment for G.I. sheeting and cladding shall be on Sq.m. basis on
finished area similar to A.C. sheeting.
d. The payment for fabricated accessories such as roof gutters, downwater

pipes etc. shall be on Kg basis.
The rates quoted shall be all inclusive covering cost of materials, labour,
supervision, transport, taxes/duties, octroi, wastage, guarantees, all
statutory requirements and all other incidental expenses required for
completing the work, including a coat of specified steel primer and 2 coats
of approved steel paints on overlapping G.I. sheets.
END
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Uhde India
UAN:
TENDER FOR CIVIL AND STRUCTURAL STEEL WORK
STANDARD
PART -II : TECHNICAL SPECIFICATIONS
Document No:
CI-UCH-016-09
SECTION-9 - PAINTING
Page 1 of 13
Contents Page
0 Cover sheet: headline, codes, table of contents, check &approval for first edition & revision .............. 1
9.1 SCOPE ....... ... ........................ .............................................. ..... ........................................ 2
9.2 WHITE I COLOUR WASH ............................................................. .. ...... .. ..... ......................... 2
9.3 OIL BOUND WASHABLE DISTEMPER. ......... ..... .. ............................................................ .... ... . 3
9.4 CEMENT PAINT ......................................................... ... ... ................................................... 5
9.5 INTERIOR PLASTIC I ACRYLIC EMULSION PAINT .... .............................. .... ........ ...... ................. 5
9.6 EXTERIOR ACRYLIC EMULSION PAINT ....................... ................................................ ............ 5
9.7 COAL TAR EPOXY PAINT ................... ............. ...... .. ....................................................... ... ... 5
9.8 CHLORINATED RUBBER PAINT ............................................... .............................................. 6 ·
9.9 EPOXY BASED PAINT........ ................................................................ ............ ... ... ................ 6
9.10 ALUMINIUM BASED HEAT RESISTANT PAINT ........................................................ ................. 6
9.11 PAINTING OF STRUCTURAL STEEL WORK .............................................................................. 6
9.12 INSPECTION & TESTING ................................................. ... ......... .... ... ..... ......... .................. 9
9.13 VARNISHING AND POLISHING ............. ................................................................... .... .... .... 10
9.14 SPECIAL INSULATING PAINT HAVING ELECTRICAL RESISTANCE: ........................................ .... 11
9.15 GALVANISING .. ......... .................................................................. ........ ........ ... ................. 11
9.16 MODE OF MEASUREMENT.......... ... .................................................................. .... .............. 13
Server \ \KUMUS671 \REFER\CIVIL\PUBLIC\ ...... ....\VOLUME-2
Soft File CI-UCH-016-09-Rl.doc

Applicable Revision: Revision 1
Checked: Approved: R.S.DESHPANDE
Prepared: RAJESH VAIDYA
NIRUPAMA KARANDIKAR
~ ~pck
Date: 2+ ·Ol..f>. 2.011 Date: .2..-=J-f ~ { d 1
First Edition: Revision 0
Prepared: NIRUPAMA Checked: P.R.KANNAN Approved: M.H.JOSHI
KARANDIKAR
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03

Element: Section: Rev.:
Copyright 2011 Uhde India Private Limited 1---- -- -- - -- - - - t - - -- - -- - -1-- ---l
ENGINEERING CIVIL 1
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Uhde India ""'~" , ~~r-
9.1 SCOPE
This specification covers painting of structural steel, varnishing, polishing etc. of both interior &
exterior surfaces of Wood work, painting of masonry, concrete, plaster surfaces, structural and
other miscellaneous steel items, rain water down comer, floor & roof drains, soil waste &
service water pipes and other ferrous & non ferrous metal item as shown on drawings or as
directed by the engineer.
9.1.1 APPLICABLE CODES
1) IS: 101 Methods of test for ready mixed paints and enamels.
2) IS:158 Specification for ready mixed paint, brushing, bituminous black, lead free, Acid
alkali and heat resisting.
3) IS:348 Specification for French polish.
4) IS:427 Specification for distemper dry colour as required.
5) IS:428 (I&II)Specification for Distemper, Oil Emulsion, Colour as Required
6) IS: 1477 (1&11) Code of practice for painting of ferrous metal in buildings
7) IS:2074 Specification for Ready mixed paint, air drying, red oxide- zinc chrome, priming.
8) IS:2338 (1&11) Code of practice for finishing of wood & wood based materials.
9) IS:2339 Specification for Aluminium paints for general purpose in dual containers
10) IS:2345 Code of practice for painting concrete, masonry & Plaster surface.
11) IS:2932 Specification for Enamel, Synthetic, Exterior (a) Undercoating, (b) Finishing
12) IS:5410 Specification for cement paint colour as required.
13) IS:5411 Specification for Plastic emulsion Paint: Part 1- for interior use.
14) IS:5411 Specification for Plastic emulsion Paint: Part 1- for exterior use.
15) IS:6278 Code of Practice For White Washing and Colour Washing
9.2 White I Colour wash
9.2.1 White Washing
This shall include providing and applying 3 coats of white wash to plastered surface with all
labour, material, plant, tools, scaffolding, etc.
The white wash shall be applied with smooth brushes and not by any other rough equipment.
Best approved quality of lime slacked in conformation to IS:1635 shall be used. Required
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amount of glue and indigo shall be added to produce solution, which, after properly filtering
through a fine cloth, will not stick to the fingers when rubbed after drying. Before any lime
wash is applied to a surface, it is required that all loose material and dirt shall be removed by a
brush and sand paper. Lime putty shall be used to make good all holes and irregularities of
surface of minor repairs, which, should be left dry before applying the second coat.
Doors, windows, floors etc. and such other parts of building shall be protected from being
splashed upon. Splashing and dropping if any, shall be removed by the contractor at his own
cost and the surfaces cleaned.
9.2.2 Colour Washing
The wash shall be prepared by adding required quantity of colouring pigment to the lime wash
as prepared for white wash. Indigo, however, shall not be added. Ultramarine blue shall be
added in this case. Mineral colours not affected by lime only shall be added to white wash. No
colour wash shall be done until a sample of colour wash prepared to the required tint or shade
has been approved by Engineer.
The surface to be colour washed shall be first treated with a priming coat of white wash.
Minimum three coats of colour shall be applied and the colour shall be of even tint or shade
over the whole surface.
The finished dry surface shall not be powdery and shall not come off on the hand when rubbed.
9.3 Oil bound Washable Distemper.
9.3.1 Material
Material for oil bound distemper shall be of approved make and manufacturer. A sealed tin
ready mixed distemper of selected make shall be opened in presence of Engineer.
9.3.2 Surface Preparation.
This includes scraping uneven surface, damaged plaster, etc. with carborundum papers of
suitable number till hard, clean surface is obtained. This is to be repeated till the work is
approved by the Engineer. Putty shall be used to cover holes and unevenness on the surface.
PART-II- TECHNICAL SPECIFICATIONS Rev. 1

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9.3.3 Preparation and application of Putty.
Putty will be prepared as under. It shall be prepared from English whiting chalk, linseed oil,
white zinc and plaster of paris in the prop. of 7:1:2:1. However, exact proportion shall be
decided as per site condition. Water, if required, can be added as per the instructions and
requirements to have proper consistency and thickness. P-utty should be smooth and free from
any coarse ingredient, etc.
Application of putty should be started only after approval of surface area by the Engineer. It
should . be applied on the whole surface to make the surface smooth . No lumps should be
allowed to dry completely.
After drying, the surface should be scraped with sand/emery paper till smooth surface is
obtained.
If no proper smoothness is obtained again apply primer, putty, etc. and repeat the process as
mentioned above, till the surface is perfect smooth as per instructions.
After application of first coat of putty, the surface shall be allowed to dry for 24 hours. sand
papering shall then be done to give smooth surface .
Subsequent applications of putty and sand papering shall be done till the Engineer is satisfied
about final surface, which should be absolutely even, levelled and smooth.
9.3.4 Primer application
Primer should be a cement primer, or as per manufacturer's specification (manufacturer same

as that of distemper). These tins should be opened in presence of the Engineer. Before
applying primer on the surface, its consistency must be approved by the Engineer and shall be
same as specified by the manufacturer. Primer should be applied with smooth brushes on
surface to cover entire surface properly. There should be no brush marks, stripes, etc. when
applied on the surface. This surface should be allowed to dry atleast for 24 hours before next
application.
9.3.5 On the surface so prepared, two coats of oil bound distemper of selected shade shall be
applied only after inspection by the Engineer. A horizontal and vertical travel of brush together
will be considered as one coat of paint. Each coat of paint shall be applied only after inspection
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of Engineer. No brush marks shall be visible on the surface at the end of final coat. Final
surface shall be smooth, even or roller finish and uniform in colour and texture.
9.4 Cement Paint
The specified surface is to be provided with 2 coats of cement paint of approved manufacturer
in shade and colour approved by the Engineer.
The surface is to be thoroughly cleaned and rubbed down and all loose particles and dust etc.
be removed. Before applying first coat, surface should be watered thoroughly and shall be
allowed to drain off. Second coat shall be started after 24 hours of first coat. The entire surface
shall then be cured for seven days.
Paint shall be prepared strictly as per manufacturer's specifications & as directed.
9.5 Interior Plastic I Acrylic Emulsion Paint
Paint shall be of approved quality and shades.
Surface preparation, primer and putty application shall be as per clause 9.3.2, 9.3.3, 9.3.4.
Three coats of Plastic I Acrylic emulsion paint shall be applied as per manufacturer's
specification. The surface on finishing shall present a flat velvety smooth finish.
9.6 Exterior Acrylic Emulsion Paint
The paint shall be of an approved manufacturer in shade and colour approved by the Engineer
and shall confirm to IS5411 Part 2
9.7 Coal Tar Epoxy paint
Concrete surface shall be thoroughly cleaned with wire brush and 3 coats of coal tar epoxy
paint shall be applied . Successive coats shall be applied only after the first coat has dried.
Usually, the paint will be supplied by manufacturers in 2 packs. The base and hardener shall
be mixed as per manufacturer's specification.

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No primer paint is necessary. The min dry film thickness (OFT) of each coat shall be 100
microns.
9. 7 A Bituminous or Tar Coating
The surface shall be sand papered, cleaned and completely coated with hot coal tar pitch of
approved manufacture and quality as per IS:216 (not heated above 375 Deg.F) using not less
than 1.5 kg. per SQ.M. When the first coat has completely dried up and approved by the
Engineer, the second coat shall be applied in the same manner using not less than 1.25 kg. per
sq. M. in case of coal tar and 1 kg. per sq. M.
SQ.M. in case of asphalt. Immediately after application of the second coat and before it is dried
up, sand shall be spread on the surface to cover it completely. Sufficient time shall be allowed
after spreading of sand before backfilling is done in order to allow the final coat to dry up
completely.
9.8 Chlorinated Rubber paint
Concrete surface shall be thoroughly cleaned with wire brush and 3 coats of Chlorinated
Rubber paint shall be applied as per manufacturer's specifications. Primer as recommended
by manufacturer shall be applied.
9.9 Epoxy based paint
Surface shall be thoroughly cleaned with wire brush and 3 coats of epoxy based paint shall be
applied as per manufacturer's specifications.
9.10 Aluminium based Heat Resistant Paint
Aluminium based heat resistant painting shall conform to IS:2339. The paint comes in
compact dual containers with the paste and the medium separately. The two shall be mixed
together to proper consistency before use.
9.11 Painting of Structural Steel work
After steel has been erected, all bare and abraded spots, field welds, bolt holes and nuts shall
be spot painted with primer. Before paint is applied, the surface shall be dry and free from

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dust, dirt, scale and grease. All surfaces inaccessible after erection shall receive two coats of
the approved paint before erection.
9.11.1 Scope
Scope of work shall include surface preparation as specified, procurement and application of
primer and coating paints as specified, providing all tools, sandblasting equipments, if required
and all labour.
9.11.2 Surface Preparation.
Durability of painting depends upon surface preparation to a great extent. Before application of
any primer or finishing paint the surface shall be free of rust, mill scale, grease, oil, dust, sharp
points, welding spatter, flux, or any other foreign materials. When the heat resisting paint is to
be applied shop primer or any other paint previously applied should be removed completely.
The surface preparation shall also depend upon the type of primers to be applied. To achieve
the required degree of surface protection any one or more of the following methods in
combination shall be used as specified.
9.11.2.1 Hand Cleaning
Hand cleaning shall consist of removing scales by sharp edged tools, hammering, hard steel
wire brush scraping, sanding with emery paper, etc.
All loose paint, ( if previously applied), scale rust, dust, foreign materials, etc. Shall be
removed in this way. If the surface is covered with any oil or grease, it should be removed with
soap solution and then be washed with clean water. All loose dust, rust, etc. shall be wiped off
with clean rag before application of paint or primer.
9.11.2.2 Mechanical Cleaning and Scrapping.
Mechanical cleaning and scrapping shall be done by mechanical striking tool, knurled grinding
wheels, abrasive wheels or rotating steel wire brushes. To avoid sparks in inflammable and
dangerous zones, stainless steel or brass wire brushes shall be used. The power brush shall
be used in such a manner that all scale, rust, foreign material, etc. scraped off from entire
surface, outside and inside corners, edges, etc. The interior surface of the structure,
~quipment, machinery, etc. that can not be reached with power brush shall be cleaned by hand
cleaning as described.

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The surface so prepared, shall be wiped with clean rags before application of primer or paint.
9.11.2.3 Blast cleaning
The Blast cleaning of the surface shall be carried out by compressed air and blasting gun using
one of the abrasive as blasting medium as A1203 particles chilled cast iron or malleable iron
and steel at pressure of 7kg/cm2 at appropriate distance and angle depending on nozzle size
maintaining constant velocity and pressure. Malleable iron and steel shall be in the form of shot
or grit of size not greater than 0.055 inch maximum. In case of Chilled cast iron the size shall
not be greater than 0.04 inch maximum. Compressed air shall be free from moisture and oil.
The blasting nozzles should be venture style with tungsten carbide or boron carbide as the
materials for liners. Nozzle orifice may vary from 3/16 to 3/4 inch. On completion of blasting
operation, the blasted surface shall be clean and free from any scale or rust and must have a
grey white metallic luster. The minimum acceptable surface shall be conforming to "Sa 2 W' as
per Swedish standard SIS-05-5900 or equivalent.
Primer or first coat of paint shall be applied within 3 to 4 hours or before any trace of oxidation
appears on the cleaned surface.
Blast cleaning shall not be done outdoors in bad weather without adequate protection or when
there is dew on the metal, which is to be cleaned .
Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such
cleaning or during humid weather conditions having humidity exceed 85%.
9.11.2.4 Chemical Cleaning
Chemical cleaning shall be adopted when a surface free from oil, grease, rust, etc. is required
and sand blasting or mechanical scrapping and cleaning is not possible. Special chemical
cleaners of approved manufacturer shall be used as per manufacturer's specifications. The
chemical is first diluted in water and then applied liberally with rag or brush. Allow the solution
to remain in contact with surface for 1 to 5 minutes as required, do not allow the solution to dry
up, if
it is dried up apply more solution. The solution is then wiped off with a clean cotton rag or by
rubbing with dry saw-dust. If any greasy spot are left after 1st application, second application
may follow for these spots only.

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Engineer's approval of the surface preparation before applying 1st coat of paint or primer will
be necessary and his decision in the matter shall be final and binding to the contractor.
9.11.3 Synthetic Enamel Painting
Surface preparation shall be by hand cleaning. Primer shall be zinc cremate or zinc phosphate
(pigmented in alkyed or phenolic medium of approved make, British or Asian Paints) of
minimum 38 microns dry film thickness. The coats of synthetic enamel paint of approved
make, British Luxol-3 or Asian apcolite, of total 100 microns OFT shall be applied as directed
by the Engineer.
9.11.4 Epoxy Paint System
Surface preparation shall be with hand cleaning OR Blast cleaning to sa 2 1h surface of

Swedish Standard and wherever stand blasting is not possible, chemical cleaning shall be
permitted.
Primer coat (one coat)
Primer shall be one coat of zinc dust pigment with ethylsilicate binder- 75 microns OFT.
Intermediate coat:[one coat]
The intermediate coat shall be Micacions Iron oxide pigment with epoxy resin binder - 100
micron OFT.
Final coat:[2 coats]
Each final coat shall be lnterpigment with Acrylic resin base alliphatic polyurethane binder - 35
micron OFT each coat.
The equivalent paint chart shall be followed for selection of paints manufactured by approved
manufactures.
9.12 Inspection & Testing
All the painting materials brought to site for the purpose of application shall be accompanied by
the manufacturer's test certificates. In case such certificates are not available, the Engineer
may direct the contractor to have the materials tested in accordance with relevant IS

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specifications or as specified in the tender at outside laboratories and all costs there of shall be
borne by the contractor.
The Engineer may call for additional tests in materials accompanied by manufacturer's test
certificates. (Contractor shall arrange to have such tests performed but costs thereof shall be
born by the owner.)
The work will be subject to inspection by the Engineer at all times. In particular, following
staged inspection will be performed and contractor shall offer the work for inspection and
approval at every stage before proceeding with the next stage:
a) Surface preparation
b) Primer application
c) Each coat of paint
Final inspection shall include measurement of paint film thickness, check of finish obtained and
adhesion test as per IS specification.
The contractor shall provide for the purposes of inspection, Elcometer, access, ladders,
lighting, and any other necessary items at his cost.
If with specified number of coats specified Dry Film Thickness (D.F.T) is not obtained,
contractor will have to apply additional coat to achieve the required OFT without any extra cost.
However, specified number of coats have to be applied even if required OFT is obtained with
lesser number of coats.
9.13 Varnishing and Polishing
9.13.1 The Varnish used shall be generally spirit varnish obtained from shellac, Gun Arabic, Resin and
Amber.
9.13.2 French polish shall be made by dissolving 1/4 kg of Shellac in 112 liter of methylated spirit or
naptha and staining the solution through a double thickness of coarse muslin.
9.13.3 Method of Application
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The prepared wood work shall be applied with a coat of thin clear qlue. This shall be allowed to
dry and rubbed down with fine sand paper. A second coat of thin clean glue with necessary
quantity of staining colour shall then be applied and allowed to dry. Varnish shall be laid on in
thin coats over this surface. The application shall be with a polishing pad and not with a brush.
Varnishing shall not be carried out on stormy and rainy days.
9.14 Special Insulating paint having electrical resistance:
9.14.1 On RCC & Masonry Surfaces:
Primer coat:
Two coats of approved primer, each 30 microns OFT shall be applied.
Final coat:
Two coats of approved paint, each coat 100 microns OFT shall be applied
9.14.2 On Steel Surfaces

The surface preparation shall be as described in clause 9.10.2.
Primer coat
One coat of primer, 100 micron OFT, shall be applied.
Final coat
Two coats of approved paint, each coat 100 microns OFT shall be applied.
9.14.3 Paints manufactured by reputed companies may be used subject to adhering of following duty
conditions.
Sodium Hydroxide , Potassium Hydroxide = 33%

Sodium Chloride , Potassium Chloride = 25%
Temperature = up to 90°C.
Electrical resistivity = 100 K-Ohms.
9.15 Galvanising
9.15.1 General

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Structural steel work for switchyard or other structures as may be specified in the Contract shall
be hot dip galvanised in accordance with the American Society for Testing and Materials
Specification ASTM-A 123 or IS:2629 - Recommendation practice for Hot Dip Galvanising of
Iron and Steel. Where the steel structures are required to be galvanised the field connection
materials bolts, nuts and washers shall also be galvanised.
9.15. 2 Surface Preparation
All members to be galvanised shall be cleaned, by the process of pickling of rust, loose scale,
dirt, oil, grease, slag and spatter of welded areas and other foreign substances prior to
galvanising. Pickling shall be carried out by immersing the steel in an acid batch containing
either sulphuric or hydrochloric acid at a suitable concentration and temperature. The
concentration of the acid and the temperature of the bath can be varied, provided that the
pickling time is adjusted accordingly.
The pickling process shall be completed by thoroughly rising with water, which should
preferably be warm, so as to remove the residual acid.
9.15.3 Procedure
Galvanising shall be carried out by hot dip process in a proper and uniformly heated bath. It
shall meet all the requirements where tested in accordance with 1$:2633 - Method for testing
uniformity of coating on Zin<: Coated Articles and l$:4759 - Specification for Hot-dip zinc
coatings on Structural Steel and other allied products.
After finishing the threads of bolts, galvanising shall be applied over the entire surface
uniformly. The threads of bolts shall not be clogged with zinc. The threads of nuts may be
tapped after galvanising but care shall be taken to use oil in the threads of nuts during erection.
The surface preparation for galvanising and the process of galvanising itself, shall not
adversely affect the mechanical properties of the materials to be galvanised. Where members
are of such lengths as to prevent complete dipping in one operation, great shall be taken to
prevent warping .
Materials on which galvanising is damaged shall be acid stripped and re-galvanised unless
otherwise directed, but if any member becomes damaged after having been dipped twice, it
shall be rejected. Special care shall be taken not to injure the skin on galvanised surfaces

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during transport, handling and erection. Damages, if occur, shall be made good in accordance
with the provisions of this Specification or as directed by the Engineer.
9.16.1 Painting (other than structural steel painting)
The payment shall be on SQ.M. basis of finished area and deductions for openings shall be
made as per clauses given under plastering item. The rate shall include all materials, surface
preparation, labour, tools and tackles, scaffolding, cleaning stairs, etc. complete as specified
and as per relevant IS Codes.
9.16.2 Painting (Structural Steel)
The payment shall be on M.T basis. The rate shall include for surface preparation, primer,
paints, labour, tools and tackles, scaffolding, etc complete as specified and as per relevant IS
Codes.
In case in bill of quantities, surface preparation and application of primer is indicated

separately, then the payment shall be made as per BOQ items.

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WATERPROOFING & THERMAL AND Rev. :R0
Uhde India Limited ACOUSTIC INSULATION Page :1
Contents Page
SCOPE 2
I.S.CODES AND STANDARDS 2
BOX TYPE WATERPROOFING 2
ROOF WATER PROOFING 5
INJECTION GROUTING SYSTEM 10
TESTING OF UNDERGROUND WATERPROOF STRUCTURES 11
THERMAL & ACOUSTIC INSULATION 12
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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10.0 SCOPE OF WORK
Waterproofing system and thermal and acoustic insulation work covered under
this section shall be inclusive of providing, laying, all materials, labour, scaffolding,
tools, equipment, finishing and testing etc. complete.
10.1 IS CODES & STANDARDS
1) IS : 73 : Specification for Paving Bitumen
2) IS : 702 : Specification for Industrial Bitumen
3) IS : 1203 : Methods of Testing Tar & Bitumen
4) IS : 1322 : Bitumen Felts for Waterproofing and Damp

Proofing
5) IS : 1346 : Code of Practice for Waterproofing of Roofs with

Bitumen Felts
6) IS :3384 : Bitumen Primer for use in Waterproofing and

Damp Proofing.
7) IS :2645 : Specification for Integral Cement Waterproofing

Compounds
8) IS :2591 : Code of Practice for Preparation & Use of Lime

Concrete.
10.2 Box Type Waterproofing
Wherever specified in drawings, underground hollow construction like building

basements should be provided with encasing box-type waterproofing to form a
barrier between subsoil water and the basement wall and rafts. The specification
shall be as given below:
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10.2.1 Before laying the basement raft :
(a) Lay the PCC (M-10) on the foundation strata. This will be by Civil
Contractor and not to be included as part of waterproofing described
under this section.
(b) Clean the PCC top by removing all loose particles of sand, aggregate,
cement etc.
(c) Lay a layer of screed in C.M. (1:3) of average thickness of 25 mm or

as specified in the drawing including approved waterproofing agent in
specified proportion, over PCC.
(d) Provide and lay minimum 38 mm thk. Rough Shahabad tiles of

minimum size 600 x 600 mm over the screed and bedded (10 mm thk.)
in waterproof C.M. (1:3). This layer should extend at least 300mm
beyond the outer face-line of the basement walls, for integrity with
vertical layers.
(e) Provide and lay average 20mm thk. screed of cement mortar (1:2:1) in
proportion of 1 Cement, 2 sand and 1 grit of size 3 mm to 6 mm
(crushed metal) including approved waterproofing agent.
This layer should be cured for minimum 7 days before allowing

reinforcement or formwork to be laid. Curing shall continue for 15 days
after laying in humid weather and for 20 days in dry hot weather.
10.2.2 Over vertical surface of the basement walls.
After the RCC walls are constructed, cured and have attained at least 15
days strength, this layer shall be taken up for waterproofing as specified
below:
(A) Clean the surface and give a coat of cement wash (1 bag of cement in
80 litres of water) uniformly all over the surface.
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(B) Provide and lay minimum 38 thk. Rough Shahabad tiles in waterproof
cement mortar (1:3). Bedding between tiling and wall should be
minimum 10-15 thk.
This layer should be done in heights of not more than 1.2 Metres at a
time (2 tiles of 600 x 600) and shall be started over the projecting
waterproofing layer of raft.
(C) After 1.2 M height is constructed, a protective brick wall 115 mm thick
in C.M. (1:4) jointing and a filling of 10-15 mm thk. CM (1:4) between
brick wall and tiling shall be constructed, leaving 75 to 100mm of tile
layer above brick wall top.
(D) This process of tiling upto 1.2 M height and brick wall shall be
continued till the entire lining reaches about 100 mm above finished
grade level around the basement.
(E) Sealing at top of vertical waterproofing shall be done by laying a

chamfered seal of cement concrete (1:1:2) at 45° covering a total
thickness of tiling and brick wall (approx. 200 mm).
(F) This layer and brickwall should be cured for minimum of 15 days
before backfilling can be taken up. Care should be taken to backfill
the space around basement with good selected murum free from
stones, grit or hard material which may damage the brickwall.
10.2.3 Rendering Rectification:
After putting the basement into operation if any leakage, seepage or

dampness is noticed inside the basement on account of ground water, the
same shall be stopped by method of injection grouting through 25 mm
sockets grouted in walls or raft from inside the basement and pouring
cement grout or any other chemical grout as necessary, through pipe
connected to the sockets/nozzles until the seepage/leakage is stopped.
Detailed procedure including materials proposed to be used for grout shall
be submitted by Contractor for Engineer’s approval. Such rectification shall
not be at contractor's cost and shall not be paid separately.
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10.3 ROOF WATERPROOFING
Following specifications shall be followed for providing waterproofing over

RCC slabs, parapet walls etc. on building roofs, terraces etc.
10.3.1 Roof waterproofing TYPE I (Cement based)
10.3.1.1 Over Slabs - Plain or Sloping
(A) Clean the surface of the slab by removing all loose materials, dust,
etc. and wash with clean water.
(B) Provide and lay a screed of C.M. (1:2) over the clean and damp
surface including waterproofing agent mixed with C.M. Total average
thickness shall be 20 mm. This is to seal all pores and make the
concrete as impervious as possible.
(C) Lay an average thickness of 125 mm consisting of brick bat layer laid
in random pattern to avoid continuity of joints on 10mm thk. bedding,
10 mm thk. jointing with water proof cement mortar of (1:3). This layer
shall be laid to appropriate slopes towards rain water downtake outlets
already provided by Civil Contractor. This brick bat layer shall continue
in rounded manner over at least 200 mm of vertical surface of parapet
walls. This layer shall be cured for minimum 3 days before taking up
the next layer. The surface which is not taken up for next layer shall
be continued to be cured for minimum 10 days.
(D) Final Layer
Provide and lay minimum 40 mm thick IPS layer in cement concrete

(1:2:4) with maximum size of aggregate 3 mm to 6 mm, finished
smooth with polishing trowel, using C.M. (1:2) wherever necessary to
hide aggregate projecting at surface level. Use waterproofing agent as
approved in this layer.
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(E) Curing
This layer shall be cured for 21 days by flooding the water to 25 mm

depth in panel of 1M x 1M formed by weak cement mortar bonding.
10.3.1.2 On vertical surface and top of parapet walls (RCC or Brick):
(A) Clean the surface to be treated and apply a coat of Cement wash
using mixture of Cement and Water in proportion (1 bag : 80 litres).
(B) Provide and apply minimum 20 mm thk. waterproof plaster with

cement mortar (1:2), finished smooth with polishing trowel, in
continuation with finish layer of terrace top. This layer shall be laid
over entire inside surface of parapet, taken over top of parapet in
slope and continued over outside surface at least upto 300 mm below
top of roof slab or as directed by the Engineer.
(C) This layer shall be cured for 21 days by spreading clean hessian/jute
cloth which should be kept wet throughout the curing period.
10.3.2 Roof Waterproofing TYPE II [Lime terracing using brick bat Coba]
(A) Lime concrete shall consist of one part of lime mortar to 3 parts of
38mm and downgraded burnt brick ballast. The mortar shall consist
of one part of lime and two parts of surkhi well ground in mortar mill.
(B) The concrete surface to be covered with lime concrete shall be

brushed thoroughly and then painted with a coat of bitumen of
2
80/100 grade applied hot at the rate of 1.5 kg per M and allowed to
cool. The surface shall then be covered with lime concrete to the
required levels, falls etc. and thoroughly consolidated by beating with
wooden thapies and continually checked during the process with
straight edges.
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(C) The beating shall be carried out with two rows of workers sitting
across the entire width of the roof as closely as they can sit slowly
traversing its length backward and forward, beating all the time with
wooden rammers (weight 1 to 2 kgs.). This process shall be
continued for not less than three days until the mortar is almost
settled and shall be sprinkled with a mixture consisting of 1.75 kg of
gur and 1.00 kg of Bel fruit boiled in 60 litres of water.
(D) As soon as beating is completed, clean water shall be sprinkled on

the surface to soften it and the mortar that would have come to the
surface shall be well rubbed and then finished smooth with a steel
trowel.
(E) The average thickness of lime concrete terracing shall be not less
than 110 mm and minimum thickness shall be 50 mm. The slope of
the finished terrace shall not be flatter than 1 in 50 unless specifically
permitted by the Engineer.
10.3.3 Waterproofing TYPE III [using Felt]
(A) Asphaltic Bonding Material
This shall consist of Air blown bitumen conforming to IS:702. The

penetration of bitumen used shall not exceed 40 in any case.
Generally blown bitumen of low penetration shall be used for the
base and intermediate layers of bonding material.
Suitable residual type petroleum bitumen is of penetration 30/40 (IS

Grade S-35).
(B) Self Finished Felt
The self finished felt shall be of the brand and manufacture

conforming to the type and grade as described in the item. They are
fibre glass or hessian base felts. These shall conform in all respects
to IS:1322 and IS:7193 [Refer to Data Sheet ‘B’ for recommended
vendor / brand information].
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(C) Stone Grit and Pea Gravel
Stone grit shall conform to specifications of stone aggregate and

shall be 6 mm down size. Where pea gravel is used it shall be hard,
round and free from dust, dirt, etc. Stone grit or pea gravel shall be
spread uniformly at the specified volume per unit area. This shall not
be spread over vertical and sloping faces and at drain mouths. At
these places the surface shall be painted with two coats of
bituminous solution. If so specified in the item, in lieu of pea-gravel
2
finish, two coats of bituminous aluminium paint at the rate of 0.1/m
per coat shall be applied. Alternatively, one coat of colour
2
bituminous emulsion at 0.5 l/m or one coat of acrylic based coating
at 0.3 l/m2 shall be applied as specified.
10.3.3.1 Laying of Waterproofing Treatment
Waterproofing treatment shall be laid by a reputed agency generally as per

IS:1346. The treatment shall be one of the following.
Normal Treatment [5 course Layer Treatment] – Five courses for moderate

conditions.
1. Bitumen Primer conforming to IS 3384 at the rate of 0.27 litre/sq.m.

min.
2
2. Hot applied bitumen @ 1.2 Kg/m minimum
3. Hessian base self finished felt type 3 grade 1;
2
4. Hot applied bitumen @ 1.2 kg/m minimum.
2
5. Pea sized gravel or grit devoid of fine sand @ 0.006 Cu.m./M ,
adequately embedded under the bitumen.
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Heavy Treatment [7 course Layer Treatment] – Seven courses for severe

conditions.
1. Bitumen Primer conforming to IS 3384 at the rate of 0.27 litres/sq.m.

min.
2
2. Hot applied Bitumen @ 1.2 Kg/m minimum.
3. Hessian based self finished felt type 3 grade 1.
2
4. Hot applied Bitumen @ 1.2 Kg/M minimum.
2
2
7. Pea-sized gravel or grit devoid of fine sand, @ 0.006 Cu.m./M ,
Extra Heavy Treatment [9 Course Treatment] – Nine courses for very

severe conditions.
1. Bitumen Primer coat conforming to IS 3384 at the rate of 0.27

litres/sq.m.
2
2. Hot applied Bitumen @ 1.2 Kg/m minimum.
2
2
2
8. Hot applied bitumen @ 1.2 Kg/M minimum.
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2
9. Pea sized gravel or grit devoid fine sand @ 0.006 Cu.m./M ,
The bitumen to be used as bonding material shall be prepared by heating to

the correct working temperature as recommended by manufacturer and
spread on the roof with a rubber squeeze or cloth brush. Rolls of self
finished felt shall be laid over the hot bitumen and pressed properly to avoid
air gaps. A minimum end lap of 100 mm and side lap of 75 mm shall be
provided in the felt layer. For multilayer treatment the joints between the
layers shall be staggered. For junction of roof and parapet wall, the felt shall
be laid over a cement concrete fillet and then tucked into a groove, 50 x 50
mm in the parapet wall. The groove shall then be filled with cement mortar
1:4. The top layer of pea-gravel or grit shall be laid over the hot bitumen.
Where pea-sized gravel or grit is not available, coarse sand may be used.
In order to prolong the life of the waterproofing treatment or when the roof
surface is subjected to foot traffic or in order to provide fire protection to the
roof surface, cement concrete flooring tiles conforming to IS:1237 shall be
provided on top if specified in the item.
In all the above treatments, a surface finish of pea-sized gravel affords a

measure of protection to the treatment and increase its durability.
Alternatively, a screeding of proportion of 1:4 of cement and sand, 45 mm
thick can be laid over the roofing treatment and marked off into squares of
600 mm made with expansion joints provided at a clearance of 3M which
shall be properly caulked with bituminous sealing compound conforming to
Grade-A of IS 1834.
10.4 INJECTION GROUTING SYSTEM
10.4.1 Introduction
This specification covers the material and method of application of water

proofing for hollow underground structures like Basements.
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10.3.2 Bottom Raft
10.4.2.1 2 coats of solventless epoxy coating shall be applied over the lean concrete
surface to act as an impermeable membrane.
10.4.2.2 12 mm dia. threaded nozzles of length equal to half the depth of raft shall be
placed in grid pattern at a spacing not exceeding 1.5 metres centre to centre
all over the raft. These nozzles shall be placed during casting of concrete.
Similar threaded nozzles shall also be placed at critical points like
construction joints. The top of the nozzle shall be kept closed by providing
plugs.
10.4.2.3 Non-shrink polymeric waterproof grouting compound mixed with neat

cement slurry shall be injected through these nozzles under pressure by
pump. The grout will run through all pores, cracks etc. thereby sealing them.
10.4.2.4 After injection operation the nozzles shall be sealed with water proofing
admixtures.
10.4.3 Walls & Roof Slabs
10.4.3.1 Solventless epoxy coating placement of 12 mm dia. Nozzles, grouting and

final sealing of nozzles shall also be carried out in walls and roof slabs as
described above for bottom raft.
2
The payment shall be made on M basis of finished area. The rate shall
include all materials, labours, tools and tackles, making ponds, curing etc.
complete as specified.
10.6 Testing of Underground Waterproofed Concrete Structures.
The contractor shall test the water proofness of the structure by the
following procedure:
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(a) After making the inside surface completely dry the outside earth shall
be suitably ponded and flooded with water. This shall remain for 24
hours. The inside surface shall then be checked for any wet patch.
(b) After external testing, the pit shall be filled with water and the level
noted. After expiry of 24 hours the level shall be again observed.
The fall in level of water shall not be more than 10 mm.
In case injection grouting or any other technique is to be adopted to

rectify the defective workmanship, the same shall be done by the
Contractor at no extra cost to the Owner. The water required for
testing shall be arranged by the Contractor in case the same is in
contractor's responsibility or otherwise the same shall be supplied to
the Contractor as per agreed relevant clause of the contract.
10.7 GUARANTEE
Water proofing treatment and injection grouting system shall be laid as per
manufacturers instruction and as directed. Contractor shall guarantee this
work for minimum period of 10 years from the date of finishing and
acceptance from Client/Engineer.
10.8 THERMAL AND ACOUSTIC INSULATION
The insulation material shall be mineral-vermiculite. Vermiculite is the

geological name given to a group of hydrated laminar minerals which are
aluminium-iron magnesium silicates.
This shall consists of thin flat flakes, containing innumerable microscopic

voids.
10.8.1 TECHNICAL DATA
Exfoliation
On being suddenly subjected to high temperatures, (700°C to 1000°C) the

flakes exfoliate (expand) to many times their original volume due to the
formation of steam which forces the laminae apart as it is driven off.
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Ex-foliated vermiculite consists of accordian-like granules, containing

microscopic layers, which gives optimum insulation properties.
CHARACTER PROPERTIES
Sintering temperature - about 2300°F (1260°C)

Melting point - about 2400°F (1315°C)
Specific Heat - 0.2
Specific Gravity - 2.6
pH value - 7.0
Cation exchange - 90-100 milli-equiv.
properties. per 100 grams.
Thermal conductivity - 0.53 - 0.56 Kcal
Incombustibility - Incombustible and can
be used upto 1100°C.
Insolubility - Inert to organic solvents.
Density of laid mix - 400 - 480 kg/Cu.m.
Cold crushing strength - 14 - 24 kg/sq.m.
Air contraction at
max. service temperature - Less than 1%
Insulation effective - Sub-Zero to 1100°C
Chemical property - Chemically inert
OTHER PROPERTIES
- Light in weight
- Fire proof
- Rot proof
- Porous
- Non-abrasive
- Flaky material
10.8.2 APPLICATIONS
(A) Building Construction
Thermal insulation, by way of :-
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a) Roof screeding
b) Interior wall plaster
c) Cavity wall filling (Loose fill)
Acoustic treatment, by way of:-
a) Interior wall plaster

b) Ceiling plaster
10.8.3 METHOD OF APPLICATIONS
Thermal Insulation
Roof Screeding
"Vermiculite" is to be mixed with cement in the proportion of 5 Vermiculite to

1 Cement by volume. After properly dry-mixing, the lot is to be mixed with
water. This mix is to be immediately spread over the slab or roof surface in
the prescribed thickness, which for non-a/c building is 50 mm and for fully
air conditioned units is 75 mm.
The layer does not need any curing and the layer should be further treated
with bitumen / tiling / or cement plaster or any other terracing as may be
desired.
Wall Plaster
Vermiculite is to be mixed with Cement in the proportion of 4 Vermiculite to

1 Cement by volume and as in the case of roof screeding, it is to be directly
plastered over the surfaces of interior walls (exposed to sun) in 25 mm layer
thickness.
No curing is to be done over this plaster.
In ordinary cases, the surface can be treated with white washing, painting
etc.
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Acoustic Treatment
Vermiculite mixed with cement in 5:1 ratio by volume is to be plastered over

the surface where acoustic treatment is desired. The thickness should be
minimum 25 mm.
The acoustic plaster may be done on all walls and ceilings.
This plaster should not be treated and should remain exposed. However,
for decoration, if desired, other perforated boards may be used over this
surface.
10.8.4 SPECIAL CARES
Vermiculite surfaces need not be cured. When used for accoustics, no

other treatment should be done on these surfaces.
No sand is required for the treatment.
10.8.5 MODE OF MEASUREMENT & PAYMENT
The measurement shall be on square meter basis. The rate shall include
supply of all materials and fixing including labour, tools and tackles
complete in all respects including all taxes / levies etc.
END
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Uhde India Limited PLUMBING & SANITARY Page :1
Contents Page
SCOPE 2
CODES 2
SANITARY WARES 4
G.I. PIPE & FITTINGS 7
C.I. PIPE & FITTINGS 8
LEAD PIPES 8
GLAZED STONEWARE PIPES 8
INSTALLATION 9
RCC PIPES 11
TESTING OF WATER SUPPLY SYSTEM 13
TESTING OF SEWER SYSTEM 14
INSPECTION CHAMBERS 15
TRAPS AND VENTILATING PIPES 15
SEPTIC TANK 16
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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11.00 SCOPE
This section includes supply of all materials, labour and incidentals for
plumbing and sanitary works for business, industrial and other types of
buildings.
11.1 CODES
IS:458 - Concrete pipes (with and without reinforcement)
IS:651 - Salt glazed stoneware pipes & fittings.
IS:772 - General requirements of enamelled cast iron sanitary

appliances.
IS:774 - Flushing cistern for water closets & urinals (valveless

siphonic type).
IS:775 - Cast Iron brackets & supports for wash basins and sinks.
IS:783 - Code of practice for laying of concrete pipes.
IS:784 - Prestressed concrete pipes.
IS:1172 - Code of basic requirements for water supply drainage and

sanitation.
IS:1200 - Laying of water and sewer lines including appurtenant items.

Part XVI
IS:1230 - Cast Iron rain water pipes and fittings.
IS:1239 - Mild Steel Tubes and Mild Steel Tubulars and other wrought
steel pipe fittings.
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IS:1536 - Centrifugally cast (Spun) iron pressure pipes for water gas &
sewage.
IS:1537 - Vertically cast iron pressure pipe for water, gas & sewage.
IS:1538 - Cast Iron fittings for pressure pipes for water, gas & sewage.
IS:1626 - Asbestos cement building pipes, gutters and fittings (spigot &
socket types).
IS:1726 - Cast Iron manhole covers & frames intended for use in
drainage works.
IS:1729 - Sand cast iron spigot & socket soil, waste and ventilating
pipes & accessories.
IS:1742 - Code of Practice for building drainage.
IS:1771 - Glazed earthen-ware sanitary appliance.
IS:2470 - Code of Practice for designs and construction of septic tank

for small and large installations.
IS:2548 - Plastic water closet seats & covers.
IS:2556 - Specifications for vitreous sanitary appliances (vitreous

Part I to XV China)
IS:3076 - Low density polythelene pipes for potable water supplies
IS:3486 - Cast Iron spigot and socket drain pipes
IS:3889 - Centrifugally cast (spun) iron and socket soil waste and
ventilating pipes, fittings and accessories.
IS:4127 - Code of Practice for laying of glazed stoneware pipes.
IS:4984 - High density polythene pipes for potable water supplies
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IS:5219 - ‘P’ & ‘S’ traps
IS:5329 - Code of Practice for sanitary pipe work above ground for
buildings.
IS:5961 - Cast Iron gratings for drainage purposes.
IS:7231 - Plastic flushing cisterns (valves siphonic type for water

closets and urinals).
11.2 Sanitary Wares
All sanitary wares shall be of white or coloured glazed earthernware. The

connections shall be of P.V.C. and fittings of C.P. brass as specified in
B.O.Q. items.
The chromium plating shall conform to IS:4827 and shall be of grade 2

(thickness 10 micron).
11.2.1 Water Closets
380 to 400 high, double trap siphonic pattern ‘P’ or ‘S’ trap with PVC cover
and toilet seat.
European or Western Closet
a) as commode or hopper type pedestal type

b) as commode or hopper with wall hung type
c) water closet and cistern coupled as one set only
Indian (Pan or squatting) style with ‘P’ or ‘S’ siphonic trap:
a) normal pan 630 x 580 size to be sunk into floor on 150 concrete
cushion.
b) Orissa pattern pan 580 x 440 to be sunk into floor on 150 mm thk.
Concrete cushion.
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With non-slippery foot rests arrangement.
Anglo Indian or Semi Western / Indian Style:
30 cm high with PVC toilet seat and cover.
CISTERN
5.0 litre capacity PVC cistern with PVC cover and valveless fittings with
bottom / side inlet and outlet and overflow shall be mounted on C.I. brackets
to walls, just below the window sill level suitably placed at a height convenient
from operation point of view.
11.2.2 Urinal
White glazed earthen ware urinal shall be fixed and provided with 5 lit.
capacity PVC automatic flushing cistern with all accessories as detailed in
water closet description. Waste pipe shall be 750 long, 32 mm dia. G.I. with
necessary unions and C.P. bottle trap. Anchor fasteners with C.P. brass
screws shall be used for fixing the urinal. Flush pipe shall be 12 dia./C.P.
brass pipe. Height of a bowl or lipped type urinal above foot level shall be
750 mm.
There are four types of urinals:
i) Bowl type flat back and angle back

ii) Slab type
iii) Stall type
iv) Squatting plate
They shall be provided as indicated in drawings or as directed by Engineer.
The foot rests or treads should be of the non-slippery type and slightly sloping
towards bottom floor channels.
11.2.3 Wash Basin
White or coloured glazed earthenware wash basin with one side flat of size
630 x 450 or 510 x 400 shall be fixed on brackets. I) without pedestal, ii)
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with pedestal, iii) as counter top as shown in drawings or as directed by

Engineer. Top of wash basin shall be 800 mm above finished floor.
It shall be provided with (a) 32 mm dia. C.P. bottle trap with waste coupling,
(b) 12 m dia. PVC connector and 12 mm dia. screw down C.P. brass stop
cock (c) 12 mm dia. C.P. brass screw down type pillar tap.
While fixing above earthen ware utmost care shall be taken to avoid
damage. Totally finished system shall be accepted after inspection and
testing is done with satisfactory results.
11.3 Bevelled Edge Mirror
The mirror shall be of approved make and of size 600 x 450 mm and of
thickness 8mm. It shall have asbestos sheet backing and fixed to wooden
cleats with C.P. brass screws and CP washers in proper line.
11.4 Towel Rail
Towel rail shall be of Stainless steel or Chromium plated (CP) brass with
stainless steel or CP brass brackets. The towel rail shall be 20 mm dia. and
600 mm long. It shall be fixed at specified place as shown in drawing or as
11.5 Glass Shelf
Glass Shelf of size 450 x 110 x 4mm thick plain sheet glass shall be provided
and fixed below mirror on suitable C.P. brass brackets with anchor fasteners
and, C.P. brass screws. Edges of the glass shall be properly rounded or
smoothened.
11.6 Marble Partition
The marble partition shall be of 5700 mm depth, 25 mm thick double

polished from both the sides and approved by the engineer. Height of fixing
shall be 670 mm above floor.
The edges of marble shall be got cut by machine to have proper smooth
edges as per detailed drawing.
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Vertical face shall be fixed in position with cement mortar 1:3 as directed by
the Engineer for a minimum depth of 100 mm in the wall.
After fixing recesses shall be made good.
11.7 Floor trap
Floor trap shall be heavy cast iron with 100 mm inlet and 100 or 75 or 50 mm
outlet with C.P pressed steel grating. It shall be either hinged or screwed
down type as directed. It shall be fixed in M-15 grade concrete bed.
11.8 Bib and Stop Cock
Bib and stop cock of screw down type shall conform to IS:781. It shall be of
heavy grade. The tap shall be of C.P. brass easy cleaning variety as
specified. It shall be fixed with white zinc and spun yarn.
11.9 Gun Metal valve
All full way and globe valves shall be of heavy gun metal and tested at 21
2
kg/cm and shall be approved by the Engineer-in-charge. Valves shall
conform to IS:778.
11.10 Galvanised Iron Pipes & Fittings
Galvanised iron (GI) pipes and fittings shall be of Heavy grade ('C' Class),
and shall conform to IS:1239. The jointing shall be done using screwed
fittings as specified in IS:554.
All G.I. pipes internal or external shall be fixed by means of approved

pattern holder bat clamps @ 1.2 m c/c.
Each galvanised pipe shall be hydraulically tested after galvanising to

withstand a test pressure of 50 kg/sq.cm. without showing any defects at the
manufacturer's work.
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Fitting in G.I. Pipes, include all couplings, elbows, tees, bends, unions,
nipples, reducers, flanges with nuts and bolts and rubber insertions, bushes
and all other fittings to make a complete job. White lead with few strands of
fine hemp shall be applied while tightening. Compounds containing red lead
shall not be used.
No extra payment shall be made for clamps, hooks, cutting holes in walls,
chasing and making them good.
11.11 Cast Iron Pipes & fittings
All C.I pipes and fittings shall be of approved make conforming to Indian
standards and subject to approval of the Engineer, free from flaw and with
clean and smooth interior. The fittings shall be of proper design, provided
with 3.2 mm rubber insertion so as not to form cavities. The spigot end shall
be above the shoulder of the socket end and leave no annular space in
between.
Each head of the drain shall be ventilated by means of 100 mm C.I guards at
terminals and the pipe fixed to the wall with standard 100 mm holder clamps.
The pipes shall be bitumen painted smooth inside and outside shall be
painted with aluminium or other paint as desired by the Engineer.
11.12 Lead Pipes
Lead pipes used for branch waste pipes from fittings to main stock shall
conform to IS:404. The pipes shall be sound and free from laminations,
flaws, pronounced extrusion marks or other imperfections and shall, as far
as possible, be circular in cross section, smooth and of uniform wall
thickness throughout. Lead pipes should be used only for short branches of
soil, waste or vent connections.
11.13 Glazed Stoneware Pipes
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Glazed stoneware pipe shall be as per I.S. Specifications made by the

approved manufacturer, absolutely smooth finished from inside, well burnt
and non-porous. The line shall be laid in the required gradient, socket facing
upstream direction, and joints filled up with dry cement mortar of 1:1
proportion, and caulked well inside and edges outside the socket splayed off
well at 45 deg.c. The spigot end shall be inserted into the socket to the full
length. No change in directions shall be allowed by partial insertion of the
spigot. The joints shall be well watered and kept moist by wet gunny bags for
at least a week's period.
11.14 All sanitary wares, fittings, pipes etc. shall be of approved make. Samples of
all fixtures, fittings, pipes etc. shall be submitted by contractor for approved
by Engineer in advance.
11.15 Installation of Pipes
11.15.1 Licensed Plumbers
The work required to be carried out under the provision of these

specifications shall only be executed by the licensed plumber or by a person
whose qualification has been approved by the Engineer.
11.15.2 Excavation
Excavation shall be done in accordance with Technical specifications

Section No.1
11.15.3 Concreting
Concreting shall be done in accordance with Technical specification Section

No.2.
11.15.4 Laying of Pipes
The pipes shall be laid with the sockets facing upstream and shall rest on
solid and even foundations for the full length of the barrel. Socket holes be
formed in the foundation sufficiently deep to allow sufficient space for the
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pipe jointer to work right around the pipes and as short as is practicable to
accommodate the socket in the proper position and allow the joint to be
made.
Where pipes are not bedded on concrete, the trench shall be left slightly high
and carefully bottomed up as pipe laying proceeds so that the pipe barrels
rest on firm and undisturbed ground. If the excavation has been carried too
low, packing done shall be in concrete.
All vertical pipe shafts, soil pipes or ventilation pipes shall be strongly
supported at the foot upon a bed of concrete and firmly attached to the walls.
It shall be fixed at least 5 cms. clear of the finished surface of the wall by
means of suitable clamps of approved type.
Each separate pipe shall be individually set for line and for level using one of
the standard procedure as approved by the Engineer.
11.15.5 Jointing of Pipes
The spigot and socket joints of cast iron pipes shall be fitted with jute or yarn
mixed with linseed oil and cement slurry, and then the entire joint shall be
covered by cement all round to ensure complete leak proof joint.
Screwed wrought iron or steel piping shall be jointed with screwed and
socketed joints, using screwed fittings of wrought iron, steel or malleable
cast iron. Care shall be taken to remove any burr from the ends of pipes
after screwing.
A joint compound may be used according to the manufacturer's instructions

together with a grummet of a few strands of fine yarn, but compounds
containing red lead shall not be used. Any threads exposed after jointing
shall be painted or in case of underground piping, thickly coated with
bituminous or other suitable composition to prevent corrosion.
Lead to Lead, Copper or brass joints shall be made as wiped solder joints.
The minimum and the maximum length of the wiped solder joints shall be 8
mm and 9 cm respectively. The solders shall consist of two parts of Portland
cement and one part of clean sharp sand.
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All pipes shall be fixed 25 mm clear off the wall with M.S Holder bat clamps
or as approved by the Engineer. Where any water closet pan or earthenware
trap connected to such pan is to be jointed with a cast iron pipe, the joint
between the stoneware spigot and the cast iron socket shall always be of a
flexible (non-rigid) nature, such joints shall be made with a mixture of
bitumen and chopped asbestos fibre (nut dust).
11.16 R.C.C PIPE
11.16.1 Materials
For pipe materials, the following specifications shall apply :
RCC Pipes & Collars IS:458

Laying of Pipes IS:783.
For cement sand, mortar, water etc. the specifications laid down for concrete
works shall apply.
All pipes must be new and perfectly sound, free from cracks, cylindrical,
straight, and of standard nominal diameter and length with even texture.
Each pipe shall have one collar with it.
The contractor shall submit manufacturer's test certificate on demand by

Engineer. Spun yarn for pipe joints shall be of best quality. It shall be clean
and free from dust etc.
11.16.2 Transportation and Stacking
The transportation of materials to the work site and stacking shall be done in
a manner to cause minimum inconvenience to the traffic and other
construction works. The pipe shall be protected during handling against
impact; shocks and free fall to avoid cracks and damage.
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The contractor shall be fully responsible for the safety and security of
materials transported and stacked in the field.
11.16.3 Lowering and Laying of Pipes
General
The laying and jointing of pipes shall conform to IS:783. The trench shall be
checked for proper level, gradient and alignment before lowering the pipes.
Lowering
The pipes shall be lowered cautiously to prevent disturbance of the bed and
sides of the trench. The heavy pipes shall be lowered by means of proper
shear legs, chain pulley blocks or as directed by Engineer. Great care should
be taken to prevent sand etc. from entering the pipes.
Laying
Laying of pipes shall proceed up grade of slopes. The error of grade shall
not be rectified by packing up earth underneath the pipes. If required,
concrete shall be used for packing.
The ends of the pipes shall be kept closed to keep out dirt, mud and foreign
materials, out. Adequate provision shall be made to prevent floating of pipe
in the event of flooding of trenches.
The body of the pipe for its entire length shall rest on an even bed in the
trench and collar location shall be excavated to receive the collar for the
purpose of jointing.
A few skeins of spun yarn soaked in neat cement shall be inserted in the
groove at the end of the pipe and the two adjoining pipes butted against each
other. Collar shall be slipped over the joint covering equally both the pipes.
Spun yarn soaked in neat cement shall be passed round the pipes and
inserted in the joint by means of caulking tools from both ends of the collar.
More skeins of yarn shall be added & well rammed home. The object of the
yarn is to centre the two ends of the pipes within the collar and to prevent
pipes becoming loose.
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Cement mortar 1:2(1 cement :2 sand) shall be slightly moistened and must
on no account be soft or sloppy and shall be carefully inserted by hand into
the joint. The mortar shall then be punched and caulked into the joint and
more cement mortar added until the space of the joint has been filled
completely with tightly caulked mortar. The joint shall be finished off neatly
outside the collar on both side at an angle of 45 Deg.
Any surplus mortar projecting inside the joint is to be removed and to guard
against any such projections, sack or gunny bags shall be drawn past each
joint after completion.
11.16.5 Curing
The cement mortar joints shall be cured at least for seven days.
11.16.6 Testing
All joints in the pipes shall be tested to a head of 1.5 metres of water above
the top of the highest pipe.
11.17 Testing of pipes
All tests shall be conducted by the contractor at his own expense in the
presence of the Engineer and as guided by the Engineer.
11.17.1 Testing for water supply system
When the service is complete, it shall be slowly and carefully charged with
water, allowing all air to escape and avoiding all shock or water hammer.
The services shall then be inspected under working conditions of pressure.
When all draw off points are closed, the service pipe shall be absolutely
water tight. All piping, fittings and appliances will be checked over for
satisfactory support, and protection from damage and corrosion. In view of
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the possibility of damage in transit, cisterns shall be retested for water

tightness on arrival at the site, before fixing.
11.17.2 Testing for Sewer System
Comprehensive tests of all appliances shall be carried out by simulating

conditions of use before the final approval. Over flow shall also be examined
for any obstruction.
11.17.3 Smoke Test
All soil pipes, waste pipes, vent pipes and rain water drain pipes and all other
pipes which are above ground shall be gas-tight. To ensure gas-tightness,
smoke test shall be conducted. The smoke can be produced by burning oily
waste or tar paper or similar material in the combustion chamber of smoke
machine.
11.17.4 Water Test
The drains pipes shall be subject to test pressure of at least 1.5 M head of
water at the highest point of the section under test. The tolerance figure of
two litres per centimeter of diameter per kilometer (or one gallon per inch of
diameter per mile) shall be allowed during a water filled period of ten
minutes. The test shall be carried out by suitably plugging the low end of the
drain and the ends of connections if any and then filling the system with
water.
11.17.5 Sterilization
All building water supply system before connected to the street main shall be
thoroughly and efficiently disinfected by the contractor under the supervision
of Engineer. The system shall be first flushed out with water having a does of
50 parts of chlorine to one Million parts of water (50 ppm). If chlorine powder
is used, the proportions shall be 150 grams to 1000 litres of water.
11.18 Stoneware Gully Trap with Chamber
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The square mouth gully trap shall be of 100 mm dia, conforming to IS:651 or
as specified and of approved quality stoneware, complete with heavy cast
iron grating, and shall be got approved by the Engineer. The size of C.I.
frame and hinged cover shall be of 300 mm x 300 mm. It shall be properly
fixed as directed by Engineer.
The size of chamber shall be min. 300 mm x 300 mm x 600mm deep

(internal). It shall be constructed of brick masonry walls of 115 mm thick in
CM 1:5 (1 cement : 5 sand) resting on 100 mm thick M-10 concrete. Inside
and outside face of masonry walls shall be plastered with 1:3 cement mortar
with cement finish.
11.19 Inspection Chambers
Inspection chambers will be constructed as per drawing at indicated intervals

and elevations. These will be generally in 230 thick Brick masonry unless
otherwise mentioned resting on 100 mm thick M-10 concrete. The minimum
internal size shall be 1200 mm x 900 mm. Inside faces shall be with
waterproof plaster and bottom face shall be with smooth finish and half-
tunnelling for easy flow. Inspection chambers are provided at every change
of direction or gradient and at the point where the vertical soil pipe joins the
house drain.
11.20 Traps and Ventilating Pipes
Pipes carrying the waste from water closets and waste water and overflow
water from baths, wash basins, sinks to drains shall be trapped immediately
beneath such fixtures. Traps shall have minimum water seal of 50 mm and
shall be ventilated whenever such ventilation is necessary to maintain water
seal of the trap.
Ventilating pipes shall be carried up vertically from the drain to a height of at

least 600 mm above the outer covering of the roof of the building or as shown
on drawings. All vertical ventilating, anti-siphonage and similar pipe shall be
covered on top with a cowl. The cowl shall be made of C.I. unless desired
otherwise by the engineer.
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11.20.1 Manhole and Inspection Chambers
The maximum distance between manholes shall be 30 meter unless

specially permitted otherwise. In addition, at every change of alignment
gradient or diameter there shall be a manhole or inspection chamber. The
distance between manhole or inspection chamber and gully chamber shall
not exceed 6 metres unless desired otherwise. Manhole shall be constructed
so as to be watertight under test. The bending at the sides shall be carried
out in such a manner as to provide no lodgement for any splashings in case
of accidental flashing of the chamber. The channel or drain at the bottom of
chamber shall be plastered with 1:2 cement, sand mortar and finished
smooth to the grade. The channels and drains shall be shaped and laid to
provide smooth flow.
Connecting to existing sewer line shall be through a manhole.
Manholes shall be provided with standard C.I. covers. The covers shall be
close fittings so as to prevent gases from coming out. Suitable heavy duty
covers shall be used where necessary as decided by the Engineer.
11.22 Septic tank & effluent disposal
11.22.1 Septic tank
Septic tank shall consist of the settling tank itself with inlet and outlets
therefrom complete with all necessary earthwork and backfilling. The details
of septic tank shall be as shown on drawings. This item shall also include
ventilating pipe of at least 100 mm dia whose top shall be provided with a
suitable mosquito proof wire mesh and cowl. Ventilating pipe shall extend to
a height of about 2 metres when the septic tank is at least 15 metres away
from the nearest building and at least 2 metres above the building when it is
located closer than 15 metres. Ventilating pipes can be connected to the
normal soil ventilating system of the building where allowed.
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11.22.2 Effluent Disposal
The effluent from the septic tank shall be disposed by allowing it into an open
channel or a body of water if the concerned authority approves or into a soak
pit for absorption by soil or shall be allowed to be absorbed by soil through
open jointed SW pipes laid in a trench filled with broken bricks.
11.22.3 Soak Pit
The soak pit shall be complete as shown on drawing. It shall consist of a 900
mm dia pit 1000 mm in depth below the invert level of the inlet pipe. The pit
shall be lined with stone, brick or concrete blocks set in cement mortar (1:6)
and filled with brick bats. Inlet pipe shall be taken down to a depth of 900
mm from the top as an anti-mosquito measure.
11.22.4 Open joined SW Pipe/dispersion trenches
Minimum dia. of the SW pipes shall be 150 mm nominal. The trench for
laying the pipes shall be minimum 600 x 600 mm. The joints of the pipes
shall be left unsealed. The entire length of the pipe within the trench shall be
buried in a 250 mm layer gravel or crushed stone of uniform size. On top of
gravel/crushed stone layer 150 mm bed of well graded coarse aggregate
shall be laid. Ordinary soil will be used for filling the top of trench.
11.22.5 Commissioning septic tank
After the septic tank has been proved watertight and the sewage system is
checked the tank shall be filled with water to its outlet level before the
sewage is let into the tank. It shall be seeded with well digested sludge
obtained from septic tank or sludge digestion tank. In the absence of
digested sludge a small quantity of decaying organic matter such as
digested cow-dung may be introduced to start with.
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11.22.6 Testing Septic Tank
The septic tank shall be tested for water-tightness. It shall be filled up with
water and allowed to soak for 24 hrs. Then, it shall be topped up and allowed
to stand again for 24 hrs and loss of level recorded. The fall shall not be
more than 15 mm.
1) Sanitary Wares
The payment shall be on Unit number basis. The rate shall include
all materials, fixing, labour, making all surfaces good, jointing,
painting, testing etc. complete as specified.
2) For all other items which are to be quoted in unit number, the rate
shall include for complete item including supply, fixing, labour, etc.
all complete.
3) For A.C.. G.I.. C.I.. Stone-ware and R.C.C pipes The payment shall
be on RM basis of finished length laid. The rate shall include all
materials, fixtures, accessories, clamps, laying, fixing, jointing,
labour, tools and tackles, painting etc. complete as specified.
END
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Uhde India Limited ROADS, DRAINS, PITS & CULVERTS Page :1
Contents Page
SCOPE 2
APPLICABLE CODE AND SPECIFICATION 2
MATERIAL 3
PREPARATION & COMPACTION OF SUB-GRADE 11
SOLING COURSE 11
WATER BOUND MACADAM 13
BITUMINUOUS SURFACE TREATMENT 16
PREMIX CARPET 19
BITUMINOUS CONCRETE 21
SEMI GROUTING 26
BITUMINOUS SHEET 28
BITUMEN MASTIC 29
BRICK ON EDGE SOLING 32
CEMENT CONCRETE PAVEMENT 32
ROAD LANE MARKING 34
PIPE CULVERTS 34
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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12. SCOPE
This specification covers the general requirements for the materials and
construction of soling, Water Bound Macadam (WBM) roads,
bituminous/concrete surface treatment of roads and walkways and drains and
culverts.
12.1 APPLICABLE CODES & SPECIFICATIONS
The following specifications, standards and codes are made a part of this
specification. All standards, tentative specifications, specifications, codes of
practices referred to herein shall be the latest edition including all applicable
official amendments and revision. In case of discrepancy between this
specification and those referred to herein, this specification shall govern.
1. IS: 73 : Paving Bitumen

2. IS:215 : Road Tar
3. IS:217 : Cutback Bitumen
4. IS:383 : Specification for coarse and fine aggregate from
natural sources for concrete.
5. IS:458 : Concrete pipes (with and without reinforcement)
6. IS:460 : Test sieves
7. IS:1077 : Common burnt clay building bricks
8. IS:1124 : Method of test for water absorption of natural building
stones.
9. IS:1195 : Specification for Bitumen Mastic for flooring
10. IS:1196 : Code of Practice for laying Bitumen Mastic flooring
11. IS:1834 : Sealing compounds, hot applied, for joints in
concrete.
12. IS:2116 : Sand for masonry mortars
13. IS:2386 : Methods of test for aggregates for concrete
Parts I to
VIII
14. IS:2720 :
15. IS:3102 : Classification of burnt clay bricks
16. IS:3495 : Method of sampling and testing clay buildings bricks.
17. IRC:16 : Tentative specification for Priming of Base Course
with Bituminous Primers.
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18. IRC:17 : Tentative specification for Single Coat Bituminous

Surface Dressing.
19. IRC:19 : Standard specifications and Code of Practice for
Water Bound Macadam.
20. IRC:29 : Tentative specification for 4 cm Asphaltic Concrete
Surface Course.
21. IRC:48 : Tentative specification for Bituminous Surface
Dressing using Precoated Aggregates.
22. Ministry of : Specification for Road & Bridge works.
Surface
Transport (MOST)
(Roads Wing)
12.1.2 Where the requirements of the above codes differ from UIL specification or
other specifications forming a part of the bid document, the latter shall govern.
12.1.3 All earthwork and concrete work shall be according to component

specifications "Earthwork” and "Concrete and Formwork" - respectively.
12.2 CONSTRUCTION SEQUENCE
12.2.1 It is the intent of this specification that the Waterbound Macadam (WBM) road
be constructed first and surfaced with bituminous surfacing as specified
hereunder. This shall then be opened to traffic, as directed by
Owner/Engineer. After such period of time as decided by Owner/Engineer,
when the major construction and/or erection activities within plant limits are
over, Contractor shall rectify all defects, wear and tear, etc. and surface the
road with bituminous treatment as specified hereunder.
12.3 MATERIALS
12.3.1 General
12.3.1.1 All materials shall be obtained from local sources and approval of Engineer
shall be obtained prior to starting of work.
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12.3.2 Soling Stone
12.3.2.1 It shall be clear, sound, dense, hard stone of uniform quality free from
deleterious material, cracks, decay and weathering. Water absorption shall
not be more than 5 percent. The height of the soling stone shall be equal to
the specified thickness of soling. The length and breadth shall not exceed
twice the specified thickness.
12.3.3 Stone Aggregate/Metal
12.3.3.1 Coarse aggregate, stone chippings shall consist of natural or crushed stone,
clean, hard, tough, durable and free from excess of flat elongated, soft and
disintegrated particles, dirt, salt, alkali, vegetable matter, adherent coatings,
organic and other objectionable matter, conforming to IS:383 and shall satisfy
the physical requirements of Tables 1 or 2 as applicable. Aggregate for
bituminous wearing courses shall in addition have good hydrophobic
properties i.e. capacity of retaining the film of bituminous material applied to
the stone in all weather conditions and especially in wet conditions. Basalt,
dolerite are good in this respect; granite, quartzite are comparatively poor.
TABLE - 1
PHYSICAL REQUIREMENT OF
COARSE AGGREGATE FOR WATER BOUND MACADAM
Sl.No. Type of Test Requirements Test Method

Construction
1 Sub-base Los Angeles 60 percent IS:2386
Abrasion Value* max. (Part-IV)
OR
Aggregate Impact 50 percent IS:2386
Value* max. Part IV
2 Base a) Los Angeles 50 percent IS:2386
Abrasion Value* max. (Part-IV)
OR
Aggregate 40 percent IS:2386
Impact Value* max. (Part IV)
b) Flakiness 15 percent
Index ** max. IS:2386
(Part-I)
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TABLE - 2
PHYSICAL REQUIREMENT OF AGGREGATES
FOR BITUMINOUS WEARING COURSE
Sl.No. Test Requirement Test Method
a) Los Angeles Abrasion Value * 40 percent max. IS:2386 (Part-IV)

OR
Aggregate Impact Value * 30 percent max. IS:2386(Part-IV)
b) Flakiness Index ** 15 percent max. IS:2386(Part-I)
c) Stripping Value 25 percent max. MOST***
d) Water Absorption 1 percent max. IS:2386(Part-III)
(*) Aggregates may satisfy requirements of either of two tests.
(**) Requirement of flakiness index shall be enforced only in case of crushed broken stone.
(***) Specification for Road & Bridge Works, Ministry of Surface Transport (roads wing).
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12.3.3.2 The coarse aggregate for water bound Macadam shall conform to one of the
gradings given in Table 3 below:
TABLE - 3
GRADING REQUIREMENTS OF COARSE AGGREGATES (IRC:19-1977)
Grading Size Range Sieve Designation Percent by Weight

No. Passing the Sieve
1 90mm to 45mm 125 mm 100

90 mm 90-100
63 mm 25 – 60
45 mm 0 – 15
22.4 mm 0–5
2 63mm to 45mm 90 mm 100
63 mm 90 - 100
53 mm 25 – 75
45 mm 0 –15
22.4 mm 0–5
3. 53mm to 22.4 mm 63 mm 100

53 mm 95 - 100
45 mm 65 - 90
22.4 mm 0 - 10
11.2] mm 0-5
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12.3.3.3 The size of stone chippings for surface dressing shall be in accordance with
Table-4.
TABLE - 4
SIZE REQUIREMENTS OF STONE CHIPPINGS
FOR SURFACE DRESSING
Sl.No. Type of Construction Nominal size of stone Specifications

chipping
1 Single coat Surface Dressing 12 mm 100 percent passing
through 20mm seive and
retained on 10mm sieve.
12.3.4 Screenings For Water Bound Macadam
12.3.4.1 Screenings to fill voids in the coarse aggregate shall consist of the same
materials as the coarse aggregate. However, where permitted, predominantly
non-plastic material such as murum or gravel (other than rounded river borne
material) may be used for this purpose provided liquid limit and plasticity index
of such material is below 20 and 6 respectively and fraction passing 75
micron sieve does not exceed 10 percent.
12.3.4.2 Screenings shall conform to the gradings set forth in Table-5. Screenings of
Type-A in Table-5 shall be used with coarse aggregates of grading 1 in Table-
3. Screening of Types A or B, as specified, shall be used with coarse
aggregates of grading 2. Type-B screenings shall be used with coarse
aggregates of grading 3. For screenings like murrum and gravel, the
gradings given in Table 5 shall not be regarded as binding.
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TABLE - 5
GRADING REQUIREMENTS FOR SCREENINGS FOR W.B.M.
(IRC:19-1977)
Grading Size of Screenings Sieve Designation Percentage by weight
classification passing the sieve
A 13.2 mm 13.2 mm 100

11.2 mm 95 - 100
5.6 mm 15 –35
180 microns 10
B 11.2 mm 11.2 mm 100

5.6 mm 90 – 100
180 microns 15 – 35
This use of screenings may be omitted in the case of soft aggregates such as brick metal,
kankar and laterite.
12.3.5 Binding Material
12.3.5.1 Binding material to prevent avelling of water bound Macadam shall comprise
of a suitable material, approved by Owner/Engineer, having plasticity index
value of less than 6 as determined in accordance with IS:2720 (Part-V).
Binding material shall consist of a fine grained material passing 100 percent
through 425 micron sieve.
12.3..5.2 Application of binding material may not be necessary, when the screenings
used are of crushable type such as murum or gravel.
12.3.6 Murum/Kankar/Gravel/Sand
12.3..6.1 Murum shall be obtained from pits of weathered disintegrated rocks and shall
contain silicious material and natural mixture of clay of calcarious origin.
Murum shall be sound and hard, of a quality not affected by weather, to be
screened at the quarry and free from all impurities. Only pure murum shall be
received at the site of work. The large lumps must all be broken at the quarry
and murum delivered at site must pass in every direction through a 63 mm
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ring. Murum shall not contain more than 5% to 8% of fine sand passing
through a 75 micron sieve.
12.3.6.2 Kankar shall be as tough as can be procured in the locality, having a blue,
almost opalescent fracture. It shall not contain any clay in the cavities
between the nodules. 100 percent shall pass through a square mesh of 63
mm.
12.3.6.3 Gravel shall be composed of large, coarse, silicious grains, sharp and gritty to
the touch, thoroughly free from dirt, organic and deleterious matter. The
gravel shall be hard, tough, dense and shall not contain particles bigger than
12 mm and more than 10 percent silt.
12.3.6.4 Sand used for building road surfaces shall be coarse, sharp, gritty, clean,
granular material. Only material passing through 4.75 mm sieve and retained
on 75 micron sieve shall be used. All material passing through a 75 micron
sieve shall be rejected.
12.3.7 Bituminous Materials
12.3.7.1 Bituminous materials shall conform to IS:73, IS:215 or IS:217 as applicable

and be of the grade specified in this specification.
12.4 SUPPLYING AND STACKING OF MATERIALS
12.4.1 The ground under the stacks shall be cleaned, levelled or dressed to a
uniform slope and all humps, depressions, etc. shall be removed. The
stacked material shall be free from vegetation and other foreign matter.
Soling stone shall be stacked compactly in stacks. In case any stack shall be
found loose and improperly made Owner/Engineer can direct the restacking of
some or of all the stacks. The stacks for all materials shall be uniformly
distributed along the road. The supply of material shall be completed for the
entire work or for a complete length of one kilometre or as directed by
Owner/Engineer. All rejected material shall be separated out and removed
from site before recording measurements.
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12.4.2 Soling stone shall be stacked in convenient units of 1 to 1.25 M height and of
uniform width and length as directed by Owner/Engineer. Actual dimensions
of stacks shall be recorded and total quantity shall be reduced by 15 percent
to arrive at the net quantity for payment.
12.4.3 Stone aggregate/metal shall be stacked in convenient units of 1 M top width,

2.2 M bottom width, 60 cm height and length in multiples of 3 M. Template of
wood or steel shall be used for making the stacks and shall always be kept at
site for check measurements.
The section of the stacks shall be taken from the standard template used and
length of the stack recorded to arrive at the contents. The total quantity so
arrived at shall be reduced by 10% to arrive at the net quantity for payment.
12.4.4 Screenings, binding material, stone chippings, murum, kankar, gravel and
sand shall be stacked in convenient units of one cu.m. The stacks shall be
made with wooden boxes open at both ends and 2 x 2 x 0.25 M dimensions.
These shall always be kept at site for stacking and check measurements.
Materials shall be measured from the actual dimensions of the stacks. No
deduction shall be made for voids to arrive at the net quantity for payment.
12.4.5 Bituminous material shall be brought to site of work in sealed original

containers. Damaged containers shall not be allowed. All drums brought to
site shall be serially numbered and used in the same order. Material shall be
recorded as per standard weights of different type of content as intimated by
manufacturers. The material shall be weighed where containers are found
leaking.
12.4.6 The rates for supplying materials as per specification and stacking them as
per the preceding clauses shall include the cost of all labour and materials
involved in all the operations described above including transportation to the
site of work along the alignment of the road as directed by Owner/Engineer.
12.4.7 Wherever separate items for supplying and stacking are not given the
rate for the same shall be deemed to be included in the items for laying
of wearing / bituminous course.
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12.5 PREPARATION AND COMPACTION OF SUBGRADE
12.5.1 The proper preparation of the sub-grade or road bed or formation for any road
is of utmost importance before the road structure (pavement) is laid over it.
The surface of the formation for a width equal to that of the sub-base course
shall first be cut to a depth below the proposed finished level, equal to the
combined depth of sub-base and wearing courses (due allowance being made
for consolidation). Any over excavation made during the time of excavation is
to be filled with good earth and compacted by Contractor at his own cost.
Surplus excavated earth shall be disposed off beyond the road limit as
directed by Owner. The surface shall then be cleaned of all foreign
substances. Any ruts or soft yielding places that appear due to improper
drainage conditions, traffic, hauling or from any other cause, shall be
corrected. The sub-grade shall be consolidated with power road roller of 8 to
10 tonnes and dressed off true to profile.
The roller shall run over the sub-grade till the soil is evenly consolidated to
95% of standard Proctor density with 2% variation in optimum moisture
content. Roller shall pass minimum of 5 runs on the sub-grade. Rolling shall
commence at the edges and progress towards the centre longitudinally except
that on super-elevated portions, it shall progress from the lower to the upper
edge parallel to the centre line of the pavement. 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 camber shall be checked and any high
spots or depressions which become apparent corrected by removing or
adding earth and sub-grade re-rolled.
12.5.2 The measurements shall be taken in sq.m. and the rate shall include the cost
of all materials, labour, plant and equipment required for all the operations
mentioned above.
12.6 SOLING COURSE:
12.6.1 Soling shall be used as a sub-base where specified in the Schedule of

Quantities. The width and the compacted thickness of the soling shall be as
shown on the drawings. Due allowance shall be made initially so that specified
compacted thickness is finally achieved. Soling shall not be laid on a wet sub-
grade.
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12.6.2 The stones in soling shall be hand packed with greatest length across the
road. The stones shall be laid closely in position on the sub-grade, with its
broadest side downwards and to make up the specified thickness of the base
with single stones to correct camber and grade. Soling shall not be laid in two
layers. Projections in stones which would result in excessive voids shall be
knocked off with a hammer and/or selected stones used to fit the shape of the
stones already laid. The joints shall be staggered. All interstices between
stones shall be wedged in with smaller stones of suitable size, well driven-in to
enable tight packing and complete filling of interstices. Such filling shall be
carried out simultaneously with the placing in position of soling stone and shall
not lag behind. All projecting corners above the surface of the level of the
soling shall be snapped off with hammer to bring them in level. Gravel shall
be spread in thin layers (to fill the remaining voids) and swept to assist the
filling of voids. Spreading of gravel, sweeping and watering shall continue till
interstices are completely filled.
At all times, only enough water shall be sprinkled to force the gravel into voids
and never so much as to soften the sub- grade. The process of filling shall be
accompanied by rolling with a power roller weighing not less than 10 tonnes.
Each pass of the roller shall uniformly overlap not less than one third of the
track made in the preceding pass and the passes shall start from edge and
proceed towards centre. The roller shall run over the same surface at least
eight times. The surface shall be checked with templates of approved design
(to be provided by Contractor) and high and low spots corrected by removing
soling and re-packing.
12.6.3 Measurements shall be made for the finished work in square metres with due
consideration of the net measurements of the stacks of soling stone used in
the work. The rate shall include the cost of all materials, labour, plant and
equipment required in all the operations described above.
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12.7 WATER BOUND MACADAM COURSE USING HAND BROKEN

METAL
12.7.1 The surface over which water bound Macadam is to be laid shall be prepared
to the specified grade and 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. Side shoulders upto a height equal to
the uncompacted Macadam course shall be made along the outer edges of
the Macadam course having a clear distance between them equal to the width
to be metalled.
12.7.1.1 WBM SUB-BASE COURSE shall be provided in lieu of a soling course where
specified in the Schedule of Quantities. The coarse aggregate for this shall
normally conform to Grading 1 of Table-3 and screening to Type A of Table-4.
The total consolidated thickness of the sub-base course shall be as specified
in the Schedule of Quantities/drawings.
12.7.1.2 WBM BASE COURSE : The coarse aggregate for this shall normally conform
to Grading 3 of Table-3 and screening to Type-B of Table-4. The total
consolidated thickness of the base course shall be as specified in the
Schedule of Quantities/drawings.
12.7.2 Spreading Coarse Aggregate
12.7.2.1 The coarse aggregate road metal is to be spread uniformly and evenly over
the prepared base to a thickness of 115 mm and rolled dry to a 75 mm
consolidated thickness. This compacted layer shall be sprinkled with water
and continuously rolled to help interlocking of stone pieces. Another 115 mm
thick layer of road metal shall be laid on previously consolidated layer and
rolled dry to a consolidated thickness of 75 mm. Water shall then be
sprinkled over the surface and rolling continued to get the proper interlocking.
During rolling, the camber and grade of the road shall be maintained. The
maximum compacted thickness of each layer shall not exceed 100 mm.
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12.7.2.2 The spreading shall be done from stockpiles by raking the stacks with rakes
so as to leave behind mud and dust. In no case shall the aggregate be
dumped in heaps directly on the surface prepared to receive the aggregate
nor shall hauling over uncompacted or partially compacted base be permitted.
The surface of the aggregates spread shall be carefully checked with
templates and all high or low spots remedied by removing or adding aggregate
as may be required. No segregation of large or fine particles shall be allowed
and the coarse aggregate as spread shall be of uniform gradation with no
pockets of fine material. The coarse aggregate shall not normally be spread
more than 24 hours in advance of the subsequent construction operation of
dry rolling. No traffic should be allowed to pass over the spread metal until the
road is declared open to traffic.
12.7.3 Rolling
12.7.3.1 Immediately following the spreading of the coarse aggregate, rolling shall be
started with three wheeled power rollers of 8 to 10 tonne capacity. The
weight of the roller shall depend upon the type of aggregate and shall be
indicated by Owner/Engineer. Rolling shall begin from the edges and
gradually progress towards the centre. On super-elevated portions the rolling
shall proceed from inner edge to outer edge. First the edges/edge shall be
compacted with roller running forward and backward and then move inwards
parallel to the centreline of the road, in successive passes uniformly lapping
preceding tracks by at least one half width. Rolling shall not be done when the
sub-grade is soft or yielding or when it causes a wave-like motion in the sub-
grade or sub-base. The rolled surface shall be checked transversely and
longitudinally with templates and all undulations shall be corrected by
loosening the surface, adding or removing necessary amounts of aggregate
and re-rolling until the entire surface conforms to desired camber and grade.
In no case shall the use of screenings be permitted to make up depressions.
12.7.4 Application of Screenings
12.7.4.1 After the coarse aggregate has been rolled in accordance with Clause 12.12.3
screenings to completely fill the interstices shall be applied gradually over the
surface. These shall not be damp or wet at the time of application. Dry rolling
shall be done while the screenings are being spread so that vibrations of the
12.7.4.2
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roller cause them to settle into the voids of the coarse aggregate. The
screenings shall not be dumped in piles but be spread uniformly in successive
thin layers. Screenings shall be applied at a slow and uniform rate (in three or
more applications) so as to ensure filling of all voids. This shall be
accompanied by dry rolling and brooming with mechanical brooms, hand
brooms or both. In no case shall screenings be applied so fast and thick as
to form cakes or ridges on the surface in such a manner as would prevent
filling of voids or prevent the direct bearing of the roller on the coarse
aggregate. These operations shall continue until no more screenings can be
forced into the voids of the coarse aggregate. Spreading, rolling and
brooming of screening shall be carried out in only such length of the road
which would be completed within one day's operation.
12.7.5 Sprinkling and Grouting
12.7.5.1 After the screenings have been applied, the surface shall be copiously
sprinkled with water, swept and rolled. Hand brooms shall be used to sweep
the wet screenings into voids and to distribute them evenly.
The sprinkling, sweeping and rolling operations shall be continued, with

additional screenings applied as necessary, until the coarse aggregate has
been thoroughly keyed, well bonded and firmly set in its full depth and a grout
has been formed of screenings. Care shall be taken to see that the sub-grade
on sub-base does not get damaged due to the addition of excessive quantities
of water during construction. In case the sub-grade or sub-base gets
damaged, the Contractor shall, without any extra compensation, rectify the
damaged portion.
12.7.6 Application of Binding Material
12.7.6.1 After the application of screenings, the binding material where it is required to
be used shall be applied successively in two or more thin layers at a slow and
uniform rate. After application, the surface shall be copiously sprinkled with
water and the resulting slurry swept in with hand brooms or mechanical
brooms so as to fill the voids properly. This shall be followed by rolling with a
10T roller, during which water shall be applied to the wheels of the rollers if
necessary to wash down the binding material sticking to them. These
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operations shall continue until the resulting slurry after filling the voids, forms a
wave ahead of the wheels of the moving roller.
12.7.7 Setting and Drying
12.7.7.1 After the final compaction of water bound Macadam course the road shall be
allowed to dry overnight. Next morning hungry spots shall be filled with
screenings of binding material as directed, lightly sprinkled with water if
necessary and rolled. No traffic shall be allowed on the road until the
Macadam has set.
The surface evenness of completed WBM course in the longitudinal and

transverse directions shall be as specified hereunder:-
Longitudinal profile measured Max. permissible tolerance

with a metre straight edge 15 mm.
Max. no. of undulations
Permitted in any 300 M length
Exceeding 12 mm : 30 Nos.
Cross profile Max. permissible undulation
when measured with a camber
template : 12 mm
12.8 MULTIPLE LAYERED COURSE
When the total consolidated thickness of the water bound Macadam course is
more than 100 mm, it shall be constructed in layers.
12.9 BITUMINOUS SURFACE TREATMENT
12.9.1 For this work stone chippings conforming to size given in Table-4 shall be
used at the rate of 0.15 cu.m per 10 sq.m. of the road surface and binder
which shall be straight run bitumen of 80/100 grade conforming to IS:73 at the
rate of 18.0 Kg per 10 sq.m of the road surface for surface dressing.
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12.9.2 Weather and Seasonal Limitations
12.9.2.1 The surface dressing work shall be carried out only when the atmospheric
temperature in shade is 16 deg C or above. No bituminous material shall
normally be applied when the surface of cover material is damp or when the
weather is foggy or rainy or during dust storms.
12.9.3 Preparation of Base
12.9.3.1 The base on which surface dressing is to be laid shall be prepared, shaped
and conditioned to the specified lines, grade and cross section by repairing all
potholes or patches and ruts. The potholes shall be drained of water and cut
to regular shape with vertical sides. All loose and disintegrated material shall
be removed. The pothole shall then be filled either with (i) coarse aggregate
and screenings and compacted with heavy hand rammers or approved
mechanical tampers or (ii) premixed chippings (using 52 Kg of bitumen grade
80/100 with one cu.m of stone chippings) after painting the sides and bottom
of the holes with a thin application of bitumen, or a combination of both (i) and
(ii) as directed by Owner/Engineer.
12.9.3.2 The surface shall be thoroughly swept and scraped clean of dust and any
other extraneous matter before the spraying of binder. The cleaning shall be
done first with hand brushes, then with softer brushes and finally by blowing
with sacks or gunny bags.
12.9.4 Application of Binder
12.9.4.1 Binder shall be heated to 150 deg C to 177 deg C, maintained at the
temperature and sprayed on the dry surface in a uniform manner with the help
of mechanical sprayers. Excessive deposits of binder caused by stopping or
starting of the sprayer through leakage or any other reason shall be suitably
corrected before the stone chippings are spread.
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12.9.5 Application of Stone Chipping
12.9.5.1 Immediately after the application of the binder, stone chippings in a dry and
clean state shall be spread uniformly on the complete surface. If necessary
the surface shall be broomed to ensure uniform spread of chippings. The
surface shall be checked by means of a camber board laid across the road
and a 3 metre straight edge laid parallel to the centre line of the road and
undulations if any, shall be corrected by addition or removal of blindage.
12.9.6 Rolling
12.9.6.1 Immediately after the application of the cover material, the entire surface shall
be rolled with a 8 to 10 tonne smooth wheeled roller. Rolling shall commence
at the edges and progress towards the centre except in super-elevated
portions where it shall proceed from the inner edge to the outer.
Each pass of the roller shall uniformly overlap not less than one third of the
track made in the preceding pass. While rolling is in progress additional
material shall be spread by hand in whatever quantities required to make up
for the irregularities. Rolling shall continue until all material is firmly bedded in
the binder and presents a uniform closed surface. Generally five to six passes
shall be made for thorough compaction of the surface or as directed by
Owner/Engineer. Along kerbs, manholes at all places not accessible to roller,
the rough compaction shall be secured by means of steel rammers or hand
rollers.
12.9.7 Opening to Traffic
12.9.7.1 Traffic shall not be permitted to run on any newly surface dressed area for 24
hours.
12.9.8 Measurements and Rate
12.9.8.1 The measurements shall be taken for the finished work in sq.m. The rate
shall include the cost of materials, labour, plant and equipment involved in all
the operations described above.
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12.10 PREMIX CARPET
12.10.1 This work shall consist of laying and compacting a premix carpet of 50 mm
thickness in a single course composed of suitable small sized aggregates
premixed with a bituminous binder on a previously prepared base.
The premix carpet may be made using standard paver machine.
12.10.2 Materials
12.10.2.1 Binder : This shall be 80/100 grade straight run bitumen conforming to IS:73.
The quantity of bitumen for the tack coat and seal coat shall each be 0.75
kg/sq.m. and for the premixing it shall be 3 Kg per sq.m. of laid carpet. A
proper record shall be kept to ensure that daily output of work is co-related
with the quantity of bitumen used.
12.10.2.2 Aggregate : These shall satisfy the physical requirements set forth in Table-2.
The aggregate shall be of 13.2 and 11.2 mm nominal size.
12.10.3.1 Premix carpet shall not be laid during rainy weather or when the base course
is damp or wet or when the atmospheric temperature in shade is 16 deg C or
below.
12.10.4 Tack Coat
12.10.4.1 Binder shall be heated to 163 deg C to 171 deg C maintained at that
temperature and sprayed on the base at 0.75 kg per sq.m. of road surface. It
shall be applied uniformly with the aid of mechanical sprayers. Binder shall
not be applied when the atmospheric temperature in shade is 4.5 deg C or
less. The tack coat shall be applied just ahead of the spreading of the premix.
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12.10.5 Preparation of Premix and Laying
12.10.5.1 The stone aggregate shall be surface dry and contain not more than 2 percent
moisture before use. It shall be first screened of dust and measured in boxes,
suitably heated to a temperature as directed by Owner/Engineer and then
loaded into the drum mixer according to the capacity of the mixing drum in the
proportion specified. The binder shall be heated to 150 deg C to 177 deg C in
boilers and maintained at that temperature. The heated binder shall be drawn
from the boiler into a suitable container or in bucket gauged to show the
weight of Bitumen in it.
12.10.5.2 The premixed material shall be spread on the road surface with rakes to a
thickness sufficient to achieve after consolidation the specified thickness,
without any undue loss of time. The consolidated thickness shall in no place
be less than the specified thickness. The camber shall be checked by means
of a camber board and inequalities evened out. As soon as sufficient length
of bituminous material has been laid, rolling shall commence with 6 to 9 tonne
power rollers, preferably of smooth wheel tandem type or other approved
plant. The edges along and transverse to the carpet laid and compacted
earlier shall be cut to their full depth so as to expose fresh surface which shall
be painted with a thin surface coat of appropriate binder before the new mix is
placed against it.
12.10.6 Rolling
12.10.6.1 Rolling shall begin at the edges and progress towards the centre
longitudinally, except that on the super-elevated portions it shall progress from
the lower to upper edge parallel to the centreline of the pavement. When the
roller has passed over the whole area once, any high spots or depressions
which become apparent shall be corrected by removing or adding premixed
materials. Rolling shall then be continued until the entire surface has been
rolled and compacted and all the roller marks eliminated.
In each pass of the roller, preceding track shall be overlapped uniformly by at

least one third of the track made in the preceding pass. The roller wheels
shall be kept damp to prevent the premix from adhering to the wheels and
being picked up. In no case shall fuel/lubricating oil be used for this purpose.
Excessive rolling shall be avoided.
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12.10.7 Seal Coat
12.10.7.1 A seal coat shall be applied to the surface immediately after laying the carpet
and rolled. The Bitumen for the premix seal coat shall be at the rate of 1.2
kg/sq.m. In low rainfall areas (i.e. less than 150 cm. Per year), a premixed
sand seal coat mixed preferably in a mechanical mixer after heating the sand,
3
should be applied. Medium coarse sand of 0.06 M per 10 sq.m. of road
surface shall be used. In high rainfall areas (i.e. over 150 cm. per year), a
liquid seal coat preferably with chippings should be applied. Coarse
aggregates – 6.7 mm size, passing IS 11.2 mm mesh, retained on IS 2.8 mm
3
mesh – 0.09 M per 10 sq.m. of road surface shall be used. The longitudinal
profile of the finished surface, when tested with a 3 M straight edge, shall have
no undulation greater than 10 mm and in any 300 m length the number of
undulations of 6 mm size shall not exceed 30. The cross profile, when
checked with a camber template, shall not show a variation of more than 6
mm from the specified profile. No traffic shall be allowed on the road till the
seal coat has been placed.
12.10.8 Opening to traffic
12.10.8.1 Traffic shall be allowed on the road after a lapse of minimum 24 hours.
12.10.9 MODE OF MEASUREMENT & RATE
12.10.9.1 The measurement shall be taken for the finished work in sq.m. The rate shall
include the cost of all materials, labour, plant and equipment involved in all the
operations described above.
12.11 BITUMINOUS CONCRETE
12.11.1 This work shall consist of constructing a single layer of 50 mm thick

Bituminous concrete wearing course to the following specifications on a
previously prepared base.
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12.11.2 Materials
The quantity of bitumen for tack coat shall be 0.75 kg/sq.m. and for the
bituminous concrete it shall be 56 kg/cu.m. of coarse aggregate and 128
kg/cu.m of fine aggregate. A proper record shall be kept to ensure that daily
output of work is correlated with the quantity of bitumen used.
12.11.2.2 Aggregates : These shall be as per Clause 12.4 and satisfy the physical
requirements set forth in Table-2. The quantity of coarse aggregate for 50
mm thick asphaltic concrete shall be 4.8 cu.m./100 sq.m. The gradation
of aggregate shall be as defined in Table-6 below:
TABLE - 6
NOMINAL SIZE OF AGGREGATE
Sieve Coarse Aggregate

26.5 mm 100
22.4 mm 82-98
13.2 mm 60 - 83
11.2 mm 55 - 77
5.6 mm 45 – 65
2.36 mm 40 - 55
600 micron 20 – 30
300 micron 15 – 25
150 micron 10 – 20
75 micron 6–9
12.11.2.3 Fine Aggregates : the fine aggregates shall be the fraction passing 2.36 mm
sieve and retained on 75 micron sieve consisting of crusher run screenings,
natural sand or mixture of both. These shall be clean, hard, durable,
uncoated, dry and free from any injurious, soft or flaky pieces and organic or
deleterious substances. The quantity of sand shall be 2.40 cu.m. per 100
sq.m.
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12.11.2.4 Quantities of materials are given as a guide. Actual proportions shall be

determined by a job mix formula prior to the start of work, unless otherwise
directed by Engineer. The mix as designed and laid shall satisfy the
requirements given in Table 7 below based on Marshall method of design.
Table 7 : REQUIREMENTS OF BITUMINOUS CONCRETE MIX
Sl.No. Description Requirement

1. Marshall stability (ASTM Designation:
D 1559) determined on Marshall specimen, compacted
By 750 compaction blows on each end, in kg. 650
(minimum)
2. Marshall flow (mm) 2-4
3. Per cent voids in mix 3–5
4. Per cent voids in mineral aggregate filled with bitumen 75 – 85
5. Per cent voids in mineral aggregate (VMA) 13 – 16
6. Binder content per cent by weight of total mix (to be
decided on Marshall design method) 5–7
Notes:
1. It is suggested that higher stability values consist with other requirements should be
achieved as far as possible.
2. At bus stops, parking areas and round abouts, stability of 750 kg. And near minimum
flow value should be adopted.
3. The attempt should be to have well graded aggregate and the per cent voids in the mix
closer to the lower limit.
4. The binder content in the case of slag is likely to exceed the limit indicated in the Table.
12.11.3.1 Bituminous concrete shall not be laid during rainy weather or when the base
course is damp or wet or when the atmospheric temperature in shade is
10°C or less.
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12.11.4.1 The base on which bituminous concrete is to be laid shall be prepared as per
Clause 12.9.3.
12.11.5 Tack Coat
12.11.5.1 Clause 12.10.4 shall apply.
12.11.6 Preparation of Mix and Laying
12.11.6.1 The stone aggregate shall be surface dry and contain not more than 2
percent moisture before use. It shall be first screened of dust and measured
in boxes, heated to 155°C to 163°C and then loaded into the drum mixer
according to the capacity of the mixing drum in the proportion specified. The
binder shall be heated to 149°C to 177°C in boilers and maintained at
that temperature. At no time shall the difference in temperature between the
aggregate and binder exceed 14°C. The heated binder shall be drawn from
the boiler into a suitable container or in a bucket gauged to show the weight
of bitumen in it.
12.11.6.2 Mixing shall be done in two stages. The coarse aggregate of the correct
standard size and proportion shall be fed into the Mixer to which 2/3rd of the
total specified quantity of bitumen heated to the appropriate temperature
shall be added. When the coarse aggregate is well coated, the fine
aggregate in the specified proportion followed by the balance 1/3rd quantity
of total bitumen shall be fed into the mixer. Mixing shall be continued until a
homogeneous mix is produced and all particles are uniformly coated with
bitumen.
12.11.6.3 The hot mix shall be discharged from the mixer, carried to the road surface
and spread to specified lines and levels immediately after applying the tack
coat, to a thickness sufficient to achieve after consolidation the specified
thickness. The consolidated thickness shall in no place be less than the
specified thickness.
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Temperature of the mix at the time of laying shall be in the range of 121°C -
163°C. Rakes and spade or drag spreaders shall be used for spreading the
mixture. Longitudinal joints and edges shall be constructed true to the
delineating lines parallel to the centreline of the road. Longitudinal joints shall
be offset by at least 150mm from those in the binder course (tack coat). All
joints shall be cut vertical to the full thickness of the previously laid mix and
the surface painted with hot bitumen before placing fresh material.
12.11.7 Rolling
12.11.7.1 Immediately after the spreading of mix it shall be thoroughly compacted by

rolling preferably with vibratory roller. The roller speed shall not exceed 5 km
per hour. Any high spots or depressions which become apparent shall be
corrected by addition or removal of mix material. The roller shall uniformly
overlap not less than a third of the track made in the preceding pass.
The wheels of the roller shall be moistened with gunny bags to prevent the
mix sticking to the wheels while rolling, but in no case shall fuel/lubricating oil
be used for this purpose. Rolling shall be continued till the mix is thoroughly
compacted and all roller marks are eliminated.
12.11.8.1 Traffic shall be allowed on the road after a lapse of minimum 24 hours,
preferably 48 hours after laying as directed by Owner/Engineer.
12.11.9 Measurements and Rates
12.11.9.1 The measurement shall be taken for the finished work in sq.m. The rate
shall include the cost of all materials, labour, plant and equipment involved in
all the operations described above.
12.12 Seal Coat
12.12.1 This work shall consist of application of a seal coat sealing the voids in a
bituminous surface laid to the specified levels, grade and camber. It shall
comprise of an application of a layer of bituminous binder followed by a cover
of stone chippings.
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12.12.2 Materials
The quantity of bitumen shall be 1.5 kg per sq.m. of the road surface.
12.12.2.2 Stone Chippings : These shall consist of angular fragments of clean, hard,
tough and durable rock of uniform quality throughout. They should be free of
elongated or flaky pieces, soft or disintegrated stone, vegetable or other
deleterious matter. Stone chippings shall be of 10 mm size defined as 100
percent passing through 12.5 mm sieve and retained on 2.36 mm sieve.
The quantity used for spreading shall be 1.05 cu.m per 100 sq.m.
12.12.3.1 The seal coat shall be applied immediately after the laying of bituminous
course which is required to be sealed. Before application of seal coat
materials the surface shall be cleaned free of any dust or other extraneous
matter.
12.12.4 Construction of Seal Coat
12.12.4.1 The binder shall be heated in boilers to a temperature of 163°C to 171°C and
the seal coat applied and the surface rolled. Traffic shall be allowed after 24
hours. After a period of seven days, surplus grit shall be swept and
collected and shall be used for binding the spots where bleeding occurs.
12.13 SEMI-GROUTED METAL COURSE OVER SOLING SUB-

BASE MATERIAL
12.13.1 Metal
12.3.1.1 The metal shall be angular, hard, tough, sound clean, dry and durable and of
approved quality. The size of the stones shall be 38 mm to 75 mm. Metal
having more than 5% rounded of flaky stone chip shall not be accepted. The
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sample of metal shall be got approved before bringing on site. This metal
may be generally hand-broken.
12.13.1.2 Stone chips to be used over grouted surface
They shall be free from dust, organic impurities etc. The size of the stone
chips shall be 6 mm down and it should be retained on 4.75 mm sieve and
should pass through 6.7 mm sieve. If the size of the grit chips does not
conform to above standard, same shall be got screened on the site. The
sample shall be got approved before collection.
12.13.1.3 60/70 Maxphalt
Asphalt required for this work shall be Maxphalt 60/70 or equivalent from
approved manufacturer as per specific standard.
12.13.2 Mixing and Laying
The metal shall be cleaned, filled in baskets, conveyed to the place where it
is required and spread evenly on the prepared surface of soling by giving a
twisting motion to the basket at the time of spreading. The stone metal shall
then be carefully hand packed and the interstices filled with downgraded
metal. The surface shall be brought to the required camber which shall be
checked at regular intervals of 5 meters by means of templates. Before and
after rolling, the metal shall be dressed accurately to camber. The loose
metal shall be rolled dry with 10 to 12 ton road roller until well compacted to
thickness of 115 mm thick. Excessive dry rolling shall be avoided.
Compacted layer shall be pressure grouted with 60/70 hot Maxphalt at the
2
rate of 5 kg/M of surface throughout and then this course covered with stone
2
grit applied uniformly at 0.1 Cu.m. per to 10 M of road surface to fill the
surface voids between large stones. The surface then shall be rolled with 8
to 10 tonne road roller so that the resulting surface is evenly smooth in
perfect line, level and camber to the satisfaction of Engineer and as per
drawing.
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12.13.4 Mode of Measurement
2
The payment shall be on M basis of finished area as per drawings.
The rate shall include for all materials, laying, rolling and compacting etc. as
specified.
12.14 BITUMINOUS SHEET
This type of treatment shall be provided for walkways, drives etc. with light
intensity traffic. It shall consist of a mixture of coarse sand and stone
chippings with bituminous binder, spread and consolidated to a thickness of
25 mm on a prepared surface after the application of a tack coat.
12.14.1 Materials
12.14.1.1 Clause 12.10.2.1 shall apply except that the quantities of materials shall be
as given below. Bitumen for tack coat shall be 0.75 kg/cu.m. and for the
bitumen sheet it shall be 56 kg/cu.m. of stone chipping and 128 Kg/cu.m. of
sand (fine aggregate). The quantity of stone chipping shall be 1.65 cu.m.
and 40% of 10 mm nominal size. The nominal size shall be as defined in
Table-8 below:
TABLE - 8
NOMINAL SIZE OF STONE CHIPPINGS
Stone Chipping Size

Sieve 12.5 mm 10 mm
Percentage Passing
20 mm 100 -
12.5 mm 85 – 100 100
10 mm 0 – 45 85 - 100
4.75 mm 0 – 10 0 - 20
2.36 mm - 0-5
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The quantity of fine aggregate (sand) shall be 1.65 cu.m. per 100 sq.m. of
road surface.
Clause 12.9.3 shall apply.
12.14.3 Tack Coat
12.15 BITUMEN MASTIC
12.15.1 This type of treatment shall be provided for flooring of industrial buildings,
warehouses, grain storage structures, surfacing of bridge decks, roads,
footpaths etc. It shall consist of a mixture of bitumen binder with aggregate.
The thickness and grade of flooring as per IS:1195 shall be as indicated in
the item nomenclature.
12.15.2 Materials
12.15.2.1 Binder : The physical properties of the bitumen used shall conform to IS:1195.
12.15.2.2 Aggregate: The fine and coarse aggregate shall comply with the requirements
of IS:1195.
12.15.2.3 The composition of the bitumen mastic mix shall conform to the range
specified by IS:1195.
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12.15.4 Tack Coat
12.15.5.1 The aggregate shall be measured in boxes, heated to 175°C to 205°C and
then loaded into a drum mixer according to the capacity of the mixing drum in
the proportion specified. The binder shall also be heated to the same
temperature in boilers and maintained at that temperature. The heated binder
shall be drawn from the boiler into a suitable container or in a bucket gauged
to show the weight of bitumen in it.
12.15.5.2 The fine aggregate in specified proportion shall be fed into the mixer and then
2/3rd of the total specified quantity of heated bitumen added. When the fine
aggregate is well coated, the coarse aggregate followed by the balance 1/3rd
quantity of total bitumen shall be fed into the mixer. Mixing shall be continued
until a homogenous mix is produced and all particles are uniformly coated with
bitumen. The material shall be mixed continuously for a period of not less
than one hour before laying is begun, and mixing shall be continued until
laying operation is completed, so as to maintain the coarse aggregate in
suspension. At no stage during the mixing process, shall the temperature
exceed 205°C.
12.15.5.3 The hot mix shall be discharged from the mixer, carried to the surface on
which it is to be laid and spread to specified lines and levels immediately after
applying to the tack coat to a thickness sufficient to achieve the specified
thickness after floating with a heavy wooden float. The surface shall be free
from roughness and imperfections. If 'blowing' occurs the bubbles shall be
punctured and the affected area carefully made good while the mastic is still
hot. At junctions between new and previously laid sections of work the contact
edge shall be cleaned and warmed by additional applications of hot mastic
before striking off so as to obtain an absolutely clean joint.
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12.15.6 Surface Finish
12.15.6.1 The type of surface finish shall be as specified.
a) Matt finish : The surface shall be rubbed in with sand during the final
floating operation. The sand shall be clean and free from foreign
matter. All surplus material shall be removed after rubbing is
completed.
b) Polished finish : The surface shall be finished with a float in a manner

similar to that used for a matt-finish but without the use of an abrasive.
12.15.7.1 The mastic flooring shall not be subjected to traffic until the material has
cooled throughout to the temperature of the surrounding atmosphere.
12.16 FLAT BRICK PITCHING FOR DRAINS
Providing and laying flat brick pitching using best quality locally available kiln
burnt bricks of approved brand, make and size as per the drawing, including
all scaffolding, plant, labour and materials etc. complete in all respects.
a) Materials : All bricks shall be of table moulded, well burnt bricks and
shall conform to IS:1077. The nominal size shall be 230 mm x 115
mm x 75 mm and approved make. No un-burnt or over-burnt bricks
shall be used.
b) Workmanship : Just prior to the start of the work, the soil base shall
be thoroughly cleaned of all dirt, loose soil and rubbish and well
washed and consolidated. All bricks shall be thoroughly soaked in a
vessel containing water. The practice of dipping the bricks in water
just before use or watering the brick-stack shall not be allowed. The
work shall be carried out in a workmanlike manner, true to slope,
level and gradient. All vertical joints shall be laid flat with the frog
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face at its bottom, and firmly bedded into the soil by tamping. Mixing
and preparation of cement mortar and filling the joints shall be as that
specified for brickwork. The entire work shall be cured for at least
seven days. Brickbats shall not be used unless used as closers.
12.17 BRICK ON EDGE SOLING
It shall be laid on edge, the bricks touching each other. Soling shall be
closely packed leaving no interstices or gaps. Appropriate filler bricks shall
be used to make up dimensions which are part of a whole brick.
12.18 CEMENT CONCRETE PAVEMENT FOR WALKWAYS,

DRIVES
12.18.1 The pavement shall consist of cement concrete of grade M15 or richer mix as
specified, laid on the prepared base including compaction and curing. All
concrete work shall be in accordance with the specification for "Concrete and
Allied Works".
12.18.2.1 Concrete shall be laid directly on top of the soling course which shall be
prepared, shaped and conditioned to the specified lines, grades and cross -
section by repairing all potholes or patches and ruts, if any, excepting that
areas inaccessible to power rollers shall be compacted with vibratory rollers.
At edges of foundations, trenches, re-entrant corners, etc. hand tamping shall
be done with steel rammers.
12.18.3 Formwork
12.18.3.1 Formwork shall be provided for all joints and other edges. All forms shall be of
a depth equal to the thickness of the slab.
12.18.4 Placing and Compacting
12.18.4.1 The sub-base shall be thoroughly watered before laying the concrete. Mixing
and placing of concrete shall be as per specifications for 'Concrete and Allied
Works'. The width of any panel shall not exceed 6 metres.
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12.18.4.2 Concrete after laying shall be compacted by hand tamping with 75 mm wide
tamper made of selected timber, shod with steel plate, the tamper shall
weigh not less than 10 kg/m and shall be 450 to 600 mm longer than and not
more than 50 kg/m the proposed width of slab. The tamper shall rest on side
forms and shall be drawn forward with a swinging motion in combination with a
series of lifts and drops alternately with lateral shifts of about 25 mm.
Compaction by tamping shall be continued till the mortar in the mix just works
up to the surface. Compaction shall be done by vibrators where so directed by
Owner/Engineer.
12.18.5 Surface finish
12.18.5.1 Float Finish : This finish shall be produced by smoothening board or wooden
floats after compaction is complete.
12.18.5.2 Belt Finish : The belt shall consist of a piece of canvas 150 mm wide and 1000
mm longer than the width of the slab, having wooden handles at each end. In
the preliminary stage the belt shall be drawn slowly across by a series of long
strokes and finally by short strokes with rapid advance.
12.18.5.3 Brush finish : This finish shall be carried out by stiff fibre brush having a long
handle attached to it, drawing it transversely across the slab standing either on
a platform bridging the slab or across half width from either side of slab. This
finish shall be carried out after the surface is slightly set.
12.18.6 Joint Filler
12.18.6.1 Joints between panels shall be filled with approved sealing compound Grade-
A (normal) after the curing is over. At expansion joints a 25 mm thick pre-
moulded joint filler with sealing compound shall be provided.
12.18.7.1 The measurement shall be in of finished concrete pavement. The rate shall
include the cost of materials and labour involved in all the operations
described above but excluding preparation of base and joint filler which shall
be paid for separately.
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12.19 ROAD LANE MARKING
12.19.1 Road lane marking shall be done for all roads having 2 or more traffic lanes.
The paints used for lane marking shall be special "Road Lane Marking Paints"
of approved make and brand and shall be applied as per the manufacturer's
recommendations. The road surface shall first be cleaned thoroughly with a
brush and then wiped with a cloth lightly soaked in kerosene oil. Paint shall be
applied only after the kerosene has dried. Traffic shall not be allowed to pass
on the lane markings until it has completely dried and hardened. No painting
shall be done in a dusty atmosphere or when the road is wet. The work shall
be measured in metres. The rate shall include the cost of all materials and
labour involved.
12.20 PIPE CULVERTS
12.20 Material
12.20.1.1 The pipes shall be with or without reinforcement as required and of the class
as specified. They shall conform to IS:458. The reinforced cement concrete
pipes shall be manufactured by centrifugal or spun process while un-
reinforced cement concrete pipes by spun (or pressure process). All pipes
shall be true to shape, straight, perfectly sound and free from cracks and
flaws. The external and internal surface of the pipes shall be smooth and
hard. The pipes shall be free from defects resulting from improper grading of
the aggregate, mixing or moulding. The un-reinforced and reinforced non-
pressure pipes (non-pressure pipes) shall withstand a test pressure equivalent
to 0.7 Kg/sq.cm (7 M head) of water. Concrete and reinforcement used for
the manufacture of pipes and collars shall be as specified in IS:458. The
maximum size of aggregate shall not exceed one third the thickness of the
pipes or 20 mm whichever is smaller. Sampling and testing of pipes shall be
done as per IS:458.
12.20.2 Laying of Pipes
12.20.2.1 Loading, transporting and unloading of concrete pipes shall be done with care,
avoiding impact. All pipes and collars shall be inspected carefully before
being laid in position. Broken or defective pipes/collars shall not be used.
Pipes shall be line true to lane and grade as specified.
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12.20.2.2 Pipes bedded on soil shall be ensured to have even and firm backing of soil.
This shall be done by excavating the bottom of trench to fit the curve of pipe
or by compacting the earth under and around the pipe to form an even bed.
The bed shall be suitably rounded to fit the lower part of the pipe, prior to
laying the pipe. The cost for this operation shall be included in the rate for
laying the pipe itself.
12.20.2.3 Where the pipes are to be bedded in a concrete cradle, the pipe shall be laid
before the concrete has set.
12.20.2.4 Pipes shall not be laid directly on any hard material such as rock, shale, hard
clay etc. Concrete, sand or compacted earth bed shall be provided over the
hard materials.
12.20.3.1 If the pipes have spigot and socket joints, the socket ends shall face
upstream. In the case of pipes with joints to be made with loose collars, the
collar shall be slipped on or before the next pipe is laid. The two adjoining
pipes shall be adjusted in correct position and the annular space filled with a
stiff mixture of cement mortar 1:2 (cement : 2 fine sand) and the same
rammed with a caulking tool. Any extraneous material shall be removed from
the inside of the pipe and the newly made joint shall be cured.
12.20.4 Backfilling
12.20.4.1 Trenches shall be back-filled immediately after pipes have been laid and
jointing material has hardened. Backfill soil shall not contain boulders,
vegetable or any other objectionable matter and shall be approved by
Engineer. Back-filling shall be done in layers not exceeding 150 mm, care
being taken not to damage the pipe while compacting. Unequal pressures
shall not be allowed to occur.
12.20.5.1 No traffic shall be allowed unless at least 0.6 metre of earth filling is provided
over the pipe unless directed otherwise by Engineer.
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12.20.6 Measurement and Rate
12.20.6.1 Pipe culverts shall be measured along their centre line between inlet and
outlet ends in metres. The rate shall include the cost of pipe including loading,
unloading, hauling, handling, storing, laying in position and jointing complete
including erecting safety protection for traffic and providing for traffic diversion.
Ancillary works such as excavation, back-filling concrete work shall be paid
for, separately.
END
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Uhde India Limited CHEMICAL RESISTANT LINING Page :1
Contents Page
SCOPE 2
APPLICABLE CODES AND STANDARDS 2
MATERIAL SPECIFICATIONS 3
METHOD OF APPLICATION 6
PROCEDURE FOR LAYING TILE LINING 9
LINING OVER EQUIPMENT FOUNDATION 9
EPOXY BASED LINING 9
LINING TYPE DESIGNATIONS AND CORRESPONDING SPECIFICATIONS 15
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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13.1 SCOPE
This section covers the specification for lining/coating to be provided over

concrete and steel surfaces to protect them from the corrosive attack of
chemicals in the form of leakages, spillages, overflows, washings etc. The
scope of application is limited only to the external surfaces such as floors,
pits, foundation sides & tops, encasing/coating to structural steel column,
equipment supports such as skirts, legs, etc. and does not cover the lining to
be provided inside the process equipment.
13.1.1 Applicable Codes & Standards
The following specifications, standards and codes are made a part of this
specification. All standards, tentative specifications, specifications, codes of
practices referred to herein shall be the latest edition including all applicable
official amendments and revisions. In case of discrepancy between this
specification and those referred to herein, this specification shall govern.
IS 4832 : Chemical Resistant Mortar

(Parts I to III)
IS 4441 : Chemical Resistant Mortar - Silicate type
IS 4442 : Chemical Resistant Mortar - Sulphur type
IS 4443 : Chemical Resistant Mortar - Resin type
IS 4456 : Testing of Mortar
IS 9510 : Bitumen Mastic - AR Grade
IS 1580 : Bitumen Compound
13.2 Types of Lining and Coating
13.2.1 Chemical Resistant Brick-lining / Mandana Stone Lining.
13.2.2 Chemical Resistant Tile-lining
13.2.3 Chemical Resistant Brushable applications
13.2.4 Chemical Resistant Monolithic screed without reinforcement.
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13.2.5 Chemical Resistant Monolithic screed with fibre glass reinforcement.
13.2.6 Chemical Resistant Bituminous coatings.
13.3 MATERIALS SPECIFICATIONS
13.3.1 Bituminous Primer Coat
This shall be of Acid Resistant Grade conforming to IS:3384. The material

may be suitable for either cold or hot applications over concrete and/or steel
surfaces.
13.3.2 Mastic Layer
The mastic for hot application over the primer coat shall be of Acid Resistant
grade conforming to IS:9510. The thickness of the layer shall be minimum
10 mm or as specified in the drgs. whichever is higher. The general purpose
A.R. mastic shall be used for floors and drain/trenches of depth not more
than 800 to 1000mm. For pits containing liquid, SPECIAL MASTIC of
approved make shall be used for horizontal & vertical surfaces and minimum
thickness shall be 10mm. The mastic layer shall be used only as an inner
layer, before application of bricks/tiles.
13.3.3 Flexivinyl Lining in Place of Mastic Layer
This material shall be used only as inner layer before the application of brick
and tile lining. Minimum thickness of flexi-Vinyl application shall be 6 mm.
The material to be used shall be from one of the approved manufacturers
(Refer to Data Sheet ‘B’).
A coat of emulsified Bituminous primer shall be applied over Flexivinyl lining

to make it compatible with the brick-lining bedding cement and to achieve the
proper bond between flexivinyl lining and brick lining.
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13.3.4 Chemical Resistant Bricks/Tiles/Mandana Stone
13.3.4.1 Bricks
These shall be of Acid resistant quality, conforming to IS:4860 and of

approved make. The size shall be 230 x 115 mm. and thickness shall be one
of the standard thicknesses namely 38,50,65,75 mm. as specified in the drg.
and schedule item description. The surfaces shall be even and free
from undulations, cracks, holes, pits etc. The dimensional tolerance shall
be ± 2%.
13.3.4.2 Tiles
Tiles shall be of Ceramic material with vitrified surface conforming to IS:4457,

having thickness not less than 20 mm x 200 mm.
13.3.4.3 Mandana Stone
This shall be from natural sand stone commercially known as Mandana

stone. The size shall be 600 mm x 600 mm or any other suitable size that
can be easily handled. The thickness shall be 25 mm to 30 mm. These shall
be resistant to Acidic / Alkaline spillage upto 98% concentration and
temperature upto 50°C.
13.3.5 Cementing materials for bedding, jointing and pointing.
The cementing materials to be used shall be of chemical resistant quality &

conforming to respective IS-Specifications. The material shall be one of the
following cements and as specified in the drawing and schedule item
description. The shelf life of the various materials shall be carefully observed
as indicated by the manufacturer.
13.3.5.1 Potassium Silicate Cement
This shall be used only as a bedding material and not for pointing work. The
application for jointing on sides shall be only to such an extent as to leave a
minimum depth of 20 mm for pointing with other types of cements not soluble
in water. Minimum thickness of bedding shall be 10 mm and for jointing 6
mm. Mixing, application shall be as per manufacturers specifications.
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Silicate cement to be supplied and used, shall be from one of the approved
manufacturers.
13.3.5.2 Phenolic Resin Based Cement
This shall be used as bedding and jointing material or pointing material.

Minimum thickness shall be 6mm for bedding and 3mm for jointing. The
material to be used shall be from one of the approved manufacturers.
13.3.5.3 Furane Resin Based Cement
This shall be used as bedding and jointing or pointing material. Minimum

thickness shall be 6 mm for bedding and 3 mm for jointing. The material to
be used shall be from one of the approved manufacturers.
13.3.5.4 Cashew-nut oil resin based cement
This shall be used for bedding and jointing or pointing material. Minimum
thickness shall be 6 mm for bedding and 3mm for jointing. The material to
be used shall be from one of the approved manufacturers.
13.3.5.5 Vinyl-Ester Resin based cement
This shall be used as bedding and jointing or pointing materials. Minimum

thickness shall be 6mm for bedding and 3mm for jointing. Materials to be
used shall be from one of the approved manufacturers.
13.3.5.6 Epoxy based cements
These shall be used as bedding and jointing or pointing or screeding/coating

materials as specified in schedule items and construction drawings. All
ingredients of Epoxy formulations to be used shall be of approved make.
Minimum thickness to be used for different applications shall be as follows:
(A) Primer coat - Minimum 50 micros of dry-film or as manufacturer,s

specifications, whichever is more.
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(B) Unreinforced brushable application with Silica or carbon powder as

filler materials - Min. thickness per coat 150 microns.
(C) Unreinforced monolithic screed - Minimum thickness shall be 3 mm per

layer and number of layers shall be as per construction drawings, to achieve
the required total thickness.
(D) Reinforced Brushable Application
Brushable Epoxy application, reinforced with Fiberglass tissue fabric shall

have a minimum thickness of 200 microns for a single layer consisting of 2
flood coats of epoxy with Fibre-glass tissue fabric, sandwiched in between.
Number of such layers shall be decided as per schedule item specifications
and construction Drawings
(E) Reinforced Monolithic Epoxy Screed
Minimum thickness of one layer consisting of two sub-layers of monolithic

epoxy mortar application with fiberglass tissue fabric reinforcement
sandwiched between the two, shall be 4mm and number of such layers shall
be decided as per schedule item specifications and construction drawings.
(F) Material specifications for Fillers and Reinf-Fabric
F/1 Silica or Carbon/graphite powder.
The powder particle size shall be passing through BS-sieve 100 for Quartz
silica powder and carbon/graphite powder and shall be clean and free from
impurities and moisture. The proportion of filler material by weight, to be
added to resin shall be as per manufacturer's specification and shall be
different for different applications as in A to E above.
F/2 Fibre Glass Tissue Fabric
This shall be of approved make. The grade to be used shall have minimum
unit weight of 450 gms per.sq.mtr of the fabric.
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13.4 Method of Application
13.4.1 Surface Cleaning & Preparation
The concrete or steel surface to be protected shall be carefully examined to

ensure evenness, freedom from cracks/holes/undulations and shall be
thoroughly cleaned of all loose particles, dust and preferably by using dry
compressed air. In underground pits and trenches, the leak test shall be
insisted upon and shall be examined for dampness, seepage etc. on the
bottom or walls. Any defects in concrete or pits and damp proofness shall be
got rectified from civil contractor through the supervising Engineer. The
surface shall be made dry before application of primer coat. If the surface is
not levelled to the required slopes and grade, the same shall be got done
through civil contractor by using cement mortar screed, properly set and
cured.
13.4.2 One coat of Bitumen primer as specified shall be applied on the clean dry
surface of the screed, after ensuring the quality acceptance of the surface to
be protected and obtaining approval thereof.
13.4.3 After the application of Bituminous Primer a layer of acid resistant mastic
shall be laid over it. The mastic layer shall conform to IS:9510 and be of acid
resistant grade. The thickness of this layer shall be 20 mm for floors and 12
mm for vertical surfaces. In HF-conditions carbon filler material shall be used
in place of Quartz powder. If Special Mastic is specified, the thickness shall
be limited to 10 mm.
13.4.4 The bricks are set in full mortar bed and jointing is done as specified in the
following paragraphs. The bricks shall be coated with the mortar on side
forming bed & joints and then placed in position, by properly pressing and
squeezing out the excess mortar to ensure 100% application over brick
surfaces. The brick laying shall be done in one of the ways specified in
following five alternatives; with respect to type of cement used in bedding and
jointing.
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Alternative 1:
The mortar bed shall consist of Potassium silicate cement and prepared
conforming to IS:4832 (Part 1) and IS:4456 (Part-1). Bricks shall be set in
position after application of mortar of appropriate consistency, over bottom
and sides, of the brick and then properly pressed in to its place ensuring
minimum thickness of 10 mm for bedding and 5 mm for jointing leaving
20mm deep joint, open from top for pointing work. All the loose particles and
impurities from the joints shall be removed and pointing shall be done using
selected Resin-based cement. The joints shall be arranged in such a way
that there is a continuous joint in the longitudinal direction of bricks and in the
direction of slope. They should be staggered in the perpendicular direction of
slope and in the cross direction of longer side of bricks.
Alternative 2:
The mortar bed conforming to IS:4832 (part II) shall consist of Phenolic resin
based cement [see para 13.3.5.2] and filler of quartz silica powder [see para
13.3.5.6(F)]. Thickness of mortar shall be 6 mm and bricks shall be laid with
3 mm wide joints filled with Phenolic resin cement completely including flush
pointing with the same cement. Arrangement of joints shall be as described
under Alternative 1 above. The mortar shall be applied with trowel over
bottom and sides of the brick before placing it in position.
Alternative 3:
All specifications shall be as per Alternative-2 except for the cement, which
shall be Furane resin based in place of phenolic resin based.
Alternative 4:
All specifications shall be same as for Alt-2 except for the cement which shall
be Cashewnut Oil resin based in place of phenolic resin based.
Alternative 5:
All specifications shall be same as for Alt-2 except for the cement which shall
be Vinyl Ester based resin.
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13.5 Procedure for Laying Tile-Lining
Procedure for tile lining shall be exactly the same as for brick laying except
that the thickness of tile shall be generally limited to max. 20mm or as
specified in drawings whichever is lower. Alternative No.1 shall not be
applicable in case of tile lining. Alternatives 2 to 5 shall be applicable to tile
lining.
13.6 Kerbs and Wall Connections
The lining and the mastic shall be taken and terminated horizontally to cover
the top of kerbs and walls. Further continuation of lining over outside
surfaces of kerbs and walls shall be as per construction drawings.
13.7 Lining Over Equipment Foundations
When lining is laid over equipment foundations the portion of bolt holes within
the thickness of tile lining shall be filled with the same cement as is used in
the lining. Pockets, if left for bolts, shall be grouted upto unfinished top of
concrete with cement grout, prior to the lining work. This shall be in scope of
others.
13.8 Wherever a pipe nozzle is penetrating through wall the lining shall be laid to
ensure that there are no crevices, gaps around the nozzles by properly filling
up the cement in the annular gap around the nozzles and puddle flanges.
13.9 Procedure for Application of Epoxy Based Lining
The following specification covers the requirements for application of epoxy

based lining.
13.9.1 All materials described here are products of HINDUSTAN CIBA GEIGY.
They shall be received and stored as per manufacturer's instructions.
Equivalent make materials may be used with Engineer's prior approval in
writing.
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13.9.2 Use of these materials shall be limited to areas where maximum

temperatures are below 90°C or as specified by the respective manufacturer,
whichever is less.
13.9.3 In all applications, the manufacturer's instructions shall be strictly followed,

since epoxy resin materials require great care in handling and application.
13.9.4 Materials (CIBA GEIGY MAKE)
ARALDITE GY - 257
ARALDITE GY - 250
HARDENER HY - 840
HARDENER HY - 830
HARDENER HY - 850
QUARTZ SILICA POWDER - Passing through BS Sieve 100 mesh or 3 mm
chips as required by the thickness of lining.
13.9.5 Method of Application and Types of Lining
This is specified as given below for following four alternatives 1 to 4 :
Alternative 1 - Brushable Application without Fibre Glass Reinforcement
(a) Primer Coat
One coat of primer shall be applied over the surface ready for lining, with a
clean brush using a mixture of 100 parts by weight of Araldite GY-257 and 50
parts by weight of Hardener HY-840 mixed and prepared and having pot-life
as per manufacturers' specification.
(b) Finish Coats
A mixture shall be prepared to the brushable consistency using following

proportion of ingredients:
- 100 parts by weight of Araldite GY 250,

- 45 parts by weight of Hardener HY 830,
- 15 parts by weight of hardener Hy 850, and
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- Min. 100 parts by weight of Quartz silica powder.
Weight of Quartz powder in a batch shall be adjusted so as to get a proper

brushable consistency. Minimum two coats shall be applied with drying and
curing time interval between the two coats as specified by the manufacturer.
Alternative 2 - Brushable Application with Fibre Glass Tissue Fabric

Reinforcement
All specs. shall be the same as for Alternative No.1, except that fibre glass
tissue reinforcement shall be laid after 2 flood coats of epoxy formulation.
The fabric shall be so laid and pressed in position as to remove all air
pockets, waviness, folding, wrinkles etc. in the fabric layer. Number of such
sandwiched layers shall be as per construction drawing.
Alternative 3 - Monolithic screed without reinforcement
(a) One coat of primer shall be applied over the prepared screed with a
clean brush using a mixture of 100 parts by weight of Araldite GY 257 and 50
parts by weight of Hardener HY 840 prepared as per manufacturer's
instructions.
(b) Screed coat
A mixture shall be prepared with following ingredients:

- 100 parts by weight of Araldite GY 250,
- 800 parts by weight of Quartz silica powder passing through 100 mesh
B.S. sieve. This mixture shall be applied with a trowel over the primed
surface to the required level and allowed to set. The thickness of this
layer shall be 3 to 4 mm or as specified in the construction drawings.
Alternative 4 - Monolithic screed with fibre glass reinforcement
Wherever reinforced screed lining is specified, it shall be applied with

following specifications:
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(a) One primer coat is applied with a clean brush using a mixture of 100
parts by weight of Araldite GY 257 and 50 parts by weight of Hardener
HY 840.
(b) First layer of the following mixture shall be applied with trowel.
- 100 parts by weight of Araldite Gy 250,

- 15 parts by weight of Hardener HY 850, and
- 400 parts by weight of Quartz silica powder passing through
100 mesh B.S. sieve.
(c) Intermediate layer of fiberglass tissue cloth shall be laid over the first
coat ensuring no air pockets and with a lap of 100 mm between two
adjacent parts of fibreglass cloth of standard width and length. A flood
coat as in Alternative No.2 shall be applied for proper lap joining.
(d) Second layer of screed shall be applied as described in (b) above. Min.
thickness and number of layers shall be as per construction drawings.
13.10 For temperatures of 100° C to 150° C the following specifications shall be

used. All materials shall be of Dr.Beck & Co. make or equivalent approved.
13.10.1 Material
DOBECKOT 520 F
HARDENER EH 408
HARDENER 758
GLASS FIBER TISSUE MATT (30 gms)
CHOPPED STRAND MAT (CSM)
The above products are from Dr. BECK & CO, PUNE. Equivalent make
materials may be used with Engineer’s prior approval in writing.
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13.10.2 Application Procedure
A) Surface preparation
Surface preparation shall be as described in para 13.14.1. Care shall be

taken to see that the surface is free from moisture. The slab is tested for
moisture content and a slab with less than 12 percent moisture is considered
suitable for application of the epoxy lining. Testing shall be carried out by
covering an area of one sq.metre with a polythene sheet with edges sealed
against external moisture for a minimum period of seven days. If moisture
collects on the under surface of the sheet then the slab is not considered
suitable for application of the epoxy coating. It should be ensured that
moisture does not enter the under side of polyethylene sheet through sources
other than evaporation.
When the time available for testing is short then the following two methods
are used.
(a) The surface shall be covered with a nonporous rubber mat for twelve
hours. If moisture collects on the under surface of the mat then the
coating shall not be applied.
(b) A few granules of calcium are placed over a small area and covered with
a dry glass plate and the edges are sealed to prevent the entry of
moisture from outside. If the granules are dry after 2 or 3 hours then the
slab is suitable to receive the coating.
Alternatively, an approved Moisture meter may be used for measurement of

moisture percentage.
B) Mixing proportion shall be as follows:
(a) Dobeckot 530 F : 100 parts by weight: for

Hardener EH 408 : 25 parts by weight: brushable
Hardener 758 : 5 parts by weight: application
Thinner 21 as required:
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(b) Dobeckot 530 F : 100 parts by weight: for

Hardener EH 408 : 25 parts by weight: screed
Hardener 758 : 5 parts by weight: applied
Sand 0.1 to 1 mm : 400 to 600 parts by weight with trowel
with a Silica powder (90size)
60 to 80 parts by weight:
13.10.3 Chemical resistant coating (Brushable application) using Dr. Beck & Co.
products
The mixture as described in 13.10.2B/(a) shall be applied over the prepared

surface with a clean brush as a primer coat. A second coat of the same
mixture shall be applied as a finishing coat if required by manufacturer's
specs.
13.10.4 Chemical resistant laminated reinforced coating
The mixture as described in 13.10.2-B/(a) shall be applied over the prepared

surface. Reinforcement such as fibreglass tissue cloth or surface tissue mat
or chopped strand mat is placed and wetted with the same mixture. On this,
a finishing coat of the same mixture as in 13.10.2-B(a) is applied.
13.10.5 Monolithic screed
Over a coat of primer with the mixture given in 13.10.2-B/(a) a screed made
out of the mixture as given in 13.10.2-B/(b) is applied as per manufacturer's
specifications.
13.10.6 The specifications under 13.10 shall be followed in conjunction with those of
Dr.BECK & Co, Pune or approved equivalent.
13.11 The recommended Corrosion resistance to different duty conditions shall be

as per Table 1,2 and 3.
13.12 The dry heat limit of various resins shall be as per Table 4.
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13.13 LINING TYPE DESIGNATIONS AND CORRESPONDING SPECIFICA-

TIONS
13.13.1 LEGEND
MA - MASTIC
FX - FLEXIVINYL
BR - BRICKS
CT - CERAMIC TILES
KS - SILICATE CEMENT
PH - PHENOLIC RESIN CEMENT
F - FURANE RESIN CEMENT
VE - VINYL ESTER CEMENT
CN - CASHEW NUT OIL RESIN CEMENT
EP - EPOXY BASED LINING
BRU - BRUSHABLE APPLICATION
SCR - EPOXY SCREED
FG - FIBREGLASS REINFORCEMENT
DRB - DR. BECK & CO. PRODUCT
GVE - GLASS REINFORCED VINYL ESTER BASED LINING
MT - MANDANA TILES
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Type Sub Type Description Spec. Ref.
MA MA/15 15mm Thick Mastic Lining 13.3.1 /

MA/20 20mm Thick Mastic Lining 13.3.2
FX FX 6 6mm Thick Flexivinyl Lining 13.3.3

FX 8 8mm Thick Flexivinyl Lining
BR BR/38/KS/PH Brick Lining 38 Thick. with 10mm Thick Silicate 13.3.4 /

cement bedding & 6mm Thick Phenolic cement 13.3.5.2/
pointing. 13.4
BR/38/KS/F Same as above but pointing with furane cement. 13.3.4/

13.3.5.3/
13.4
BR/38/KS/VE Same as above but pointing with vinyl ester 13.3.4 /
based cement. 13.4/
13.3.5.5
BR/38/KS/CN Same as above but pointing with cashew nut oil 13.3.4 /
resin cement. 13.3.5.4/
13.4
BR/38/PH Brick lining in 6mm Thick cement bedding and 13.3.4/

3mm Thick Phenolic cement jointing. 13.4/
13.3.5.2
BR/38/F Same as above but with furane cement. 13.3.4
13.3.5.3
13.4
BR/38/VE Same as above but with vinyl resin. 13.3.4
13.3.5.5
13.4
BR/38/CN Same as above but with cashew nut resin based 13.3.4
cement. 13.3.5.4
13.4
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The Sub-type 'BR' designation shall change according to recommended brick thickness. For
example, if 75 mm brick is used with silicate bedding and phenolic cement pointing, the sub-
type shall be BR/75/KS/PH.
13.14 Specification for Cast Iron Gratings
The overall dimensions of C.I. gratings shall be as detailed in drawings. The

material shall be grey Cast Iron not inferior to FG 150 grade as per IS:120.
2
The minimum tensile strength shall be 150 N/mm and Brinell hardness of
130 to 180. The gratings shall be cast smooth true to dimensions as detailed
in working drawings and properly levelled.
13.15 RECOMMENDED TYPE OF LINING FOR DIFFERENT DUTY CONDITIONS
Duty Cond. Exposure Temp. Recommended

Lining
1 Upto 98% Within OR 25 Deg. C BR/38/KS/PH
H2SO4 Outside to OR
80 Deg. C BR/38/PH
2 5% TO 50% ---do--- ---do--- ---do---

NaOH
3 30% Hcl ---do--- ---do--- ---do---
4 5% TO 50% INSIDE 50 Deg. C EP/SCR/5

NaOH & Electrical resistance OR
of 50K Ohm EP/SCR/3
5 50% Alkaline with INSIDE 50 Deg. C GVB

no Silica pick-up. SATURATOR
PITS
The payment shall be on square metre basis of finished area. The rates
quoted shall be all inclusive of materials, labour, supervision, transport,
taxes/duties, octroi, wastage, guarantees, profits and all other incidental
expenses.
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TABLE 1 : CHEMICAL RESISTANCE OF RESIN TYPE MORTARS

Sr. Substance Epoxy Polyester Phenolic Furane Cashew Nut
No. Shell Liquid
1 2 3 4 5 6 7
Acids:-
I) Acetic Acid 10% R R R R R
ii) Cromic Acid 10% N R L N L
iii) Hydrochloric Acid (conc) R R R R R
iv) Hydrochloric Acid 40% N N R R R
(see Note 2)
v) Lactic Acid 2% R R R R R
vi) Nitric Acid 10% L N L N L
vii) Nitric Acid (conc) N N N N N
viii) Phosphoric Acid 10% R R R R R
ix) Sulphuric Acid 10% R R R R R
x) Slphuric Acid 40% R R R R R
xi) Sulphuric Acid (conc.) N N L N N
Alkalies:
I) Ammonia 0.880 R N L R R
ii) Sodium Hydroxide 40% R N L R L
iii) Sodium carbonate R L R R R
iv) Calcium Hydroxide R N R R R
Salt Solutions:
I) Salt solution (acidic) R R R R R
ii) Salt solution (alkaline) R L R R R
Solvents:
I) Aliphatic hydrocarbons R R R R N
ii) Aromatic hydrocarbons L N R R N
iii) Alcohols R R R R R
iv) Ketones L N L R R
v) Chlorinated hydrocarbons L L R R N
Wet Gases (oxidising) N N N N N
Wet Gases (reducing) R R R R R
Mineral Oils R R R R L
R R R R L
Vegetable Oils and Fats
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Note 1 - R = Generally recommended

L = Limited use (occasional spillage)
N = Not recommended
Note 2 - Carbon and graphite filters should be used for hydrofluoric acid service
TABLE 2 : CHEMICAL RESISTANCE OF SILICATE TYPE MORTARS (from IS:4441-1980)

Sr.No. Substance CHEMICAL RESISTANCE
Sodium Silicate Potassium Silicate
Type Type
1 2 3 4
Acids:
I) Hydrochloric Acid (concentrated) R R
I) Sulphuric Acid 10% R R
iii) Sulphuric Acid (10 to 50%) L R
iv) Sulphuric Acid ( above 50%) (see Note) N R
v) Nitric Acid (concentrated) R R
vi) Organic Acids (conc.) R R
vii) Hydrofluoric Acid (any strength) N N
Alkalies:
I) Sodium Hydroxide (any strength) N N
ii) Sodium Carbonate (any strength) N N
Salt Solutions:
I) Acidic (pH value less than 4) R R
ii) Alkaline N N
iii) Neutral L L
Solvents:
I) Aliphatic hydrocarbons R R
ii) Aromatic hydrocarbons R R
iii) Alcohols R R
iv) Ketones R R
v) Chlorinated hydrocarbons R R
Fats and Oils R R
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R = Generally recommended
L = Limited use (occasional spillage)
N = Not recommended
Note - Potassium Silicate mortar used for resistance of sulphuric acid (above 90
percent), for a prolonged period, may cause crystal formation with
subsequent growth within the pores and can disintegrate these mortars.
TABLE 3 : CHEMICAL RESISTANCE OF SULPHUR TYPE MORTARS (From IS:4442-1980)
Sr.No. Substance Chemical Resistanceodium

1 2 3
Acids:
I) Hydrochloric Acid (concentrated) R
ii) Sulphuric Acid (70%) R
iii) Sulphuric Acid (above 70%) L
iv) Nitric Acid (40%) R
v) Nitric Acid (above 40%) N
vi) Organic Acid L
vii) Hydrofluoric Acid (40%) (see Note) R
Alkalies:
I) Sodium Hydroxide (1%) R
ii) Sodium Hydroxide (above 1%) N
iii) Sodium Carbonate (concentrated) R
iv) Salt solutions (acidic) R
v) Salt solutions (alkaline) L
Solvents:
I) Aliphatic hydrocarbons L
ii) Aromatic hydrocarbons L
iii) Alcohols R
iv) Ketones L
v) Chlorinated hydrocarbons L
Fats and Oils L
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R = Generally recommended
L = Limited use
N = Not recommended
Note - Graphite and carbon filler should be used for hydrofluoric acid service.
TABLE 4 - DRY HEAT LIMITS IN AIR OF RESIN TYPE MORTARS (From IS:4443-1980)
Sr.No. Type of Resin Dry Heat, Max °C

1 2 3
I) Phenolic 150
ii) Furane 150
iii) Epoxy:
a) Ambient temperature system 90

b) Heat-cured system 200
iv) Polyester 110-120
v) Cashewnut Shell Liquid Resin 170-180
END
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PART – II CIVIL DOC NO.:
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SECTION-14
Uhde India Limited EARTHWORK & LAND DEVELOPMENT Page :1
Contents Page
EXCAVATION FOR CUTTING AREAS 2
EXCAVATION FOR NALLAH DIVERSION 3
FILLING 4
CLASSIFICATION 6
Date: Date: Date:

First Edition: R0
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Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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14.1 EXCAVATION FOR CUTTING AREAS:
14.1.1 In ordinary soil :
a) Removal of Top Soil :
Top 150 mm top soil including grass, bushes, small trees and
vegetation shall be removed by mechanical equipment data like bull
dozer etc. In case of trees having trunk of 300 mm or more shall be
cut by saw and the roots to be removed fully.
All the above materials shall be transported and dumped outside the
plant area or to the location as identified by the Engineer.
b) Excavation in ordinary soil shall be done using mechanical earth

moving equipment such as scrapers, bull-dozers, tractors etc. in major
portion of the areas where levels are to be lowered for the purpose of
grading. Manual excavation may be adopted in the places where
moving equipment have no access.
c) Cutting shall be done to a fairly correct grade level within + 50 mm

tolerance.
14.1.2 In soft rock or boulders:
Excavation may be done by pneumatic vack hammers in case

bulldozers cannot be effectively used to remove the boulders or soft rock
with prior approval of the Engineer.
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14.1.3 In hard rock

This shall be executed with prior approval of the Engineer.
a) Excavation shall be done by controlled blasting method. Necessary

licence for using blasting powder and permission to carry out blasting
operations shall be obtained by the contractors at their own cost from
concerned authorities. All necessary precautions including warning
signals during blasting operations shall be taken to avoid damage to
existing nearby structures and injuries to human life and other animals
(as per Sect. 1).
b) Necessary storage of blasting powder shall be at contractor's cost and

shall be done complying with relevant statutory regulations.
c) Blasting operations shall be done under the supervision of licensed

foreman holding necessary certificates from the concerned authorities.
14.1.4 Excavation for Nalla Diversion & Cutting areas
Necessary dewatering of subsoil water, flowing water, bunding for diversion

etc. shall form the part of the excavation work in open areas or in nallas. The
expenses towards this work shall be included in the rates for excavation of
respective soils.
14.1.5 Measurements
14.1.5.1 Initial ground levels shall be jointly taken at a grid of 10 M x 10 M max.

spacing or as required and jointly agreed upon with site engineer. These shall
be jointly recorded on a grid-map to be prepared by the contractor and
forming part of measurement documents to be submitted along with bills.
14.1.5.2 After all excavation and surface levelling is completed, final finished levels
shall be jointly recorded at the same spot on 10 M x 10 M grid or otherwise
as in 14.1.5.1 above.
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14.1.5.3 Earthwork computation shall be done in accordance with IS:1200 or by the

method jointly agreed upon with Engineer. In case the same excavated
material are used for filling the low land area, measurement for payment shall
be on the basis of volume of excavation. The rates deemed to include the
filling and compacting the low land area.
14.2 FILLING WORK
14.2.1 Materials for filling work
a) If the materials obtained from excavations are to be used for filling the
low land area as directed by the Engineer, the filling operation shall be
as specified in 14.2.2.
b) If materials brought from borrow areas, the material shall have the
following properties.
c) This shall be free from vegetation, deleterious organic materials, wooden

pieces or tree trunks and other harmful materials which on
deterioration would have undesirable effects on filled up soil.
d) Material to be used for filling shall have following properties:
i) Cohesive soil - if the soil to be used for filling, either from

excavated materials or brought from outside, is of cohesive nature
then,
- Clay contents shall not exceed 5% by weight.
- 90% shall be of quality of hard or soft yellow or red murrum.
- Swelling of soil in presence of moisture shall not exceed 5% of the

soil mass.
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- Maximum density of optimum moisture contents shall not be less

than 1800 kg/cu.m.
- Liquid and plastic limits shall be in accordance with IS:2720 (Part ).
- Laboratory tests shall be conducted before using the soil and be

got approved from concerned engineers. All testing charges shall
be borne by the Contractor.
ii) Non-cohesive soils: if the soil to be used for filling is of non-

cohesive nature, then they shall have following properties:
- Clay contents shall exceed 5% by weight.
- Balance soil may have silt contents not exceeding 60% and
balance sand with 90% of it not exceeding the mean particle size
of 1 mm.
- All other properties shall be in accordance with relevant IS Code.
c) Materials excavated from cutting areas on site shall be used for filling
work to bring the ground to required grade level, after the prior testing
in laboratory and approval of the concerned site engineers.
14.2.2 Filling Operations
a) Filling shall be done in layers of thickness not exceeding 300 mm of

loose soil or 150 mm after compaction.
b) Consolidation shall be done at optimum moisture contents (O.M.C.) pre-

determined in laboratory and further assessed by core samples taken
at site. 8 to 10 tonne mechanical rollers shall be used for consolidation
of every layer in sufficient no. of passes until maximum density is
achieved at OMC.
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c) Contractor shall set up his own site laboratory for carrying out the
necessary field tests of filled up soil as per IS:2720.
d) Final level of filling shall not deviate from the specified level in
construction drawing by more than + 25 mm. Final surface shall be
uniformly graded using mechanical grades and rolled with 8 to 10
tonne roller.
14.2.3 Measurement
14.2.3.1 If the materials obtained from excavation in site levelling, no separate

measurement is required. Payment shall be paid on the basis of excavation.
In case of materials brought from borrow areas or other areas, the method of
measurement shall be as follows:
Before starting the filling work, initial ground levels shall be jointly recorded on
a grid of maximum spacing 10 M x 10M or as jointly agreed upon. These
shall be plotted on a grid map by the contractor and shall be used for
computation of earthwork and shall form part of work-bills.
14.2.3.2 After filling is completed upto specified levels and as per specifications, final
fill levels shall be recorded jointly with concerned Consultant's supervisor at
the same.
14.2.3.3 Quantity computation for filling shall be calculated based on actual average
fill level as measured above or level specified on drg. whichever is less.
14.3 CLASSIFICATION
All materials to be excavated shall be classified by Engineer, into one of the

following classes and shall be paid for at the rate tendered for that particular
class of material. No distinction shall be made whether the material is dry,
moist or wet. The decision of Engineer regarding the classification of the
material shall be final and binding on Contractor and not be a subject matter
of any appeal or arbitration.
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Any earthwork shall be classified under any of the following category:
a) Ordinary & Hard Soils
These shall include all kinds of soils containig kankar, sand, silt,
moorum and/or shingle, gravel, clay, loam, peat, ash, shale, etc. which
can generally be excavated by spade, pick axes and shovel, and which
is not classified under "soil and decomposed rock" and "hard rock"
defined below. This shall also include embedded rock boulders not
longer than one metre in any direction and not more than 200 mm in
any one of the other two directions.
b) Soft and Decomposed Rock
This shall include rock, boulders, slag, chalk, slate, hard mica schist,
laterite and all other materials which in the opinion of Engineer is rock,
but does not need blasting and could be removed with picks, rammer,
crow bars, wedges, and pneumatic breaking equipment. The mere fact
that Contractor resorts to blasting for reasons of his own, shall not
qualify for classification under 'hard rock'. This shall also include
excavation and tarred roads and pavements. This shall also include
rock boulders not longer than 1 metre in any direction and not more
than 500 mm in any one of the other two directions. Masonry to be
dismantled will also be measured under this item.
c) Hard Rock
This shall include all rock occurring in large continuous masses which
cannot be removed except by blasting or chiselling for loosening it.
Hardener varieties of rock with or without veins and secondary
minerals which, in the opinion of Engineer, require blasting shall be
considered as hard rock. Boulders of rock occurring in such sizes and
not classified under (a) and (b) above shall also be classified as hard
rock. Concrete work both reinforced and unreinforced to be dismantled
will be measured under this item, unless separate provision is made in
the Schedule of Quantities.
END
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Uhde India Limited FENCING AND COMPOUND WALL Page :1
Contents Page
COMPOUND WALL 2
CHAIN LINK FENCE 2
BARBED WIRE FENCE 3
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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15.0 COMPOUND WALL
15.1 Items involved in compound wall shall refer to their relevant specs. as given
below:
- Excavation and backfilling Sect. 1

- Concreting Sect. 2
- Masonry Sect. 3
- Pointing & Plastering Sect. 3
- Reinforcement Steel Sect. 4
15.2 CHAIN-LINK FENCE
15.2.1 Specifications for angle iron posts shall be same as for struct. steel work of
Sect. 7.
15.2.2 Precast Concrete Posts -
a) Concrete mix shall be M:15 as per IS:456.
b) Reinforcement shall be M.S. or/and torsteel bars as per drawings.
c) Posts shall be cast in smooth steel forms made to correct dimensions as

per drawing and concrete shall be compacted by table vibrators or
needle vibrator to give smooth finish.
d) Curing of concrete shall be done by submerging the posts in water tank

for 15 days minimum.
e) Damage to the post shall be avoided during installation of the posts in

position, aligning and levelling.
f) Diagonal post bolted to the vertical posts shall be provided at every

eighth bay and on either of the corner posts.
g) Spacing of the posts shall be not greater than 3M c/c or as per drawing
whichever is less.
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15.2.3 All hardware used for bolting the posts or chain link shall be of hot-dip
galvanised steel.
15.2.4 Chain Link:
a) This shall be procured in rolls of appropriate length and width and

shall consist of 10g hot dip galvanised steel wires woven in the form
of zig zag mesh giving opening size of 50 mm sq.
b) Chain-link shall be secured to the well wired and properly installed

fence posts with G.I. hook bolts and washers as per drawing and 6
mm G.I. wire rod on every post.
c) Tension wires shall be provided passing through the mesh at top,

centre and bottom of the erected chain link mesh and shall be of 3
mm dia. hot dip galvanised wire and shall be stretched to keep the
chain link in taut position.
15.3 BARBED WIRE FENCING
a) Spec. for angle iron or concrete posts and G.I. hardware shall be
same as for Sect. 15.2.
b) Barbed wire shall be made from hot dipped galvanised wire of 12 g

with bars of 16 g spaced at 100 mm c/c.
c) Barbed wire shall be procured in bundles of standard weights and

shall be fully stretched across the posts and secured with G.I. hook
bolts and washers as per drg.
d) Spacing of horizontal wires shall not be greater than 225 mm c/c or

as specified in the drawing. Diagonal wires shall be provided in each
bay between two adjacent posts. No wire shall be left loose or
sagging.
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1. The payment for chain link fencing shall be on M¨ basis. Angle iron
posts will be paid separately as per Sect. 7.
2. The payment for barbed wire fence will be on RM of barbed wire.
END
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Uhde India Limited PILING Page :1
Contents Page
GENERAL 2
MATERIAL 3
GUARANTEE 6
LOAD TEST ON PILES 7
DRIVEN CAST-IN-SITU PILES 11
BORED CAST-IN-SITU PILES 12
PRECAST DRIVEN PILES 14
BORED PRECAST PILES 18
UNDER REAMED PILES 25
MICROPILES 29
SEQUENCE OF PILING 29
Date: Date: Date:

First Edition: R0
KARANDIKAR
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Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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16.1 GENERAL
Piles find application for foundations in low bearing capacity soils to transfer
loads from a structure to competent subsurface strata having adequate load
bearing capacity. Piles transfer axial loads through friction along its shaft
and/or by the end bearing. The installation of piles demands careful control
on position, alignment and depth and involve specialised skill and experience
of working in soils of different characteristics.
These specifications cover scope of work, the material specification.

installation, load test on piles, mode of measurement.
16.1.1 SCOPE OF WORK
The scope of work covers the Geo-technical design of pile and construction
of reinforced concrete load bearing piles, the load tests on the pile,
installation and testing of test piles and guarantee of pile capacities, mix
design including all materials and kentledge for testing. It also covers the
preparation and submission of As-built drawings indicating the actual location
of piles and the pile records for each pile.
16.1.2 APPLICABLE CODES & SPECIFICATIONS.
a) Unless otherwise specified the design materials and workmanship

shall conform to the following standards.
IS:456 : Code of Practice for Plain & Reinforced Concrete
IS:269 : Ordinary Portland Cement
IS:6909 : Specs. For Super Sulphated Cement
IS:383 : Test of materials
IS:1200 : Mode of Measurements for Civil Works
IS:432 : Mild Steel & Medium Tensile Steel bars and wires
for concrete reinforcement
IS:1139 : Specs. For Mild Steel and medium tensile steel bars
and high yield strength steel deformed bars for
concrete reinforcement.
IS:1786 : Cold twisted Steel Bars
IS:1566 : Hard drawn steel wire fabric for concrete
Reinforcement
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IS:2502 : Bending and fixing bars

IS:2911 : (Part I to IV) - Design & Construction of Piled
Foundations.
IS:12330: Sulphate Resisting Portland Cement
IS:8112 : Specification for 43 grade cement
IS:2062 : Specs. for Structural Steel (Standard Quality)
IS:12269: Specs. for 53 grade cement
IS:2720 : Methods of Test for Soil
IS:1489 Specs. For Pozzolona Portland Cement
b) UIL's specification, standards and codes referred herein are made

part of this specification and shall apply to work except as may
otherwise be stated.
c) For such items of work which may arise and which are not covered
by the specifications or by relevant Indian Standard Specification, the
decision of the Owner/Engineer regarding specifications of such work
shall be final and binding to the Contractor.
16.1.3 MATERIAL
1. CEMENT : The cement shall be conforming to IS-12330 / IS-269 / IS

12269 / IS-1489 / IS-6909.
2. REINF. STEEL : Major reinforcement shall be conforming to IS:1786

Stirrups/spiral shall conform to IS:432.
3. AGGREGATE : All aggregates shall conform to IS:383 and IS:515,

coarse aggregate shall be crushed from blue basalt/hard granite and
shall be hard and free from weathering. The material shall be
graded to achieve homogeneous mix.
4. FINE AGGREGATE : This shall be free from dust and silty sand
and from original impurities. Sand shall be washed by the contractor
at no extra cost to the client, if it contains silt more than 4%. River
sand approved by Engineer/Owner must be used for RCC works.
The grading of fine aggregates shall be determined as per IS:2386
(Part I) and shall be within the limits given in Table 4 of IS:383. Sand
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shall also have to be washed off if it contains silt more than allowable
limits.
5. WATER : Water to be used shall be free from injurious and

deleterious materials. Water safe for drinking shall be used. Clean
water, free from acids and other impurities shall be used in the
manufacture of concrete. Water shall be conforming to IS:456
Clause 5.4 & Table-1.
6. CONCRETE :
a. Materials and methods of manufacture of cement concrete

shall in general be in accordance with the method of
concreting under the conditions of pile installation.
b. The slump for concrete shall be as follows:

Min. Max.
i) Driven cast-in-situ piles 100 180
ii) Cast-in-situ bored piles:
a) water free unlined bore
with wide space
reinforcement. 100 180
b) Tremie concreting 150 180
iii) Under reamed piles:
a) water free unlined
bore holes 100 150
b) Tremie concreting 150 200
c. Consistency of concrete to be used for the piles shall be

suitable to the method of installation of piles. Concrete shall
be so designed or chosen as to have a homogeneous mix
having a slump/workability consistent with the method of
concreting under the given conditions of pile installation.
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d. The grade of concrete to be used for piling shall be Min M25

or as indicated in the BOQ, with the minimum cement content
of 400 kg/Cu.M. Mixing shall be carried out in mechanical
mixer only. In case of piles subsequently exposed to free
water or in case of piles where concreting is done under water
or drilling mud using method other than trimie, 10% extra
cement over the design grade of concrete at the specified
slump shall be used subject to a minimum quantity of cement
specified above. The contractor shall carry out the mix design
for the above grade of concrete and submit the report prior to
concreting at no extra cost to the Owner. For the design
purpose of bore cast-in-situ piles, the strength of concrete mix
using above mentioned quantities of cement shall be taken as
M20.
e. Concreting for the piles shall be done with tremie of suitable

diameter.
f. Natural rounded shingle of appropriate size may be used as

coarse aggregate. It helps to give high slump with less water
cement ratio. For tremie concreting aggregates having
nominal size more than 20mm shall not be used.
g. Weigh Batching: The aggregate shall always be measured by

weigh batching making due allowance for the water content in
the aggregate. Volume batching of aggregate shall not be
permitted.
16.1.4 The Contractor shall design and indicate the load carrying capacities of piles
in direct compression, lateral thrust and uplift which is achievable by him,
alongwith supporting calculations based on Soil Investigation Report supplied
to him. The Contractor to note that the design calculations included in the
Geotechnical investigation report (if any), are indicative only. The
calculations of set shall also be submitted in case of precast piles. The
Contractor will give a written confirmation in case the same is agreeable to
him. In case the contractor feels necessary to have additional exploratory
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investigation, the same shall be done by the contractor. The cost towards
this investigation shall be included by the Contractor in his piling cost.
16.1.5 Guarantee
The Contractor shall stand guarantee for vertical, horizontal and uplift
capabilities of proposed piles under all operating, erection and driving
conditions for loads imposed by permanent structure resting on piles and will
be responsible for all damages due to the failure of pile foundation and hence
the structure.
The guarantee will be operative for a period of 1 (one) year from the date of
completion of piling.
16.1.6 The tenderer / Contractor shall furnish the Quality Assurance plan alongwith
the tender furnishing the name of the Engineer who will be responsible for the
quality.
16.1.7 For each pile, record of the following data shall be kept:
A. Type of Pile
B. Identification mark with Drg.No. and Rev.
C. Dia. of Piles
D. Ground level
E. Cut-off level of pile
F. Founding Level
G. Length of Pile
H. Grade of Concrete
I. W/C Ratio
J. Reinforcement Details with Drg.No. and Rev.
K. Piling - i) Starting Time
ii) Finishing Time
L. Concrete - i) Starting Time
ii) Finishing Time
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16.1.8 LOAD TEST ON PILES
These would be conducted on piles on completion of 28 days after casting.
Two types of tests namely initial and routine tests, for each type of loading
viz. Vertical, horizontal (lateral) pull out, are performed on piles.
16.1.8.1 Initial Tests
This test shall be performed to confirm the design load calculations and to
provide guidelines for setting up the limits of acceptance for routine tests. It
also gives an idea of the suitability of the piling system.
Initial Test on piles are to be carried out at one or more locations depending
on the no. of piles required.
Load applied for the initial (cyclic) load test shall be 2.5 times the safe
carrying capacity of the pile.
Loading for Initial Tests shall be conducted as per Appendix 'A' Clause 6.3 of
IS-2911 Part IV .
16.1.8.2 Routine Tests

Selection of piles for the Routine Test shall be done by the Engineer subject
to a maximum of ½% of total no. piles required. The no. of tests may be
increased to 2% depending on the nature / type of structure.
The test load applied shall be 1½ times the safe carrying capacity of the pile.
The Maintained load method as described in Clause 6.2 of IS-2911 (Part IV)
1985 shall be followed for loading for the Routine Tests.
This test will be performed for the following purposes:
a) To ensure the safe load capacity of piles

b) Detection of any unusual performance contrary to the findings of the
Initial Test.
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16.1.8.3 THE TESTS SHALL BE PERFORMED AT THE CUT-OFF LEVEL ONLY
16.1.8.4 The Contractor shall submit a detailed report for the test result in duplicate to
client / consultant.
16.1.8.5 Vertical Load Tests

This test will be carried out as stipulated in IS-2911 (Part IV) 1995.
Pile Head - The pile head shall be chipped off till sound concrete is met
wherever applicable. The reinforcement shall be cut and head levelled with
Plaster of Paris. A bearing plate with a hole shall be placed on the head for
the jack to rest.
Reaction - Kentledge shall be suitably designed to get the desired reaction on

the piles. Anchor piles (if required) shall be placed at a centre to centre
distance of 3 times the pile diameter subject to a minimum distance of 2 M.
Settlement - 2 dial gauges for a single pile and 4 dial gauges for a group of
piles with 0.01 mm sensitivity shall be used. They shall be positioned at
equal distance around the piles on datum bars resting on immovable
supports at a distance of 3D (min. of 1.5 m) where D is the diameter of pile or
circumscribing circle for non-circular piles.
Application of load - It shall be applied as specified depending on the type of

test (routine / initial). Each load shall be maintained till the rate of
displacement of the pile top is either 0.1 mm in the first 30 minutes or 0.2 mm
in the first one hour or 2 hours whichever occurs first. The next increment in
the load shall be applied on achieving the aforesaid criterion.
The test load shall be maintained for 24 hours.
Initial Tests - The safe load on a single pile shall be the least of the following:
rd
(i) 2/3 of the final load at which the total displacement attains a value
of 12 mm unless otherwise required in a given case on the basis of
nature and type of structure in which case, the safe load should be
corresponding to the stated total displacement permissible.
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(ii) 50% of the final load at which the total displacement equals 10% of
the pile diameter in case of uniform diameter piles or 7.5% of the
bulb diameter in case of under reamed piles.
Routine Tests - Acceptance
The maximum settlement at test load should not exceed 12 mm.
16.1.8.6 Lateral Load Tests:
The jack should be placed horizontally, between two piles. The load on the
jack shall be the same on both the piles. The load will be applied in
increments of 20% of the estimated safe load and at the cut off level. The
load will be increased after the rate of displacement is nearer to 0.1 mm per
30 minutes. If the cut-off level is approachable, one dial gauge exactly at the
cut-off level shall measure the displacement. In case the cut-off level is not
approachable, 2 dial gauges 30 cms. apart vertically, shall be set up and the
lateral displacement of the cut-off level calculated by similar triangles.
The safe load on the pile shall be the least of the following:
a) 50% of the final load at which the total displacement increases to 12
mm.
b) Final load at which the total displacement corresponds to 5 mm.
16.1.8.7 Pull out Tests
A suitable set up shall be designed to provide an uplift force to the piles. The
load increments and the consequent displacements shall be as per the case
of a vertical load test.
The safe load shall be the least of the following:
rd
a) 2/3 of the load at which the total displacement is 12 mm or the load
corresponding to a specified permissible lift.
b) Half of the load at which the load displacement curve shows a clear
break.
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Uhde India Limited PILING Page : 10
16.1.9 PILE HEAD
16.1.9.1 All the pile shall be concreted to a level at least 0.6 M above the cut off level.
The extra height of pile to be cast shall be minimum as per IS stipulations
and also so determined by contractor in such a way that after stripping to the
cut off level, the concrete at the cut off level shall be dense and sound. This
shall be taken into account and included in Contractor's rates for piles. A
few piles will be exposed upto 4 to 5M depth by the contractor at his own cost
for inspection of pile shaft. If the pile shaft shows defect, the Contractor shall
rectify his equipments and methods.
16.1.9.2 In the circumstance where cut-off level is below ground water, the need to
maintain a pressure on the unset concrete equal to or greater than water
pressure should be observed and accordingly length of extra concrete above
cut-off level shall be determined.
In such case, if required the contractor may have to cast the pile above cut-
off level upto overflowing the concrete, above ground.
16.1.10 CONTROL OF ALIGNMENT
Piles shall be installed as accurately as possible according to the drawings.

Greater care shall be exercised in respect of installation of single pile or piles
in two pile groups . For vertical pile a deviation of 1.5% of plumb shall not be
exceeded. Piles shall not deviate more than 75mm or D/4 whichever is less
(75 m or D/10 whichever is more in case of piles having diameter more than
600 mm) from their designed positions at the working level of piling rig. In
the case of single pile under column, the position deviation shall not exceed
50 mm or D/4 whichever is less (100 mm in case of piles having diameter
more than 600 mm). Piles not conforming to this requirement may at the
discretion of the Engineer be totally rejected and extracted if necessary at the
contractor's cost. All consequences of such rejection such as providing extra
beams or any other measure whatsoever shall be at the Contractor's
expenses.
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16.2 DRIVEN CAST-IN-SITU-PILES
16.2.1 The safe capacities of different diameter of driven cast-in-situ-piles

considered in arriving at the quantities are as indicated in the Geotechnical
investigation report.
16.2.2 The contractor may indicate his alternative geotechnical design with
specification and achievable pile capacities alongwith the supporting geo-
technical design calculations. However the alternative shall be only for driven
cast-in-situ-piles.
16.2.3 The above pile design calculations shall be reviewed by the consultant and
approved for the load test and execution.
16.2.4 CONSTRUCTION
The pile shall be formed within the ground by driving the temporary casing of
uniform diameter and adequate thickness and subsequently filling in the hole
so formed with reinforced concrete. The casing shall be installed with slug or
a shoe at the bottom and to displace the subsoil. The concrete shall be
properly rammed to get maximum density. Construction procedure of piles
shall be as per IS:2911 (PART - 1 / SEC.1). Contractor's equipment and
procedure shall be inspected and approved by consultant before starting the
job.
16.2.4.1 Set Criteria
Contractor shall submit his calculations for set criteria for the driven pile
capacities and diameters based on his equipment details in accordance with
Appendix-B (Clause 5.3.12) of IS:2911 (Part 1/SEC .1)
The piles not conforming to the acceptance criteria shall be totally rejected at
the discretion of the Engineer/Owner and removed if required, at Contractor's
cost. All consequences and expenses of such rejection as providing
additional piles, enlarging pile caps, providing extra beams or any other
measure whatsoever shall be borne by the Contractor.
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16.3 BORED CAST-IN-SITU PILES
16.3.1 For this piling work, use of the following piling system is contemplated:-
Bored piles installed by boring holes of suitable diameter with the help of
guide casing; the concrete being poured through a tremie pipe extending to
bottom of hole. The DMC method with bentonite shall be used for boring.
The Contractor shall prevent collapse of hole and ensure proper quality of
concrete. The piles shall be capable of sustaining safe vertical downward
load, vertical uplift and lateral load as shown in drawing.
Alternatively, casing shall be used for the loose / soft soil strata. As boring in
soft material is liable for cavitation, boring tools should not be operated below
the toe of the casing. The casing shall be driven down through the soft layer
to penetrate a hard strata not subjected to cavitation and shall be sealed in
this material as far as possible. Thereafter, the boring shall continue by
means of boring tools until the approved bearing strata is reached.
a. The choice of the piling equipment is left to the Contractor provided

he can achieve the desired strength, quality of concrete and the
desired penetration into the hard bearing strata. Also the contractor
should use such equipment so as to install piles where the clear
distance between the outer face of the pile and obstruction (in the
form of wall, footing existing structure etc.) is about 1.20 M from
vertical face of obstruction to the centre of the pile. The final
diameter/size of the cured pile shall be not less than that specified.
16.3.2 Construction technique and construction of pile foundation shall be as per

IS:2911 (Part I). Section III and they should further conform to the following
particular requirements :
16.3.3 For bored piles : Not leaner than M-25 mix or as specified in BOQ.
16.3.4 The lengths of bars to be left over the cut-off level of the pile shall be as
shown in drawings.
16.3.5 The bored piles should penetrate into the hard acceptable strata by a
minimum of 550 mm or equal to pile dia. whichever is greater, unless
otherwise noted.
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16.3.6 The density of the freshly prepared bentonite solution should be between
3
1.03 and 1.10 gm/cm .
16.3.7 The Contractor shall note that the pile shall be installed in such sequence that
the carrying capacity of the previously installed pile is not reduced. The
sequence for piling shall be as per working drgs. and/or instructions of the
Engineer.
16.3.8 Immediately before concreting, the bore hole shall be cleaned of all loose
materials debris and all the water shall be removed by pumping and bailing.
Great care shall be taken to ensure that fluid alluvial soil does not fall between
batches of concrete.
For marine situation, piles may be formed with permanent cases (liner). In
case, liner is used and the bore is filled with water or drilled fluid the bottom
part may be concreted using tremie method so that the liner is effectively
sealed against ingress of ground water and then the upper part can be
concreted in dry after proper inspection of the top surface of the concrete in so
placed under water.
16.3.9 Jetting may have to be used to penetrate the pile through top stiff clay. The
cost of such jetting is assumed to be included in basic pile cost and no
additional payment will be made on this account.
16.3.10 Test Pile:
The test pile shall be bored and cast as per design at the location. However,
if the test pile fails, Contractor has to fabricate new test pile of suitable length
and drive immediately.
Contractor to note that working pile shall not be driven until test piles satisfy
load test requirement. However Contractor can keep his material, labour and
equipments ready to fabricate the working piles in shortest time.
16.3.11 Clearance of site subsequent to pilling operations
Contractor must include in his rate clearing of muck arising out of pilling
operations and depositing the same anywhere within site and dressing the
same or disposing it of with a lead upto 1 to 3 Kms. as directed by the
Engineer.
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16.4 PRECAST DRIVEN PILES
16.4.1 Scope
This specification covers the technical specifications for the precast piles
16.4.1.1 Type of Piles
a. These piles shall be precast concrete piles and are installed in place
by driving to the specified depth or specified resistance (SET, as per
IS:2911) or combination of both.
b. Based on the attached soil investigation report details, the Contractor

shall indicate the type they propose along with technical
specifications for execution, size and length of precast piles, and
details.
c. Piles shall be preferably square in shape with chamfers.
16.4.1.2 Design of Pre-cast piles
a. Pile design and construction shall conform to latest applicable

sections/parts of IS:2911
b. Grade of concrete for pre-cast piles shall be M30 or as indicated in

BOQ with minimum cement content as 500 kg/M cube. and
water/cement ratio shall be restricted to 0.45
c. The drawing supplied by Owner/Engineer may, if required, show the
necessary design data such as vertical load, horizontal thrust,
bending moment (Exclusive of self weight of foundation) to enable
piling Contractor to specify the capacities and lengths of piles to be
offered as per the soil report.
d. Contractor shall submit design calculation and details of pile along

with tender for safe vertical and lateral loads on piles and also the
calculations for the settlements for piles/pile groups. Negative skin
friction if any shall be supported by the necessary calculations. The
calculations shall also include driving stresses, construction /
operational stresses and set requirement.
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e. After the contract is awarded, Contractor shall submit drawings

showing concrete mix used, sections of pile, length of pile (as per soil
report), shoe and reinforcement details, lifting and driving
arrangement of piles, and other necessary details for
Owner/Engineer approval. After getting final approval from
Owner/Engineer the Contractor shall start the construction of piles
and submit final certified as-built drawings to Owner/Engineer.
f. The contractor shall submit detailed calculations and drawing for the
piles he proposes to use. The calculations must include vertical
horizontal and uplift capacity and combination of vertical and lateral
loads and uplift and lateral loads. The calculations shall be done
generally as per Indian Standard and will be included in Technical
Bid. These shall also include driving stresses and constructing
operations stresses in case of precast piles. The calculation for set
shall also be submitted.
16.4.2 Fabrication, stacking, Storing, Handling
a. For proposed pile handling systems i.e. Two point, three point or
multiple point, adequate lifting holes are to be provided at appropriate
locations. Heavy gauge pipe sleeves are to be embedded in pile to
form lifting holes.
b. Pile bottom should be safeguarded with the help of pile shoe and the
area of top of shoe shall be such that the stresses in concrete in this
part of pile are within the safe limits. All the longitudinal reinforcement
of pile shall be continued upto the bottom of the pile in addition to the
special steel in the shoe.
c. Piles shall be cast in a continuous operations from end to end of

each pile. Piles shall be kept continuously wet for 7 days but longer
curing shall be done as directed by Engineer when hard driving is
expected. Piles shall be covered to protect from rapid drying by wind
and direct sun light. Driving shall not be done before 28 days of
casting and curing of pile that they are not damaged or cracked.
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Before the operation of handling and driving the piles, the minimum
periods counted from the time of casing shall be as stated
hereunder:
TIME FOR CURING PRECAST PILES

TYPE OF CEMENT
MIN. PERIOD FROM TIME OF OPC R.H.P.C.
CASING
Strike Side Shutters 24 Hours 12 Hours
End of wet curing 07 days 07 days
Lift from casting bed 10 days 10 days
Drive 28 days 10 days
OPC - Ordinary Portland Cement

RHPC - Rapid Hardening Portland Cement
d. Piles shall be stored on firm ground free from liability to unequal

subsidence or settlement under the weight of stack of piles. Levelled
timber or any other supports are to be used to stack the pile.
Suitable supports shall be spaced so as to avoid undue bending of
piles. Supports shall be vertically above the other for each layer of
stack. Separate stacks shall be provided for piles of different
lengths. If curing is needed during storage, then arrangement shall
be made by the contractor for this.
e. Piles shall be carefully handled at all stages of transportation, lifting,

erection in such a way that they are not damaged or cracked.
16.4.3 Driving of Pre-cast piles
a. The head of precast pile shall be protected with packing of resistant

material. Standard helmet with a dolly of hard wood shall be placed
on pile head if drop hammer or single acting hammer is used. A
steel plate of 25 mm (min) shall be used on top dolly to distribute the
hammer blow. The use of wood chips, small wood blocks or such
other material is prohibited.
b. In general, sequence of driving of piles shall be from the centre of

pile group towards periphery of the pile group. Piles shall be driven
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in a continuous manner without interruptions as per the specified

SET or depth or combination of both.
c. Piles may be driven with any type of hammer, provided they

penetrate the prescribed depth or attain the specified resistance
without being damaged. While choosing the size of the hammer,
regard should be given to whether the pile is to be driven to a given
resistance or to a given depth. The stroke of the hammer should be
limited to 1.0 m.
d. The pile shall be driven as accurately as possible to the vertical or

specified batter.
e. During driving of piles, if any localised / obstruction is natural
encountered then that has to be removed physically by the contractor
at no extra cost.
f. Jetting may be used as a means of minimising / eliminating the

resistance at the toe. Jetting of piles should be carried out only when
it is desired and in such a manner as not to impair the bearing
capacity of piles already in place, the stability of the ground or safety
of any adjoining building.
g. The quantity of water for effective jetting is limited upto 2 Lpm per
square centimetre of pile cross-section. Two pipes attached to the
opposite sides of the pile may be used. These pipes / nozzles
should not be placed at the tip of the toe.
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16.5 BORED PRECAST PILES
16.5.1 Scope
This specification covers the technical specifications for the Bored precast
piles
16.5.1.1 Type of Piles

These piles shall be precast concrete piles and are installed in pre-bored
holes with annular space of minimum 40 mm thickness and duly grouted.
16.5.1.2 Design of Pre-cast piles
a. Pile design and construction shall conform to latest applicable

sections/parts of IS:2911
b. Grade of concrete for pre-cast piles shall be M30 or as indicated in

BOQ with minimum cement content as 500 kg/M cube. and
water/cement ratio shall be restricted to 0.45. cement of approved
make only shal be used for precasting of piles.
c. The drawing supplied by Owner/Engineer may, if required, show the

necessary design data such as vertical load, horizontal thrust,
bending moment (Exclusive of self weight of foundation) to enable
piling Contractor to specify the capacities and lengths of piles to be
offered as per the soil report.
d. Contractor shall submit design calculation and details of pile along

with tender for safe vertical and lateral loads on piles and also the
calculations for the settlements for piles/pile groups. Negative skin
friction if any shall be supported by the necessary calculations. The
calculations shall also include construction / operational stresses
e. After the contract is awarded, Contractor shall submit drawings

showing concrete mix used, sections of pile, length of pile (as per soil
report), reinforcement details, lifting and driving arrangement of piles,
and other necessary details for Owner/Engineer approval. After
getting final approval from Owner/Engineer the Contractor shall start
the construction of piles and submit final certified as-built drawings to
Owner/Engineer.
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f. The contractor shall submit detailed calculations and drawing for the
piles he proposes to use. The calculations must include vertical
horizontal and uplift capacity and combination of vertical and lateral
loads and uplift and lateral loads. The calculations shall be done
generally as per Indian Standard and will be included in Technical
Bid. These shall also include and constructing operations stresses in
case of precast piles.
g. The piles have to designed for loads and moments including the
effect of resultant shift of 50 mm and tilt of 1.5 % inclination. The
piles shall be installed vertically in prebored holes and in true position
as indicated in the plan and any deviation from true vertical position
shall not exceed the limiting values of shift and till stipulated above at
the level of bottom of pile cap.For positional deviations beyond limits
stipulated above the Contractor shall provide extra piles as directed
by the Engineer and shall bear all costs of such remedial measures.
h. If certain piles are rejected by the Engineer on account of their

improper location or deviation from the verticality by more than
specified tolerances or due to defective construction or due to any
other reasons, the Contractor shall pull out all such rejected piles and
reinstate new piles with proper workmanship and materials to the
satisfaction of the Engineer without any extra cost. The Engineer,
however, may allow the rejected piles or be left in their places and
additional piles to be installed to take up the load of the rejected
piles, without any extra cost, if he considers it feasible and correct. If
any such changes involves additional expenditure due to increased
size of pile caps, tie / grid beams, the same shall be borne by the
Contractor.
i. The safe load carrying capacity of the pile shall be confirmed by the
initial cyclic test loading as per IS-2911 (Part IV).
j. While evaluating the capacity of the pile, the safe base resistance shall
be limited to maximum of500 T / sq.m. on pile cross section which
includes the socketing effects of the pile of min.8 times diameter of pile
as depth of socket into rock and further limited to results of initial /
routine load tests of pile.
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k. The skin friction of the overburden fill and marine clay shall not be
taken into account while evaluating the capacity of pile.
16.5.2 Fabrication, stacking, Storing, Handling
a. The casting bed shall be prepared on firm ground to prevent bending of

piles during and soon after casting.
b. The casting yard shall have fully drained surface to prevent excessive
or uneven settlement due to softening of bedding due to collection of
water during manufacturing and curing of piles.
c. On removal of the side forms, the piles shall be marked with the
reference number, date of casting, length, etc. to ensure that they are
lifted, format he casting bed at the correct time and to ensure that
each pile is used at its correct locations.
d. The anchorage bars for the proposed pile caps / floor slab shall be left
while precasting the piles.
e. Borehole data is available for inspection in the Client’s /Consultant’s
Office. Rock cores are also available for inspection in the same office.
To determine the the length of precasting additional trial bores as
directed by the Engineer, shall be taken in advance by the contractor
which will be paid for under relevant Items of Bill of Quantities. Based
on the trial bores, the precasting lengths will be decided by keeping a
margin of variation. The payment for the pile shall be made as per the
mode of measurement as per the Bill of Quantities in the tender.
f. The conventional types of cover blocks are undesirable in precast piles.
Hence the requisite number of concrete loops in the spiral laterals are
to be kept and they shall be manufactured with 10 mm maximum
aggregate size and shall be same strength as that of pile concrete.
g. As far as possible each longitudinal reinforcement bar shall be one
length. In case where a joint in reinforcement bar cannot be avoided,
the joints in the bars shall be staggered and shall be made by butt
welding as directed by the Engineer.
h. The links (laterals) shall spiral and may be either welded to main
reinforcement or tied by mild steel wire.
i. The reinforcement cage shall be tight and aligned perfectly before
concreting. For this purpose, the cage shall be suspended from
bearers with spacing forks not more than 1.5 m apart.
j. The reinforcement shall be free form the rust and pitting.
k. The concrete between the steel and the form shall be worked with
slicing tools to eliminate honey combing patches and thoroughly
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compacted with immersion / shutter vibrators to ensure denseness

of concrete.
l. For proposed pile handling systems i.e. Two point, three point or
multiple point, adequate lifting holes are to be provided at appropriate
locations. Heavy gauge pipe sleeves are to be embedded in pile to
form lifting holes as per the method to be adopted by the contractor.A
grouting hole of 40 mm diameter shall be provided in the precast pile
by providing a M.S. sheathing of approved make while casting the
piles.
m. While vibrating the pile concrete it shall be seen that the piles already
cast earlier are not affected.
n. The shuttering for the pile to be precast may be wooden or steel as
o. Piles shall be cast in a continuous operations from end to end of each
pile. Piles shall be kept continuously wet for 7 days
p. Piles shall be covered to protect from rapid drying by wind and direct
sun light.
q. Before the operation of handling, the minimum periods counted from
the time of casing shall be as stated hereunder:
TIME FOR CURING PRECAST PILES

TYPE OF CEMENT
MIN. PERIOD FROM TIME OF OPC R.H.P.C.
CASING
Strike Side Shutters 24 Hours 12 Hours
End of wet curing 07 days 07 days
Lift from casting bed 10 days 10 days
OPC - Ordinary Portland Cement

RHPC - Rapid Hardening Portland Cement
r. The piles shall also be cured in stacking yard by spraying water, till
they are lifted for installation as they develop shrinkage cracks if
allowed to be dried completely before installation.
s. The lifting of the piles shall not be delayed for long time. To avoid
shrinkage cracks and / or creep deformations.
t. One set of six cubes shall be taken for every ten piles concreted,
subject to a minimum of six cubes per shift.
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u. Before lifting pile from the casting bed, cubes taken from the same
batch shall be tested.
v. As soon as the crushing test of concrete cubes form each pile after
the due date indicate that the pile is strong enough to be lifted, it shall
be slightly canted by careful level with a crow bar and packed with
wedges to release the suction between the pile and the bottom
shuttering. The lifting slings of bolts shall then be fixed and the pile
lifted for transportation to the stacking yard. The operation of the first
casting and lifting must be under taken with great care since the piles
have still only a comparatively immature strength and any cracks or
incipient cracks formed at this stage will open up while installing the
piles.
w. Piles shall be stored on firm ground free from liability to unequal
subsidence or settlement under the weight of stack of piles. Levelled
timber or any other supports are to be used to stack the pile. Suitable
supports shall be spaced so as to avoid undue bending of piles.
Supports shall be vertically above the other for each layer of stack.
Separate stacks shall be provided for piles of different lengths. If
curing is needed during storage, then arrangement shall be made by
the contractor for this.
x. Space shall be left around the piles to enable them to be lifted for
installation without any difficulty and for air to circulate around the
piles.
y. The order of stacking shall be such that the older pile can be with
drawn earlier for installation without disturbing the newer piles.
z. Separate stack shall be provided for piles of different length.
aa. During transportation, the piles shall be supported at the appropriate
lifting holes as per design provided for the purpose. If the piles
required to be put down temporarily after being lifted, they shall be
placed on trestles or blocks located at the lifting points.
bb. Piles shall be carefully handled at all stages of transportation, lifting,
erection in such a way that they are not damaged or cracked.
16.5.3 Pile boring and chiselling
a. The setting out of piles shall be done by the contractor. The

reference points / pillars with finished top in line and level shall be
established as directed to enable checking of setting at any time
b. The pile bore holes for installation for precast piles shall be formed
with percussion tools by using a simple tripod and which, etc.
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Temporary steel casing shall be driven upto hard strata to prevent the
walls of the bore hole from caving in. Alternatively walls of borehole
may be stablised with drilling mud / bentonite slurry. The payment of
boring per metre shall be inclusive of providing temporary casing and
/ or providing mud/ bentonite slurry, and no separate payment
shall be made for provision of steel casing and / or for bentonite slurry.
Necessary chiselling will be done to reach the founding level. Minimum
weight of the chisel shall be 1 T and min. fall / drop shall be 1.5 m.
c. The nominal diameter of the pile bore hole shall be at least 80 mm
more than the diameter of the pile.
d. After reaching the foundation strata, the rock fragments shall be
examined visually and compared with the exploratory or trial bore
sample. Chiselling will be done to obtain a socket of min 8 times
diameter of pile in the founding stratum which is expected to be
brownish Breccia. At the pile termination level minimum energy
required for extending the piile bore with a drop chisel and a fall used
as above shall be 75m/Sq.m. of pile cross section per cm
penetraiton. This shall be verified by giving set of 100 blows 3 times
consecutively. If the criteria is not met with these blows chiselling
shall be continued.
e. After confirming the foundation stratum, the bottom of the bore hole
shall be thoroughly cleaned of all spoils and loose rock fragments
before pitching the precast pile for installing. If directed , tip zone
cleaning shall be done by operating an air-lift system for at least 20
minutes during which bentonite slurry shall be circulated using
compressed air. Minimum discharge shall be 500 litres / minute.
Otherwise conventional cleaning by tremie method shall be done.
f. After cleaning the bore the pile is pitched up by a crane and made
vertical and lowered into the bore hole. Before leaving the pile on the
founding stratum, the bottom of the bore hole shall be thoroughly
flushed by water under pressure through the central grout hole. The
bore hole shall be considered clean only when the return water is clear.
g. After lowering the precast pile into the socket formed in the founding
stratum, a colloidal mix of cement sand grout of 1: 2 proportion by
volume, prepared in high speed mixer shall be pumped under
pressure to the bottom of the bore hole through the central grout
hole so as to fill the annular space around the pile. In the process if
the rising of the grout in annular space of the bore hole to the
ground level, it displaces the water that was filled during flushing.
Care must be taken at this stage not to lift the precast pile from its base
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while grouting is in progress as it will undesirably allow a layer of grout

to form between the founding stratum and the precast pile. The grout
shall be allowed to overflow until it attains the consistency of the mortar
that was fed in. At this stage, the grout from the central hole shall be
stopped.
h. Level marks shall be put accurately on each pile, immediately after it is
installed. The piles shall be observed closely and if any pile shows a
tendency to heavy up due to installation of another pile later on or due
to any other reason, the pile shall be re-pitched firmly socket stratum
without showing tendency to heave up, in a manner as approved by the
Engineer-in charge, at no extra cost.
i. After the grouting from the central hole is stopped, the casing shall be
withdrawn one by one is the reverse sequence in which they are
driven. This shall facilitate the filling of the grout into the bore hole as
the grout slumps to fill the void left by the withdrawal of the casing.
j. It is necessary to keep a sufficient head of grout in casing to resist
external pressure and to prevent the soil and sub-soil water getting into
the space to be ocupied by the grout.
k. As the extraction of the casing continues, the drop in the grout shall be
made good from the top of the boreholes.
l. All possible care shall be taken to see that the bore holes are truly
vertical to ensure the resting of the precast pile on the founding
stratum and to avoid the bending of the pile during installation. Any
deviation from true alignment and verticality beyond permissible
tolerance values stipulated in 6.7.1.2 above shall be rectified in the
manner specified, at Contractor's own cost.
m. In the process of boring all the intermediate boulders or fragments of
harder materials shall be bored through to reach the foundation
stratum.
n. The resultant eccentricity of the pile after installation shall not be
more than 50 mm positionally and 1.50% in inclination.
o. Before casting pile cap, the concrete in the top portion of pile shall be
chipped away upto the specified cut off level. During the process of
cuttng, care shall be taken not to damage the concrete below the
cut off levels and the reinforcement exposed in the pile above the
cut off level. However, if any damage is done to them the same shall
be made good by the contractor to the entire satisfaction of the
Engineer, at his own cost. As one of the safety precaution a PCC
levelling course shall be cast first below pile cap and allowed to gain
sufficient strength before chipping operation is started. This
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however, does not relieve the contractor of his ultimate responsibility

vis-a vis prevention of damage to pile concrete.
16.5.4 Load Test
Various load tests for piles shall be carried out as per 16.1.8.
16.6 UNDER REAMED PILES
16.6.1 Under reamed piles shall be bored cast-in-situ having one or more bulbs
formed by suitably enlarging the bore hole for the pile stem.
16.6.2 For concrete, water and aggregate, the specification aid down in IS:456 shall
be followed. The minimum cement content for piles upto 300 mm dia. and
upto a depth of 10M, shall be 350 kg/Cu.m. For larger diameter and deeper
piles the minimum cement content shall be 400 Kg/Cu.m.
16.6.3 EQUIPMENT AND ACCESSORIES & CONSTRUCTION
16.6.3.1 The selection of equipment and accessories will depend upon the type of
under-reamed piles, site conditions and nature of strata. Also it will depend
on economic considerations and availability of manually or power operated
equipment. Normally the following equipment will be required in manual
operation:
a) Auger
b) Under reamer
c) Boring guide
d) Accessories like spare extensions, cutting tool, concreting funnel etc.
It is convenient to have a tripod with a hand operated winch to do the

augering of the bore.
16.6.3.2 Bore holes may be made by augers. In case of manual boring, an auger
boring guide shall be used to keep the bores vertical or to the desired
inclination and in position.
16.6.3.3 In ground with high water table having unstable pile bores, boring and under-
reaming may be carried out using a suitable drilling mud. In normally met soil
strata, drilling mud can be poured from top while boring and under-reaming
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can be done by normal spiral earth auger and under-reamer. The level of
drilling mud should always be about one meter above water table or the level
at which caving in occurs. In case of very unstable strata with excessive
caving in, continuous circulation of drilling mud using suitable pumping
equipment and tripod, etc. alongwith modified auger and under-reamer may
be used.
16.6.3.4 Sometimes permeable strata overlying a rim clayey stratum may be cased
and normal boring and under-reaming operation may be carried out in clayey
stratum.
16.6.3.5 To avoid irregular and widening of bore hole in very loose strata at top, a
casing pipe of suitable length may be used temporarily during boring and
concreting.
16.6.3.6 For improved control over the inclination of batter piles, a tripod hoist with
fixed pully should be used for lowering in of under-reaming tools.
16.5.3.7 For placing the concrete in bore holes full of drilling mud or subsoil water,
tremie pipe of not less than 150 mm diameter with flap valve at the bottom
should be used.
16.6.3.8 For batter under-reamed piles, the reinforcement cage should be placed
guiding it by a chute or any other suitable method. If concreting is not done
by tremie, it should be done by chute.
16.6.3.9 In under-reamed compaction piles, suitable devices should be used for

guiding the movement of drop weight and specified core assembly for its
vertical driving. For operating the drop weights of adequate capacity, suitable
winch with hoisting attachment should be used.
16.6.4 CONSTRUCTION
16.6.4.1 Under-reamed piles may be constructed by selecting suitable installation

techniques at a given site depending on subsoil strata conditions and type of
under-reamed pile and number of bulbs.
16.6.4.2 In construction with the equipment given in initially boring guide is fixed with
its lower frame levelled for making desired angular adjustment for piles at
batter. Boring is done up to required depth and under-reaming is completed.
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16.6.4.3 In order to achieve proper under-reamed bulb, the depth of bore hole should
be checked before starting under-reaming. It should also be checked during
under-reaming and any extra soil at the bottom of bore hole removed by
auger before reinserting the under-reaming tool.
16.6.4.4 The completion of desired under-reamed bulb is ascertained by :
(a) the vertical movement of the handle, and
(b) when no further soil is cut.
16.6.4.5 In double or multi-under-reamed piles, boring is first completed to the depth

required for the first (top) under-ream only and after completing the under-
reaming, boring is extended further for the second under-ream and the
process is repeated.
16.6.4.6 Concreting shall be done as soon as possible after completing the pile bore.
The bore hole full of drilling mud should not be left unconcreted for more than
12 to 24 hours depending upon the stability of bore hole.
16.6.4.7 For placing concrete in pile bores, a funnel should be used and method of
concreting should be such that the entire volume of the pile bore is filled up
without the formation of voids and/or mixing of soil and drilling fluid in the
concrete.
16.6.4.8 In empty bore holes for under-reamed piles a small quantity of concrete is
poured to give about a 100 mm layer of concrete at the bottom.
Reinforcement is lowered next and positioned correctly. Then concrete is
poured to fill up the bore hole. Care should be taken that soil is not scrapped
from sides if rodding is done for compaction. Vibrators shall not be used.
16.6.4.9 If the water is confined up to the bucket length portion at the toe and seepage
is lower, the water should be bailed out and concreting should be done as in
16.5.4.7.
16.6.4.10 In case the pile bore is stabilised with drilling mud or by maintaining water
head within the bore hole, the bottom of bore hole shall be carefully cleaned
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by flushing it with fresh drilling mud, and pile bore will be checked for its
depth immediately before concreting.
Concreting shall be done by tremie method. The tremie should have a valve
at its bottom and lowered with its valve closed at the start and filled up with
concrete. The valve is then opened to permit the flow of concrete which
permits the upwards displacement of drilling mud. The pouring should be
continuous and tremie is gradually lifted up such that the tremie pipe opening
remains always in the concrete. If the final stage the quantity of concrete in
tremie should be enough so that on final withdrawal some concrete spills
over the ground.
16.6.4.11 In inclined piles, the concreting should be done through a chute or by tremie
method.
16.6.4.12 For under-reamed bore compaction piles, the pile bore is first filled up without
placing any reinforcement. Concreting is done as in 16.30 depending upon
situation. Soon after, the specified core assembly shall be driven and extra
concrete shall be poured in simultaneously to keep the level of concrete up to
ground level. If hollow driving pipe is used in core assembly, the pipe shall
be withdrawn after filling it with fresh concrete which will be left behind.
16.6.4.13 Defective Pile - In case, defective piles are formed, they shall be removed or
left in place whichever is convenient without affecting performance of the
adjacent piles or the cap as a whole. Additional piles shall be provided to
replace them as directed at Contractor's cost.
16.6.4.14 Any deviation from the designed location alignment or load capacity of any
pile shall be noted and adequate measured taken well before the concreting
of the pile cap and plinth beam if the deviations are beyond the permissible
limit.
16.6.4.15 Load Test
Various load tests for piles shall be carried out as per 16.1.8.
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16.7 MICROPILES
16.7.1 Micropiles are used especially when very limited space or headroom is
available for execution with conventional pile rigs. Micropiles are small
diameter bored cast-in-situ piles of diameter 150 to 300 mm constructed by
rotary drilling machine and grouted using rich grout with fine sand by injection
process.
16.7.2 The methodology of executing these piles is as follows:
16.7.2.1 A borehole of required diameter 150 to 300 mm is drilled using bentonite

slurry by a rotary drilling equipment to stabilise the sides of the bore hole.
16.7.2.2 A liner of full depth upto hard rock / strata is necessary. M.S. or HDP pipe
liners are being used MS liners are however preferable.
16.7.2.3 Tor steel reinforcement cage of a bundle of large diameter rebars is provided
as pile reinforcement
16.7.2.4 Pile is grouted with rich grout of cement and fine sand with water cement
ratio of 0.5 and this grout shall have compressive strength of minimum 480
kg.cm2 on 28 days. Contractor may also propose alternatively any other
suitable method including filling the bore with coarse aggregate upto
specified height of about 1M and filling it subsequently with cement grout.
16.7.2.5 The piles are socketed adequately into the hard strata / rock necessary to
develop the capacity which comes mainly in friction in the socket.
16.7.2.6 The safe vertical load capacities are generally from 25 to 35 MT and lateral
(shear) capacities are generally from 2 to 4 MT.
16.7.2.7 Various load tests shall be carried out as per 16.1.8.
16.8 SEQUENCE OF PILING
The Contractor shall note that the pile shall be installed in such a sequence
that the load carrying capacity of previously installed pile is not reduced. The
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sequence of piling shall be as per working drawings and/or instructions of

Engineer.
In a pile group, the sequence of installation of piles shall normally be from the
centre to the periphery of the group or from one side to that the soil is
restrained from the flowing out during operations.
16.9 MODE OF MEASUREMENT:
1. The length of piles shall be measured from the cut-off level to the
lower edge of pile (i.e. pile toe) for the purpose of payment (Please
refer drawing). For precast piles, the length of the piles shall be
measured according to the specified length as mentioned on the
drawing.
2. The concrete to be broken upto the cut off level shall be measured
on cubic metre basis for Precast piles.
3. Empty boring shall be paid separately in running metre measured

from ground level to cut off-level.
4. No extra payment will be made for the casing to be provided

during boring and grouting operations.
5. Reinforcement Steel shall be paid separately in M.T.
6. Excavation from existing ground level upto pile cut-off level to be

included in pile rate for test piles.
7. The Contractor shall include in his unit rates the cost of setting and
shifting of rigs, personnel, auxiliary equipment at different locations
as required within the site premises of the project.
8. Payment of shoe plate left in the soil shall not be separately made
to the Contractor.
END
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Uhde India Limited STONE COLUMNS Page :1
Contents Page
GENERAL 2
MATERIAL 2
STONE COLUMN SPECIFICATIONS 4
CONSTRUCTION 5
VIBROFLOTATION TECHNIQUE 5
RAMMED STONE COLUMNS IN CASED BORES 6
LOAD TEST 11
ACCEPTANCE CRITERIA 12
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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17.1 General
The ground is proposed to be improved by installation of stone columns with

a view to improve the bearing capacity and control the settlements. These
specifications cover the design guidelines, material specifications and
installation of stone columns.
17.2 Scope
As per the soil investigation report the contractor shall undertake the design
and shall submit 2 copies of design calculations of safe loads, bearing
capacity, spacing, settlement, corresponding to a particular diameter of stone
column that the contractor proposes to use, grouping, thickness of sand
draining layer along with 2 copies of drawing showing arrangement, size,
spacing material of construction etc. for Owner/Engineer approval. After
getting the final approval the contractor shall start the construction and
submit 4 copies of final certified drawings. Acceptance of design calculations
and methodology of installation does not relieve the contractor of his
responsibility and performance. Contractor shall submit at the time of
quoting his method of adopting the technique of construction. Contractor, if
required by him shall carry out further investigation of soil at no additional
cost to the Owner.
17.3 Material
17.3.1 Cement (In case cement is supplied by the contractor)
Cement shall be portland cement conforming to Indian Standards 269 grade

33 or Portland blast furnace slag cement conforming to IS:455 or Sulphate
resistance cement as per IS:6909. Test Certificate for the cement stored
shall be obtained by the contractor at his own cost when desired by the
Owner/Engineer. Damaged or bad quality cement shall be rejected by the
Owner/Consultant and the decision of the Owner/Engineer will be final and
binding to the Contractor. The rejected cement shall be removed from the
site forthwith. Cement shall be stored carefully on raised platform and will be
protected against rains. The stacks shall not be more than 12 bags, to
prevent lumping of cement under pressure as also chances of injury to any
workmen.
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The Contractor shall if required arrange testing of cement, and shall satisfy
themselves about the quality of cement. Subsequently, in cube tests of
concrete if the strength of concrete is found lower than specified by IS:456,
then no complaints regarding the quality of cement will be accepted by the
Owner/Engineer.
17.3.2 Coarse Aggregate
All aggregates in general shall conform to IS:383 and IS:515. They shall be
crushed from blue basalt / fresh hard durable broken basalt / hard granite
and shall be hard, clean and free from weathering, lamination , pores, dust,
loose shales, clay and organic impurities . The material shall be graded to
achieve homogeneous mix.They shall be size between 40mm to 75mm. The
requirements of soundness for the aggregate will be same as that for
concrete aggregates subjected to approved relaxation for alkaline impurities
and coatings. Hand broken aggregates shall be permitted.
17.3.3 Fine Aggregates (Sand)
This shall be free from dust , clay, silt and from organic impurities. Sand shall
be washed by the Contractor at no extra cost, if it contains silt more than 4%.
Sand will also have to be washed off if it contains salts more than allowable
limits. River or creek sand approved by the Owner/Consultant must be used
for the work. The grading of fine aggregates shall be determined as per
IS:2386(part 1) and shall be within the limits given in Table 4 of IS:383. The
sand shall not have particles coarser than 3mm in diameter. The percentage
passing through IS sieve (80 micron) shall not be more than 5% of the total
weight.
17.3.4 Water
Water used shall be free form injurious and deleterious materials. Water
safe for drinking shall be used. The water/cement ration for concrete shall
not be more than 0.5 depending upon the moisture content in the aggregate.
17.3.5 Drilling Mud (Bentonite)
Bentonite shall conform to IS:2911 shall be used to stabilize sides of bore for
stone column work, if specified.
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17.4 Stone Column Specifications
Stone column foundation technique is used for improving soil bearing

capacity and to minimise post construction settlement.
17.4.1 Stone columns shall not be less than 600 mm nominal dia. depth not less
than 10 M and spacing shall not be more than 3.00 m in triangular
grid/square grid pattern, (if design is by contractor).
Construction technique can be as per using good engineering practice but

generally shall be with vibro floatation technique.
Contractor shall submit at the time of quoting his tender his method of
adopting a technique of construction for stone columns.
Granular filling material consisting of crushed stones and sand, (Grading for
stones shall be 100 mm to 2 mm and for sand 3mm to 75 micron) shall be
thoroughly compacted to attain required compaction. It should not contain silt
or clay particles, organic impurities, dust etc.
Sand shall be used as filling material only when permitted by

Engineer/Owner, but shall not exceed by 50% of crushed stone.
17.4.2 Compaction shall be exercised based on the pressure developed by

hydraulic drive of vibrators in case of vibro flotation technique or based on
settlement per number of blows in case of compaction of cased columns.
17.4.3 Sand Draining Layer
Top of all stone column shall be one level. Area near stone column and shall
be cleaned such that no lumps of original soil, gravels or crushed stone,
organic impurities, clay etc. is left over. Area shall be watered before laying
sand layer. Sand Draining Layer shall be provided at the top of all stone
columns of thickness specified as per Bill of material/Design by contractor, in
the entire area where stone column foundation is provided. Sand shall be
river sand and shall be of gradation as per IS:383. (3mm to 75 micron) free
from all boulders, dust, brickbats, organic impurities, clay etc. If required
shall be washed before laying. Laying shall not be more than 150 mm
thickness, each layer well watered, rammed and consolidated before putting
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next layer to attain finish level. Each layer shall be sufficiently watered,
rammed and consolidated before putting the next layer. Top finished surface
shall be per levels shown in the drawings. All compaction shall be done by a
smooth wheeled roller or by mechanical vibrators in such a manner that
every layer shall be compacted to a density of 90% of max. dry density. As
and when required by the Owner/Engineer, the contractor shall determine the
actual dry densities attained by performing field density tests at his cost.
Measurements shall be based on compacted volume of sand layer.
Sand draining layer shall not be less than 1.00M thickness above stone
columns and shall extend upto 1.5M from centreline of last peripheral stone
column (applicable if design by Contractor).
17.5 Construction
17.5.1 Stone columns shall be constructed with any technique as per good
engineering practice, but shall generally be as per:
a) Vibroflotation technique
b) Compaction/rammed stone columns in cased bores
Contractor shall submit at the time of quoting his method of adopting a

technique of construction. If it is different from (a) or (b) he shall submit all
technical details and stages of construction along with his offer.
17.5.2 Stone Column by Vibrofloatation technique
Vibrofloat of adequate size capable of making diameter of stone column

specified shall be used.
Vibrofloat suitable with other accessories, dimension, weights, flow of water,

pressure, frequency of vibrations etc. shall be used for specified diameter
and depth of stone column. Vibrofloat shall be suspended from crane and
positioned on a location marked on ground previously.
While making the bore, a sufficiently large flow of water shall be maintained
through jetting tubes in order to wash away all fine material which may
contaminate the granular filling material of stone columns.
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During withdrawal of the vibrofloat, vibration, lifting, jetting of water shall be

done in such a manner that necessary and uniform compaction of granular fill
is achieved for the entire depth of stone column.
17.5.3 Specification for the rammed stone columns

The rammed stone columns are to be installed using conventional bailor boring
equipments used for bored piles. The rammers should have hole in the
bottom plate and adequate clearances so that piston action does not develop
during operation of the rammer through the hole filled with water. All
modifications and improvements in the equipment required to suit the site
conditions and to achieve the desired performance regarding ‘set’ stipulated
minimum consumption and satisfaction of the settlement criteria in the load
test as well as realisation of the stipulated capacity and safety margins with
regard to the safe load is contractor’s responsibility. In the work schedule
allowance should be made for conducting the initial test and making the
necessary modifications in the equipment and procedure to achieve the
desired performance. No extra payment or time extension will be allowed on
this account.
17.5.3.1 Definitions
a) Loose Overlap: is the height of loose fill measured from lower

edge of casting to the surface of filled material inside the casting
before ramming. This is measured always after extraction of casting
and before commencing ramming operation.
b) Compaction Overlap: Compacted overlap is the height of the

compacted fill material measured from lower edge of the casting to
surface of fill material after driving. This is measured always after
conducting ramming operations and before filling the casing with
loose aggregates for subsequent stages of filling.
c) Negative/Positive Overlap: These are the heights of the fill material

with respect to lower edge of casing. If the level of fill material in the
hole is below lower edge of casing, the overlap is said to be
'negative'. If the level of fill material is above the lower edge of the
casing, the overlap is said to be 'positive'.
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d) 'Plug' of compact Overlap: is the blockage created by the compacted

fill material in casing which prevents the material within the casing
from slipping downwards when the casing is lifted during construction
of stone column.
e) "Set": It is the operation of conducting a check for verifying the

intensity of driving carried out on the loose material by means of drop
hammer. The drop hammer shall have a flat bottom and the
diameter of the hammer shall not be less than 10 centimeters than
the inside diameter of the casing. The driving is carried out in air dry
condition by dropping 1.5T hammer through 1.5M height.
However, it should be ensured that loose fill of material is never

rammed dry. It must be always surface wet and saturated. But the
water above the surface should never exceed 5 to 10 cms.
The set criteria recommended for various levels are detailed as

under:
The first set shall be taken at about 2 to 3 M height from bottom of

hole. The last set shall be taken at about 1.0 to 1.5M below ground
level (operating level). Knowing the depth of bore hole set level
interval shall be selected such that at least two sets are taken in
each stone column
The set at each level shall be maximum of 2 centimeters for 25

blows of 1.6 ton rammer with a free fall of 1.5M height. The set shall
be measured by attaching a flexible wire rope (3mm) to the swivel
hook of the hammer or any such method as may be directed by the
Engineer. While measuring the set, the rammer shall rest on top of
the compacted fill and the flexible wire shall be drawn out over the
tripped leg on winch side. Initial reference mark shall be made on
the tripod as well as on flexible wire rope. The penetration shall be
measured with respect to original mark on tripped leg or top of
casing which is at fix level. the set shall be confirmed three times
consecutively at each set level.
f) Consumption of fill material: For quality control it is necessary to

exercise a check through consumption of fill material. The
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consumption factor should be determined in initial installation of a

few numbers of stone columns.
Consumption should be worked out for different levels where sets are
observed. On the basis of the observation, control criteria would be
developed for different zones and level depending on soil conditions
as indicated by boring / dynamic probing or SCPT determinations.
This would enable rapid field control and optimise the number of
conducting single stone column and multiple stone column load test
during regular course of operation. Based on past experience, it is
expected that the actual compacted volume for a satisfactory stone
column would be about 140% of the nominal volume of the column at
each respective level of set.
g) Length of stone columns: The length and depth of stone column

shall be measured from lower edge of the top of finished stone
column or ground level whichever is lower.
h) Nominal Volume of stone column: This shall be the product of the

cross sectional area of the casing considering outer diameter and
measured length as defined above.
i) Net Consumption of stone column: The net consumption shall be

calculated as 80 % of the aggregate volume of stone (metal) and
sand poured in stone column measured with the help of boxes of
standard size.
j) Stipulated minimum net consumption: It is defined as a volume

equal to 140% (one hundred and foutry percent) of the nominal
volume. This factor of 140% shall be confirming by the Engineer on
the basis of load tests conducted during the course of trial and
regular work. However any increase will not be paid extra.
k) All aggregates shall conform to IS:383.
17.5.3.2 Technique of Installation for Rammed Stone Column:
a) A heavy casing tube of 750mm outside diameter is driven into the

ground either by using conventional bored piling equipment or
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employing bailer boring method. The casing is driven to the requisite

depth. The joints of the casing should be preferably threaded so that
the mud does not follow into the casing during driving. The casing
shall be driven to the depth as shown in the drawings or as directed
by the Engineer during execution.
Care should be taken to see that water is supplied so that hydrostatic
pressure is always maintained in the casing to compensate the
external ground water pressure. This is irrespective of the method of
advancing the casing.
b) After driving the casing to final depth, 0.05 Cu.m. of well-graded

sand shall poured in the casing. Then a mixture of stone and sand in
the proportion of (2:5) by volume shall be poured in the casing upto
1M above first set level.
c) Casing shall be then withdrawn to 1st level. This will render a

maximum positive loose over lop of about 1M within the casing.
d) Compact the material by ramming with free fall of hammer. Check

the set at 1st set level.
e) If the set criteria is not achieved continue the ramming till the criteria
is satisfied.
f) If the positive overlap between the lower edge of casing and top of
material become less than 300 mm during ramming, add the stone
sand mixture to make up the positive overlap of 1M. Compact the
mixture should be noted that in no case negative overlap shall be
allowed.
Minimum 300 mm positive common overlap should be observed,

while satisfying the set criteria. The contractor shall properly
maintain and submit the record in triplicate on the prescribed format
to enable computation of excess consumption for each level of "set"
observation. Such a record is required to be maintained for each
and every stone column. The contractor shall make suitable
arrangement for easy pouring of material when tube remains
projected above ground level during building up of stone column.
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Uhde India Limited STONE COLUMNS Page : 10
g) At the end of the set observation at each level extract the casing by
10 to 15 cms and ensure that the plug of compact overlap is not
formed at the lower edge of casing. Check this before and after
extraction is formed, break it by giving the jerks to the plug
simultaneously.
h) Fill the casing with stones mixture in proportion 2:5 so as to keep

nd
loose overlap of 1M above and 2 set level. Extract the casing to
nd
the 2 set level. Ensure the loose positive overlap of about 1M.
Compact the mixture by free falling hammer, check the set.
i) Repeat the same procedure as explained in (a to h above ) till the

last set. The last set level should be maintained at about 1.0M below
operating level. This can be achieved after knowing the bored depth
and adjusting the set levels.
After the last set is taken at stipulated level material (stone & sand)
shall be filled upto the stipulated finished level and 10 blows of 1.5T
rammer shall be applied with a fall of 3m. Adequate material shall be
placed to ensure that the compacted stone / sand after the final 10
blows shall remain at or above the finished level or as specified by
the Engineer.
j) Those stone columns shall be accepted for payment which satisfy

the set criteria at different set level as will as which satisfy the
"Minimum Net Consumption". These stone columns should also
satisfy the stipulated settlement criteria as per the single column load
test. The stone columns which do not satisfy the tolerance limits of
eccentricity (150 mm at top) shall not be accepted for payment. If
the consumption of any stone column is less than the stipulated
'Minimum set Consumption' the stone column shall be rejected.
The contractor shall have to install stone column at his cost for each
of the stone columns which do not satisfy the above criteria with
reference to set, consumption, settlement in the load test and
eccentricity as stipulated. The decision of the Engineer on the
number and location of such additional stone columns shall be final
and binding on the contractor.
17.5.3.3 Load Tests
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Any number of stone columns at the discretion of the Engineer be subjected

to load tests for which purpose the contractor shall provide all necessary
material and equipment as detailed below:
17.5.3.4 Single column load test details
i) The test equipment shall be as per the procedure for pile load test
vide IS:2911 (part I) Appendix D and USBR Earth Manual
Designation E-26.
ii) The load shall be applied in two cycles. The column shall be subjected
to a test load of 30 (thirty) tones in first cycle. This test load shall be
maintained for 24 hours and released to zero, and the settlement
shall be measured. In second cycle the load shall be maintained
for 7 days. Settlement shall be noted from the initial condition and for
each cycle at the start and the end of cycle.
iii) The contractor shall provide and install at his cost settlement markers,
heave markers and reference pillars for measurement of settlement
and heave. He shall also provide and install necessary equipment,
platforms, jacks, structural frame work, mobile kentledge instruments
etc. He shall include in his price for load tests any incidental
excavation, removal of debris, filling, site clearance etc. Markers
and reference pillars shall be installed as directed by the engineer. All
labour (skilled and unskilled) as well as technicians required for load
tests shall also be provided by the contractor at his cost.
iv) The rate shall include all items of work connected with the load
test and clearing the load etc.. after completion of test(The rate
shall also include any incidental excavation, removal of debris,
backfilling, site clearance etc. as stated above).
17.5.3.5 Acceptance Criteria for Load Test:
The stone column shall be deemed to be satisfactory when:
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i) There is no heave to the adjoining areas.

ii) There is subsidence or tilt of the loaded area after application of
the final test load.
iii) The net maximum total settlement of the 750 and 600 mm diameter
single column shall be as follows:
24 hours load : 750 mm dia. 40 T maximum - 10 mm settlement.

600 mm dia. 30 T maximum - 10 mm settlement.
7 days load - 750 mm dia. 30 T maximum - 20 mm settlement.

600 mm dia. 20 T maximum - 20 mm settlement.
.
Maximum set consumption and set criteria stipulated for 750 and 600 mm
dia. rammed stone columns would satisfy above load test criteria based on
past experience. Engineer shall review the load test results to decide the
"Minimum Net Consumption" and load capacity for stipulated settlement
criteria. The number of stone columns and spacing may vary accordingly to
these load test results. During execution, load test shall be carried out for
routine cross check.
The number of locations of load test shall be decided according to the

discretion of the Engineer. The Contractor shall have no claim due to
variation in number of load tests.
Separate water tube level system shall be installed at no extra cost with fixed
referencing system for each load test. The system should be capable of
measuring one mm settlement. The cost is deemed to be included in the
item of the load test.
iv) Net maximum total settlement for an internal stone column is 10

MM.
17.6 Instructions for single column test (General)
1. Load test should be conducted at the set level.
2. Minimum 4 dial gauges of least count 0.01mm should be used.
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3. Apart from dial gauges 4 water tube settlement markers should be

installed and connected to a bench a mark of permanent mark.
4. The overlap should be removed upto the casing tip (set level).
5. Shallow settlement marker should be ready.
6. The hydraulic jack should be calibrated and calibration curve should

be suppled to the Engineer.
7. The load test data should be furnished in the prescribed form.
8. The reference beam should be fixed by concreting.
9. Before fixing the kentledge all other set up should be examined by

the Engineer.
10. The load test shall be conducted as per IS code for load test on piles
(IS:2911 part I) with modifications given by the Engineer.
11. Testing will be conducted in the presence of Engineer.
17.7 The preparatory work for single stone column test will be as follows.
1 Initial readings of four dial gauges and four water tubes are to be
taken.
2. Load of 6T (1/5 of the maximum test load is 6T).
3. Take dial gauge and after tube readings immediately and at an

interval of 15 minutes.
4 Continue till the settlement rate stabilizes to 1mm hour. This rate to
be checked over at an interval of half an hour.
5. After stabilization release the load to zero.
6. Take dial gauge and water tube reading immediately and at an

interval of 15 minutes.
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7. Continue till the settlement rate stabilizes to 1mm/hour. This rate to

be checked over an interval of ½ hour.
8. After stabilization increase the load to 12T.
9. Repeat (3) to (7).
10. Next increment load will be 6T i.e total load of 18T.
11. Continue till maximum jack capacity/max. kentledge capacity/yield is

attached.
12. after maximum load is attached. Release the load to zero and let it
stabilise.
13. Load to maximum that was attained in step 11 and keep it for 7 days
taking readings at one hour interval.
14. After 7 days release the load to zero and continue reading till
stabilization.
17.8 Mode of Measurement and basis of Payment
a) Only those columns shall be measured and paid for which have
satisfied the acceptability limits as specified above
b) The contractor shall quote unit rates of Bill of Quantities by assuming
stipulated minimum net consumption as 140% (one hundred & forty)
of nominal volume as described earlier.
c) Notwithstanding the requirement of set criteria as stated before, an
acceptable stone column shall have consumption equal to or greater
than stipulated “Minimum Net Consumption”.
b) The consumption at intermediate level shall be determined on a
similar basis after deduction for the material remaining within the
casing at the time of measurement.
c) In case the fall of hammer or driving set finally adopted is different

from those mentioned in the tender, the contractor shall not claim
any extra on that account. The contractor shall make it sure that
he strictly adheres to the procedure laid down by the Engineer. The
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contractor shall install additional stone columns free of costs if he

deviates from the procedures and the decision of the Engineer shall
be final and binding on the contractor. The contractor shall not have
any claim due to above reasons.
d) The contractor shall include in his unit rates the cost of setting and
shifting of rigs, personal, auxiliary equipment at different locations as
required. The rate shall be complete in all respects.
END
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Uhde India Limited FRP INSULATORS & GRATINGS Page :1
Contents Page
SCOPE 2
FRP GRATING 2
FRP INSULATORS 3
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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18.01 Scope
This specification covers the material, workmanship, tolerances and

installation of FRP Gratings manufactured by reputed manufacturers like M/s.
Coromandel Prodorite, Indiana Engineering Works, Yamuna Gases &
Chemicals or equivalent approved manufacturers.
FRP GRATINGS
18.02 Duty Conditions
The exposure to various chemicals, thermal and other allied conditions shall
be as shown in respective drawings.
18.03 Load Carrying Capacity
500 Kg/M¨ distributed load (minimum).
18.04 Span : The span of gratings shall be as shown in respective drawings.
18.05 Arrangement of Mesh
18.05.01 The gratings shall be generally of rectangular mesh construction with main
bearing bars 40 mm x 8 mm spaced at 40 mm c/c/ parallel to span and
distribution bars 40 mm x 8 mm spaced at 40 mm c/c/ across the span.
OR
18.05.02 Rectangular mesh construction with main bearing members 25 mm deep

spaced at 30 mm c/c and Transverse holding members of 10 mm dia. rods
spaced at 150 mm c/c.
18.05.03 Alternative mesh arrangement adopted by reputed manufacturers for

specified load carrying capacity shall also be acceptable. However, the same
shall be approved by the engineer.
18.06 The resin material for manufacture of gratings shall be either Isophtalic
polyester resin or liquid polyester resin or vinyl ester resin as indicated in the
drawings depending upon the duty conditions.
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18.07 Resin Properties
18.07.01 Physical Resistance
Water absorption = 25%
Linear expansion = 16.10 E-6 mm/mm
Temperature = 80 to 120 Deg.C min.

(continuously)
18.07.02 Electrical Resistance
Breakdown voltage = 7 to 10 KV/mm

Surface resistance = 10 E13 Ohms
Dielectric Constant = 5 at 50 Hz
18.07.03 Method of Measurement
The measurement shall be based on square metre basis. Openings or

cutouts upto 300 mm size shall not be deducted. Any opening beyond 300
mm size shall be deducted for area calculations.
FRP INSULATORS
18.07.04 The FRP insulators shall be circular in shape with single or double threading
as per drawing. The material shall be cast resin and the screwed material
shall be brass. The load carrying capacities shall be as follows:
Safe working vertical load = 100 KN

Safe working horizontal load = 4 KN
Rated voltage = 6 KV
The insulators shall be from Baroda Bushings or equivalent approved

supplier.
18.07.05 Method of measurement
The measurement shall be on number basis

END
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Uhde India Limited CAVITY FLOORING & FALSE CEILING Page :1
Contents Page
SCOPE 2
CODES 2
MATERIAL 2
FABRICATION DRAWINGS 3
GALVANISING 5
ERECTION 5
SPECIFICATIONS FOR CAVITY FLOORING 6
SPECIFICATIONS FOR FALSE CEILING 8
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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SCOPE
19.1 Providing, fabricating and erecting etc. of Cavity floor and false ceiling of all
jobs herein enumerated including providing all labour, tools and plant, all
materials, consumables, galvanising, all of approved quality. The work shall
be executed according to the drawings, specifications, in an expeditious and
workmanlike manner as detailed in the specifications and the relevant Indian
Standard Codes and standard practices and to the complete satisfaction of
the Engineer.
NOTE
The Contractor has to co-ordinate with the work of the Civil, Electrical,
Instrumentation and other connected Agencies or any other agency working
concurrently, without causing damage to the installation done by others. Any
such damage shall be recoverable from Contractor's bill.
19.2 CODES
specification. All specifications, standards, codes of practices referred to
herein shall be the latest edition including all applicable official amendments
and revisions. In case of discrepancy between this specification and those
referred to herein, this specification shall govern:
IS:2062 - Standard Quality Structural Steel

IS:814 - Welding Electrodes
IS:1367 - Bolts & Nuts for structural use
19.3 General Specifications

Materials
19.3.1 Structural Steel
The following grades of steel shall be used for steel structures.
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Structural Steel shall generally be of standard quality conforming to IS:2062

Grade A. Whenever welded construction is specified, plates of more than 20
mm thk. shall conform to IS:2062 Grade B.
19.3.2 Welding Materials
Welding electrodes shall conform to IS:814.

Approval of welding procedures shall be as per IS:9595/823.
19.3.3 Bolts, Nuts and Washers
Bolts and nuts shall be as per IS:1367 Class 4.6 (UNO) and tested as per
IS:1608. It shall have a minimum tensile strength of 44 kg/mm¨ and minimum
elongation of 23% on a gauge length of 5.65 x A (A = original cross sectional
area). Washers shall be as per IS:2016.
All materials shall conform to their respective specifications. The use of

equivalent or higher grade or alternate materials will be considered only in
very special cases subject to the approval of the Engineer in writing.
Aluminium section shall conform to IS:733, IS:1948, IS:1949 as applicable.

Contractor shall produce necessary quality assurance certificates for the
material to be used for Engineers approval.
19.3.4 Fabrication Drawings
The Contractor shall prepare all fabrication and erection drawings on the
basis of general layout drawings, drawings supplied to him and submit the
same in triplicate to the Engineer for review. The Engineer shall review and
comment, if any, on the same. Such review, if any, by the Engineer does not
relieve the Contractor of any of his required guarantee/responsibilities.
CONTRACTOR SHALL TAKE ACTUAL MEASUREMENTS AT SITE
BEFORE THE PREPARATION OF FABRICATION DRAWINGS.
Fabrication drawings shall include the following but not limited to:
- Member sizes and details.

- Types and dimensions of welds and bolts.
- Shapes and sizes of edge preparation for welding.
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- Details of shop and field joints included in assemblies.

- Bill of Materials.
- Quality of structural steels, welding electrodes, bolts, nuts and
washers, any other material used.
- Erection assemblies, identifying all transportable parts and sub-
assemblies associated with special erection instrumentation if
required.
- Calculations where asked for, for approval.
- Connections, splices and other details not specifically detailed in
design drawings shall be suitably given on fabrication drawings
considering normal detailing practices and developing full member
strengths, where asked for and calculations for the same shall also
be submitted for approval.
ANY ALTERNATE DESIGN OR CHANGE IN SECTION IS ALLOWED ONLY

WHEN APPROVED IN WRITING BY THE ENGINEER.
However, if any variation in the scheme is found necessary later, the

Contractor will be supplied with revised drawings. The Contractor shall
incorporate these changes in his shop drawings at no extra cost and
resubmit for review.
The Engineer's review shall not absolve the Contractor of his responsibility
for the correctness, adequacy of details and connections.
The Contractor shall supply five/more prints each of the final reviewed
drawings to the Engineer and one copy to the OWNER within a week of final
review at no extra cost for reference and records.
If any modification is made in the design drawing during the course of

execution of the job, revised design drawings will be issued to the Contractor.
Further changes arising out of these shall be incorporated by the Contractor
in the fabrication drawings already prepared at no extra cost and the revised
fabrication drawings shall be duly got revised as per the above clauses.
19.3.5 Fabrication
Fabrication of structural steel shall be in accordance with IS:800 in addition to

the following:
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Fabrication shall be done as per approved fabrication drawings adhering

strictly to work points and work lines on the same. The connections shall be
welded as per design drawings.
Any faulty fabrication pointed out at any stage of work shall be made good by
the Contractor at his cost.
Any other material used which is not covered above shall conform to relevant
IS Codes.
19.3.6 Galvanising
Galvanising of material shall be carried out as per IS:2629 - Recommended

Practices for Hot Dip Galvanising of Iron & Steel, which guarantees a
minimum coating of zinc of 85 microns.
19.3.7 Erection
The erection work shall be permitted only after the structures over which the
work is to be erected, is accepted and is ready for erection.
Any faulty erection done by the Contractor shall be made good at his cost.
Approval of the Engineer at any stage of work does not relieve the Contractor
of any of his required guarantees of the Contract.
Erection in general shall be carried out as required and approved by the

Engineer.
The following checks and inspection shall be carried out before, during and
after erection:
- damages during transportation

- accuracy of alignment of structures
- erection according to drawings and specifications
- progress and workmanship
The various parts of the said structure shall be so erected as to ensure

stability against inherent weight, wind and erection stresses.
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19.3.8 Final Acceptance and Handing Over of Structure
At the time of acceptance of the work, the Contractor shall submit the
following documents:
- Fabrication drawings - either in tracings or reproducibles.

- Quality certificates for the materials used.
Approval by the Engineer at any stage of work does not relieve the
Contractor of any of his required guarantee of the Contract.
19.4 SPECIFICATIONS FOR CAVITY FLOORING
Providing, erecting and installing cavity floor of module 610 mm x 610 mm

including ramps and steps as required in Control Room as specified below as
per drawings.
a. Support system consisting of suitable structural steel with adjustable

vertical supports on base plates and grid beams of Tee section or any
other suitable section resting over the vertical supports, including
necessary welding, bolting, providing screw jacks, with or anti-
corrosive base coat and finished with paint after surface preparation
by mechanical brushing. The support system shall be secured to the
concrete base floor to be provided by others with adhesive agent like
Araldite.
b. The false floor system shall consist of 35 mm thick Novateak super

particle board or equivalent in panels of 600 mm x 600 mm fire,
termite and moisture resistant quality. The edges and bottom of the
panels shall be covered with suitable anti-corrosive, anti-termite
sealant and the top shall be finished with PVC laminate of approved
make and colour. The panels shall be set in the saddles provided in
support system (a) above in perfect level free from any undulations.
c. The entire floor system shall be designed to carry a uniformly

distributed load of 500 kg at the centre of the panel, the permissible
deflection being 2 mm (i.e. SPAN/300).
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d. Blockouts should be left in the support system and the flooring for
Control panels and other installations resting on the floor as per
drawing.
e. The floor panel should be easily removable by a vacuum pick up

made of rubber bell mouth and handle.
f. The entire flooring should be designed to give noiseless system under

movement of personnel and equipment by providing suitable rubber
packings on all sides and in bearings of the panels, and should be fire
proof.
g. Contractor may offer his standard flooring system with all details,
dimensions and material specifications, principally conforming to the
above incidental expenses.
h. Contractor shall furnish guarantee for the performance of the floor

system for the minimum operative of one year after date of completion
certificate. Any damages, failures or unsatisfactory performance of the
floor shall be rectified by the supplier at his own cost.
I. Payment shall be made on M¨ of finished area basis allowing

deduction for cutouts.
19.5 SPECIFICATIONS FOR FALSE CEILING (ALT.1)
Providing and installing Jolly Insulex (compressed particle board) or

equivalent approved False Ceiling System for horizontal, inclined or vertical
surfaces comprising of Jolly Insulex or equivalent fire, termite, moisture
resistant quality boards/tiles supported on 600 mm grid aluminium framing
with 40 x 25 mm aluminium tees with all necessary G.I. suspenders of 3 mm
dia. including all other accessories such as clips, hooks etc. Cutouts,
supports for air diffusers, light fittings etc. wherever required shall be
provided with appropriate additional framing. The rate shall be inclusive of
material, labour, fixing and all works complete in all respect including
preparation and detailed drawings.
Concealed side of ceiling boards to be painted with one coat of approved fire
retardant paint.
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Measurement of completed work shall be made on sq.m. of finished area

basis, allowing deductions for cutouts / openings.
19.6 SPECIFICATIONS FOR ALUMINIUM FALSE CEILING (ALT.II)
19.6.1 Providing and installing false ceiling system for horizontal, inclined or vertical
surfaces comprising of square edged plain panels, 84 mm wide x 15 mm
deep with 25 mm recessed flanges, formed out of 0.5 mm thk. aluminium
alloy electrically powder coated in standard colour shades as per drawings as
19.6.2 The panels shall be fixed on formed carriers 15 mm wide at top x 43 mm

deep made out of 0.91 mm thk. aluminium alloy electrically powder coated in
stain black with protruding ears to hold panels in a module of 100 mm (16
mm gap between the panels) at a maximum spacing of 1.3 Mtrs. c/c carriers
suspended from the slab/roof by 4mm dia. galvanised steel wire/rod hangers
with height adjustment suspension springs made out of galvanised spring
steel hangers shall be fixed to roof/slab by J-hooks and nylon inserts. Edges
of the ceiling shall be neatly trimmed with suitable matching edges profiles to
cover the gap between the false ceiling and the walls.
19.6.3 Insulation
The acoustical and thermal insulation blanket, 25 mm thk. of resin bonded

mineral wool covered in a polythene bag shall be laid over the aluminium
panel ceiling.
19.6.4 However, the bidder may offer his own standard system of aluminium false
ceiling, keeping in mind the basic requirement as above. The details of such
system shall be submitted with the offer.
19.7 MODE OF MEASUREMENT & RATES
The mode of measurement shall be on Sq.m. basis less the area for cutouts.
The rate shall include materials, labour, wastage, supervision, taxes and
duties, transport and all other incidental charges, preparation of detailed
drawings and by works, taxes, duties etc. to complete the work in all
respects. No additional payment shall be made to complete the work.
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Rates to be all inclusive of above and also shall include all necessary taxes,
duties and any other incidental expenses required to complete the entire
work in scope.
END
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SECTION-21
Uhde India Limited DISMANTLING & MISC. WORK Page :1
Contents Page
SCOPE 2
DISMANTLING 2
GENERAL 2
TOOLS AND TACKLES 3
RECONSTRUCTION 4
MEASUREMENT AND RATES 4
INSTALLATION OF ANCHOR FASTENERS 6
PAYMENT 6
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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21.1 SCOPE
This specification defines the dismantling of reinforced concrete, plain

concrete, brick work and structural steel work or any such other work. Any
special requirement as shown or noted on the drawing shall govern the
provision of this specification.
21.2 DISMANTLING
The term dismantling implies carefully removing without damage below or

above ground. This shall consist of dismantling one or more parts of the
building / structure as specified or shown on the drawings.
21.3 GENERAL
21.3.1 Precautions
All materials obtained from dismantling shall be property of the "Owner"

unless otherwise specified and shall be kept in safe custody until handed
over to the Engineer or reused as directed by the Engineer.
21.3.2 The dismantling shall always be planned before hand and shall be done in
reverse order of the one in which the structure was constructed. The scheme
shall be got approved from the Engineer before starting the work.
21.3.3 Necessary propping and/or under-pinning shall be provided for the safety of
the adjoining work or property before dismantling work is taken up and the
work shall be carried out in such a way that no damage is caused to the
adjoining structure or property. Temporary enclosures or partition shall also
be provided as deemed necessary.
21.3.4 Necessary precautions shall be taken to keep down the dust nuisance.
21.3.5 Dismantling shall be done in a systematic manner. All materials which are
likely to be damaged by dropping from a height or demolishing roofs,
masonry etc. shall be carefully removed first. The dismantled articles shall be
passed by hand, where necessary, lowered to the ground (and not thrown)
and then properly stacked as directed by the Engineer.
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21.3.6 Where fixing is done by nails, screws, bolts etc. dismantling shall be done by
taking out the fixing with proper tools and not by tearing or ripping off.
21.3.7 Any serviceable material, obtained during dismantling shall be separated out
and stacked properly as directed by the Engineer. All unserviceable
materials, rubbish etc. shall be disposed of as directed by the Engineer.
21.3.8 The Contractor shall divert and maintain disconnected services whether
temporary or permanent, if required as directed by the Owner/Engineer.
21.4 TOOLS & TACKLES TO BE USED FOR DISMANTLING
21.4.1 As the dismantling activity shall be undertaken within the existing

buildings/structures, utmost care shall be taken to prevent transmission of
vibrations during dismantling and damage to adjoining members or
structures.
21.4.2 Pneumatically operated dismantling equipments like power chisel or

pavement breakers may be used for dismantling concrete only after prior
inspection and permission of the Engineer. However, the Contractor to note
that while using such pneumatically operated tools, necessary precautionary
measures to be taken so that adjacent members are not damaged / cracked.
21.4.3 Dismantling shall be done manually using hand operated chisel with flat face
hammers. The weight of hammer shall be generally limited to 15 lbs, where
pneumatic / electric driven tools are not permissible.
21.4.4 Concrete sawing or cutting using standard concrete cutters / or any other
method shall also be permitted depending upon the type of structure and with
the approval of the Owner / Engineer.
21.4.5 Wherever shown in the drawing or directed by the Engineer, the

reinforcement shall be left untouched for further lapping and shall NOT be
cut.
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21.5 RECONSTRUCTION
21.5.1 The dismantled surface shall be thoroughly cleaned by wire brush and then
with compressed air jet to remove all loose particles, lattence etc. before
recasting.
All reinforcement bars / inserts etc. shall be cleaned properly with brush /
compressed air and place in position beffore concreting. Concreting can be
carried out ONLY after the inspection and clearance of the Engineer.
Wherever required (as shown in the drawing or as directed by the Engineer,
welding to the existing reinforcement / inserts shall be carried out. In such
cases, welding work shall be carried out as per relevant I.S. Code.
If, as per drawing or directed by the Engineer, bonding point to be applied to

the old concrete faces as per the manufacturer's instructions before placing
new concrete.
21.6 MEASUREMENTS & RATES
a) Brickwork
Dismantling of brickwork (reinforced or otherwise) shall also include

plastering. The measurement for payment shall be on the basis of
brickwork only (excluding plastering) in cubic metre (M^3) after
deducting for all cutouts, openings etc. The rates shall conclude
supplying of all dismantling equipment, scaffolding and protecting,
stacking and disposal cleaning as directed, labour and taxes,
insurance etc. all complete in all respects including all safety
measures and at all heights.
b) Plain Cement Concrete
Dismantling of PCC at all levels shall be measured in cubic metre

excluding all openings and cutouts of plaster (if any). The rate shall
include supplying of dismantling equipment, scaffolding and
protecting stacking of serviceable material and disposal of
unserviceable materials as directed, labour, all taxes and levies,
insurance and safety measures complete in all respects at all
heights.
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c) Reinforced Concrete
Same as item no.(a)
Additionally, the rates shall also include exposing and cleaning of

existing reinforcement, straightening of the same and / or bending
the same as per drawing / direction of the Engineer, welding with
new reinforcement if required as per drawing, all complete in all
respects.
21.6.1 Dismantling of floors and roofs of concrete or brick shall be measured in

cubic metres (cu.m.), beams, cantilevers or other subsidiary supports of
similar materials, shall be included in the item. In measuring thickness of
roofs provided with water proofing treatments with bitumen felts, the
thickness of water proofing treatment shall be ignored.
21.6.2 Reinforced Concrete and Brick Work
Reinforced concrete structures and reinforced brick roofs and walls shall be
measured in cubic metres and square metres as specified in schedule of
rates and reinforcement if required to be salvaged, shall be so stated.
21.6.3 Steel and Iron Work
21.6.3.1 All steel and iron work shall be measured in metric tonnes (MT). The weight
shall be computed from standard tables unless the actual weight can readily
be determined.
21.6.3.2 Rivetted work, where rivets are required to be cut, shall be measured
separately as specified in schedule of item.
21.6.3.3 Marking of structural steel required to be re-erected shall be properly done

and measured separately.
21.6.3.4 In frames steel items, the weight of any covering material or filling such as
iron sheets and expanded metal shall be included in the weight of the main
article unless such covering is not ordered to be taken out separately.
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21.7 INSTALLATION OF ANCHOR FASTENERS
The anchor fasteners shall be from reputed manufacturers and shall be

installed as per drawing and manufacturer's catalog. For proper installation
in concrete, drill bits as specified in manufacturer's literature shall be used.
21.8 PAYMENT
21.8.1 Measurements of all work except hidden work shall be taken and no
allowance for increase in bulk shall be allowed.
21.8.2 Specifications for deductions for voids, openings etc. shall be on the same
basis as that employed for construction of the work.
21.8.3 The rate shall include the cost of all labour involved and tools used in
demolishing and dismantling including scaffolding. The rate shall also include
the charges for separating out and stacking the serviceable material properly
within a distance of 50 metres and disposing of unserviceable materials as
directed by Engineer.
21.8.4 For installing anchor fasteners, the rate shall include all labour involved,
tools, concrete drill bits and staging / scaffolding.
END
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Uhde India Limited FIRE PROOFING OF STRUCTURES Page :1
Contents Page
INTRODUCTION 2
SCOPE 2
STRUCTURAL STEEL 2
EQUIPMENT SUPPORTS 3
SPECIFICATION 3
GUNITING 4
MEASUREMENT AND RATES 6
LIGHT WEIGHT CONCRETE 7
Date: Date: Date:

First Edition: R0
KARANDIKAR
SD/- SD/- SD/-
Date: 07.08.03 Date: 07.08.03 Date: 07.08.03
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SECTION-22
INTRODUCTION
As a safety precaution the structural steel supports of various equipments and structures are
required to be encased in concrete (including providing suitable nominal reinforcement steel
rods/wire mesh) for the purpose of fireproofing.
22.1 SCOPE OF WORK
Fire proofing of structural steel work by encasing in concrete or by Guniting

the surface.
A. STRUCTURAL STEEL
a. When supporting fire potential equipment within the battery

limits, columns and beams transmitting the equipment load
to the columns shall be fireproofed from their bases to a
minimum height of 10 meters above grade.
b. All bracing which contributes to the support of vertical loads

or stability of columns shall be fireproofed when part of a
fireproofed supporting system with the following additions or
exceptions:
I. On structures over 10 m in height, wind bracing shall

be fire proofed.
ii. On structures less than 10 m in height, bracing used

only for wind loading need not be fireproofed.
c. Platforms, runaways, stairways, and their supports need not

be fireproofed.
d. Top flange of structural steel that supports floor plate need

not be fireproofed.
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B. EQUIPMENT SUPPORT
1. All lugs, brackets, skirts and legs supporting fir potential equipment
located within fire potential area and below a height of 10m from
grade (min.) shall be fireproofed.
2. Equipment supporting saddles measuring more than 300 mtr in

height at their lowest points and located within fire potential area shall
be fire proofed.
3. Skirts :
a. Outside of all the skirts supporting process vessels shall be

fireproofed.
b. Insides of skirts over 1200mm in diameter and bottom heads

of uninsulated vessels supported on skirts over 1200 mm in
diameter shall be fireproofed.
c. Skirts requiring insulation shall be fireproofed on their

uninsulation portions only.
4. Supporting legs of air cooled exchangers shall be fireproofed.
C. HEATERS
Main supports and bracings (with exception of wind bracings) shall

be fireproofed upto the filling floor level of the heater.
22.2 SPECIFICATIONS
The specification of Cement, Coarse and fine aggregate, water and

reinforcement rods shall be as per Section 2 and Section 4 of the Technical
Specifications.
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22.3 CONCRETE STRENGTH
The specified characteristic Compressive cube strength of concrete at 28

days shall be 15 N/mm sqr. (min).
22.4 PROTECTION
All concrete shall be adequately protected from mechanical or other damage

for 7 days from pouring. The concrete shall also be wet cured for 7 days
from pouring starting from 24 hours of pouring by continual water spray or
wet cover.
22.5 GUNITING
1. Cleaning
Before applying guniting to steel surface to be fireproofed, they shall

be mechanically cleaned to remove all scale, rust, loose concrete
grease etc. or any other material which will impair the bond between
the surface of the member to be encased and the gunite.
2. Proportion
Gunite shall be mixed in the proportion of one part of cement to

approx. 3 parts of sand by loose volume. Actual proportion to be
adjusted based on quality of sand. The sand fine aggregates shall be
well graded having a maximum size of 6 mm. (Usually 4.75 mm)
downwards.
3. Reinforcement
The reinforcement shall consist of 2" x 2" galvanised fabric 12 gauge

bent to a template confirming to the outline of the member and
secured in place with minimum 18 gauge binding wire with the nuts
welded to structure.
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4. Pressure
The guniting gun shall be operated at a pressure of 30 lb/sq. inch

gauge on the gun tank having 50 ft. of hose. The pressure
shall be increased thereafter by 5 lb/sq. inch for every additional 50
ft. or part thereof of hose. A steady pressure shall be maintained all
the time. Water used for hydratop shall be fit for drinking and shall
be maintained a uniform pressure of atleast 15 lbs above pressure
used for air but not more than 60 lbs.
5. Application of Gunite
The water use for mixing shall be free from oil, salt, acid, alkali,
vegetable matter etc. The consistency of the mix shall be controlled
by the nozzle operator. Too much water washers away material and
too little water results in unsound gunite. It is therefore essential to
use highly experienced operator.
The nozzle shall always be held at right angles to the surface to be

gunited and at a distance of approx. 75 to 90 cms.
On vertical surfaces the limit of the thickness that can be built is

reached when material starts to sag or separate.
On Horizontal surfaces the depth is a factor of the plasticity and the

limit is reached when material starts to spatter or show other
evidence of moisture.
The thickness of guniting shall be minimum 50 mm. The thickness

may be built-up if necessary in layers. Longer the interval between
the applications (while the first material is still plastic) greater the
thickness which can be applied without separation. Each preceding
layer shall be light broomed prior to time of Initial Set and cleaned
with a stream of water or blast of air and water prior to application of
succeeding layer.
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Curing shall be done with a light spray of water as soon as possible

without damaging final finish. The period of curing shall be atleast 7
days. Final finish may be obtained by brushing with a Brush after
application of finish layer of gunite.
Shooting at surface should start at bottom and should be worked up

for vertical surfaces. For dish end the shooting shall start at
circumference and shall be completed at the centre.
6. Precautions
a. Gunite shall not be applied when air temperature is less than

5 deg.C.
b. At the end of day's work, slope off the gunite to thin edge.
Before resuming clean the surface and wet with water. Cut
out loose pockets of sand and replace with gunite.
c. Apply gunite preferable after all piping work in completely

assembled.
22.6 MEASUREMENT AND RATES
22.6.1 Measurement for payment shall be on the basis of finish surface area of
guniting in sq.metre for the following average thickness.
a) 25 mm
b) 50 mm
c) 75 mm
The rates shall include supplying and fixing of all material including fabric
reinforcement as specified, cleaning the surfaces, guniting, curing,
scaffolding, providing all plant and equipment, providing safety gears etc.
complete in all respects including labour, taxes and levies etc. and cleaning
the area of all debirs.
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22.6.2 In case, reinforcement steel to be provided additionally or instead of welded

fabric as specified, providing and welding of rods will be measured and paid
separately.
SPECIAL INSTRUCTIONS
Tack welding of reinforcement rods, cleats, nuts etc. wherever required shall
be covered in unit rates for fireproofing.
Where steel rods and encasing is provided on only 3 sides of a Beam, the
rods shall be welded to beam.
The rates of concreting shall include cost of providing and removing from
work and cost of fabricating reinforcement steel rods.
22.7 LIGHT WEIGHT CONCRETE FOR FIRE PROOFING
Scope of services shall be inclusive of all labour, materials, tools and tackles,
equipments all by-works and any other services required for successful
completion of the system of encasing as described below.
22.7.1 SPECIFICATIONS FOR FIRE ENCASING WITH LIGHT WEIGHT

CONCRETE
a. Encasing material shall have following composition:
i) OPC (Ordinary Portland Cement) conforming to IS:269.
ii) Light weight vermiculite aggregate (NUKELITE or

equivalent).
iii) Suitable insulating binders and additives.
Proportioning by weight of the above materials, (equivalent

volumes) should give following properties as in (b) to (d)).
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b. DENSITY : 800 TO 900 kg/cu.m (max)
c. COMPRESSIVE STRENGTH : 20 to 25 kg/cm sqr (min)
d. THERMAL CONDUCTIVITY : 0.174 Kcal/hrm.sqr./deg.C
e. ANCHORAGE FOR TIEING THE REINFORCEMENT
It shall consist of 3/4" STD or hexagonal nuts or 16g GI wire.
f. REINFORCEMENT
It shall be done with welded wiremesh of 14g with 2" x 2" mesh tied
to the anchor nuts/lugs.
g. PAINTING
The encased concrete surface shall be painted with 2 coats of

cement based paint of approved make and quality after proper
curing.
h. Immediately during initial set-up while the concrete is still moist, all
the necessary pointing shall be carried out.
I. The concrete shall be cured by keeping it in damp condition for a

period of 7 days else the surface shall be given a sprayed on coat of
curing compound.
22.8. Fireproofing shall be coated with 2 coats of cement based paint of approved
make and shade after complete curing.
22.9 Sealing of top exposed joints between concrete and steel on surfaces shall
be done with neat cement mortar (1:1) to fill up all crevices left during
guniting.
END
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TECHNICAL SPECIFICATION FOR PORTA CABINS

Rev 01 Page 1 of 10
01 Revised and issued for tender 18-05-18 BHK 18-05-18 VBV 18-05-18 VBV
00 Issued for tender 09-03-18 BHK 09-03-18 VBV 09-03-18 VBV -
Category Code: -
Barcode
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Contents:
1 INTRODUCTION ......................................................................................................................... 3
2 DESCRIPTION OF THE UNITS ...................................................................................................... 3
3 SCOPE OF WORK....................................................................................................................... 6
4 DESIGN CRITERIA: ..................................................................................................................... 7
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1 INTRODUCTION
M/S NALCO (National Aluminium Company Limited) intends to set up the fifth stream
Alumina Refinery at their Damanjodi Site in the state of Odisha, India.
ThyssenKrupp Industrial Solutions (India) Private Limited (tkIS - India) has been selected
as EPCM Consultant for the same.
In order to facilitate the construction activities for the 5th stream Refinery Project, it is
necessary to carry out the Area Grading & Enabling Works as a separate Contract prior to
the main works contracts.
As part of the Area Grading & Enabling Works Contract, it is required to supply and install
Porta cabins for various purposes / units described below.
This specification is for complete supply, fabrication and installation of Porta Cabins
(including foundations, sanitary works, etc.) for different purposes as described below.
2 DESCRIPTION OF THE UNITS & TECHNICAL SPECIFICATIONS
2.1 Following are the details of Porta Cabin :
Sr. Name of Unit Dimensions Number of Units

No.
1. EPCM Supervisors’ 40’ x 10’ 1
Site Office (20
Users)
2. Training Centre (50 40’ x 10’ 1
Users)
3. Security Office (5 20’ x 10’ 1
occupants)
2.2 Porta Cabin manufacturing and construction shall be free of asbestos material.
2.3 The main structural elements of porta cabin shall be designed and fabricated for
the various loading e.g wind etc. as per GES ( Doc no 6695-CVC-G00-EC-0001),
attached.
2.4 The floor (bottom sheet and supporting framework) of the porta cabin shall be designed
to take minimum floor load of 3 kN / sqm. Maximum deflection of bottom sheet shall not
be more than 10 mm or SPAN /200 whichever is less. Anti-scratch and anti-skid PVC
carpet shall be provided as final flooring.
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2.5 Side walls and roof of Porta Cabins shall be double-skinned with suitable and permitted
insulation material sandwiched between the skins so as to provide adequate thermal
insulation. Outer skin shall be made of GI sheets of adequate thickness to withstand
relevant loads. Inner skin of roof shall be waterproof Bakelite board. Inner skin of walls
shall be waterproof laminated PVC sheets.
Side walls and roof shall be resistant to extreme weather conditions (rain and heat) to
provide maximum personnel comfort.
2.6 The roof of porta cabin shall be designed for live load of 75 kg /m2 plus weight of
insulation with maximum deflection limit of not be more than 10 mm or SPAN/200
whichever is less. The contractor to choose the thickness for roof plate accordingly.
2.7 The roof shall be provided with adequate slope , which will allow rain water to drain
towards the end.
2.8 The surface preparation and painting of all the fabricated steel part shall be as per
painting specification no. 6695-EQS-G00-EC-0007, attached.
All elements of Porta cabin shall have suitable, pleasant and durable finish.
2.9 The architectural & plumbing items shall g e n e r a l l y c o n f o r m t o t h e s t a n d a r d s

a n d r e q u i r e m e n t o f Construction specification, document no. 6695-CVC-G00-EC-
0002, attached.
2.10 Internal doors and windows shall be from powder coated aluminium sections.
Windows shall be fully glazed with tinted glass. MS safety grills shall be provided for all
windows.
Internal doors shall be partly glazed and bakelite sheet.
External door shall be pressed steel with insulation. Panic bars shall be provided for
external doors.
Doors shall be provided with mortise latch and door closers.
External doors and windows shall be provided with weather shades.
2.11 Porta cabin shall be installed (bolted to) on RCC pedestals. Pedestals shall be minimum
300 mm high above Finished grade level.
2.12 Porta cabin shall be designed for minimum life span of 10 years.
2.13 Clear height within Porta Cabin shall be minimum 3 meters.
2.14 The peripheral edges of the door / window openings shall be provided with rubber seal
to prevent the ingress of water and dust.
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2.15 In order to facilitate personnel entry, fabricated steel steps of detachable type shall be
provided for each porta cabin at external doors. These shall be made of 6/7 mm thk
chequered plates and formed channel sections.
2.16 Necessary arrangement shall be provided at top four corners of the porta cabin for safe
and easy lifting and transportation. The porta cabin shall be designed to take care of
handling stresses during lifting and transportation. During transportation, temporary
packings / temporary bracings shall be installed to avoid any damage to the main porta
cabin structure.
2.17 The permissible tolerance on all dimension, including diagonal dimension is +/- 10 mm.
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3.0 SCOPE OF WORK
Contractor’s scope of work shall include but not limited to the following:
3.1 Supply of Porta Cabins and installation at site.
3.2 Design and installation of foundation and all other allied works required for the complete
installation of the system.
3.3 Preparation of foundation drawings.
3.4 Submission of drawings and documents for approvals.
3.5 Supply of complete structure as described in the description of unit.
3.6 Transportation of pre-fabricated material including necessary permits, duties, charges etc.
3.7 Erection and alignment of complete structure as described in the description of unit, in
accordance with safety norms, including mobilization of equipment, cranes, manpower
required.
3.8 Construction of temporary access for mobilization of machinery.
3.9 Contractor shall be responsible for true and proper setting out of work, the correctness of
position, level, dimension and alignment. Contractor shall provide necessary equipment,
appliances, manpower with no additional cost.
3.10 If any error is detected in specified work, the same shall be rectified by Contractor at his
own cost.
3.11 Final touchups after erection for damaged members during transportation and erection.
3.12 Submission of As-built documents and drawings and stability certificate.
3.13 Contractor shall provide minimum 10 years leak-proof guarantee for the Porta Cabins.
3.14 Electrical works necessary for the habitable completion of the Porta Cabins.
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4.0 DESIGN CRITERIA:
4.1 Design codes

Sr. Code Description
No Number
1. IS 800 General construction in steel – code of practice
2. IS 875-I Code of practice for design loads (other than
to V earthquake) for buildings and structures
3. IS Criteria for earth quake resistance structures,
1893- IV
Part-IV industrial structure including stack like
structure.
4. IS 2062 Hot rolled medium and high tensile structural steel
specification
5. IS 808 Dimensions for hot rolled steel beam, column,
channel and angle sections
6. IS 801 Code of practice for use of cold-formed light gauge
steel structural members in general
All latest copies of code shall be followed.
4.2 Structural steel: Refer GES attached.
4.3 Wind data: Refer GES attached.
4.4 RAINFALL: Refer GES attached.
4.5 EARTHQUAKE DATA: Refer GES attached.
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5.0 ELECTRICAL REQUIREMENTS:

Each Porta Cabin shall be equipped with the following electrical equipments (fittings &
wiring) as a minimum –
5.1 EPCM Supervisor’s Site Office –
a. 1no. Lighting & Small Power Distribution Board comprising of the following feeders :
• Incomer feeder - 1no. 32A, 415V, 4pole MCB with R,Y,B indicating lamps
• Outgoing feeders -
 3 Nos. 10A, 240V, 2pole MCB + ELCB
 6nos. 16A, 240V, 2pole MCB + ELCB
b. 8nos. 35W LED Decorative mirror optic recessed mounted lighting fixture complete with all
accessories. However Contractor to ensure that illumination level of 300 lux (average) shall
be obtained at a working plane of 1.2m. If required no. of lighting fixtures shall be
increased.
c. 2nos. 20W LED Industrial tubelight fixture outdoor weatherproof type at the entrance to the
porta cabin.
d. 40nos. Decorative type switch socket box with 1 no. 5/15A switch socket unit and 1 no.
modular piano type switch.
e. 3nos. Decorative type switch in single module with 1 no. 5A modular piano type switches.
f. 2nos. 20A, single phase socket outlet with 1 No. 20 A, 10 kA, SPMCB, in sheet steel
enclosure.
g. 2nos. Decorative type switch socket switchboard with 5/15A, 5 pin, socket outlet with 15A
switch and 'ON' LED indication & fuse
h. 4nos. Decorative type wall / ceiling mounted fans (300mm size)
i. 1 NO. Emergency LED lighting fixture with built-in battery suitable for capacity of 30min.
back-up
j. 650/ 1100 V, copper conductor, PVC insulated, single core, multi strand, industrial wires
with ISI mark, of required conductor cross section and colour
k. Conduits & accessories – PVC (Heavy Duty, Grey Color), All required accessories such as
joints, bends, tees, reducers/ adaptors, etc., including edge protection grommets
l. 2nos. external earthing terminals of suitable size for connection of 75x10mm HDGI strip.
m. All necessary hardware material, accessories, nuts, bolts, etc. required to make the
installation complete
5.2 Training Centre

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b. 8nos. 35W LED Decorative mirror optic recessed mounted lighting fixture complete
with all accessories. However Contractor to ensure that illumination level of 300 lux
(average) shall be obtained at a working plane of 1.2m. If required no. of lighting
fixtures shall be increased.
c. 2nos. 20W LED Industrial tubelight fixture outdoor weatherproof type at the entrance
to the porta cabin.
d. 20nos. Decorative type switch socket box with 1 no. 5/15A switch socket unit and 1
no. modular piano type switch.
e. 3nos. Decorative type switch in single module with 1 no. 5A modular piano type
switches.
enclosure.
g. 4nos. Decorative type wall / ceiling mounted fans (300mm size)
h. 1 NO. Emergency LED lighting fixture with built-in battery suitable for capacity of
30min. back-up
i. 2nos. 1.5Ton Split Air Conditioner with voltage stabilizer with Auto/ Cool/ Fan/ Dry/
sleep and power saving modes, automated vertical swing for horizontal louvers,
antifreeze thermostat, activated carbon cartridge, dust proof and anti-bacteria filter,
powder coated/high quality paint finish with associated tubing as required
j. 650/ 1100 V, copper conductor, PVC insulated, single core, multi strand, industrial
wires with ISI mark, of required conductor cross section and colour
k. Conduits & accessories – PVC (Heavy Duty, Grey Color), All required accessories such
as joints, bends, tees, reducers/ adaptors, etc., including edge protection grommets
l. 2nos. external earthing terminals of suitable size for connection of 75x10mm HDGI
strip.
m. All necessary hardware material, accessories, nuts, bolts, etc. required to make the
5.3 Security Office

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b. 8nos. 35W LED Decorative mirror optic recessed mounted lighting fixture complete
with all accessories. However Contractor to ensure that illumination level of 300 lux
(average) shall be obtained at a working plane of 1.2m. If required no. of lighting
fixtures shall be increased.
c. 2nos. 20W LED Industrial tubelight fixture outdoor weatherproof type at the entrance to
the porta cabin.
d. 10nos. Decorative type switch socket box with 1 no. 5/15A switch socket unit and 1
no. modular piano type switch.
e. 4nos. Decorative type switch in single module with 1 no. 5A modular piano type
switches.
enclosure.
g. 4nos. Decorative type wall / ceiling mounted fans (300mm size)
h. 1 NO. Emergency LED lighting fixture with built-in battery suitable for capacity of
30min. back-up
i. 2nos. 1.5Ton Split Air Conditioner with voltage stabilizer with Auto/ Cool/ Fan/ Dry/
sleep and power saving modes, automated vertical swing for horizontal louvers,
antifreeze thermostat, activated carbon cartridge, dust proof and anti-bacteria filter,
powder coated/high quality paint finish with associated tubing as required
j. 1no. Junction box having krone type terminals (10 pair DB)
k. 3nos. Telephone socket RJ11 + telephone
l. 100m 1 pair outgoing cable ( 0.63mm ANN. Tinned Cu telephone cable)
m. 650/ 1100 V, copper conductor, PVC insulated, single core, multi strand, industrial
wires with ISI mark, of required conductor cross section and colour
n. Conduits & accessories – PVC (Heavy Duty, Grey Color), All required accessories such
as joints, bends, tees, reducers/ adaptors, etc., including edge protection grommets
o. 2nos. external earthing terminals of suitable size for connection of 75x10mm HDGI
strip.
p. All necessary hardware material, accessories, nuts, bolts, etc. required to make the
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TECHNICAL SPECIFICATIONS FOR

BOREWELL
Rev 01 Page 1 of 10
01 Finalised after NALCO comments and 15-06-18 BHK 15-06-18 VBV 15-06-18 VBV
issued for tender
00 Issued for Tender 09-03-18 BHK 09-03-18 VBV 09-03-18 VBV -

Category Code: -
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Contents:
0 Cover sheet: headline, check & approval for first edition & revision 1
1 INTRODUCTION ..................................................................................................................................... 3
2 SCOPE OF WORK................................................................................................................................... 3
3 SPECIAL TERMS & CONDITIONS ............................................................................................................. 3
4 TECHNICAL SPECIFICATIONS: ................................................................................................................ 6
5 QUALITY CONTROL AT SITE ................................................................................................................... 8
6 SAFETY PRECAUTIONS .......................................................................................................................... 9
7 LIST OF IS CODES REFERRED & RELATED TO PRESENT SPECIFICATIONS .................................................. 9
8 CASING PIPES – TECHNICAL SPECIFICATIONS ....................................................................................... 10
9 BOREWELL LOCATIONS ....................................................................................................................... 10
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BOREWELL
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1 INTRODUCTION
This document covers the scope of work of Construction of Tube / Bore Well. The work shall
include the mobilization of necessary equipments, providing necessary Supervisors & Technical
Personnel and providing the technical services as and when called for by Engineer-In-Charge.
The detail scope of work is described in the section 'Scope of Work'.
2 SCOPE OF WORK
2.1 The present scope involves construction of tube wells each minimum 100 M deep with 500 mm
dia. drilled hole including supplying and lowering of heavy duty UPVC casing pipes / ribbed pipes
and other fittings like reducers, bull nose etc. complete. The existing water table varies from 5 to
10 meters below G.L during dry season. The tube well successfully executed should give an yield
of 50 TO 60 M³/Hour of water of potable quality. The scope does not include provision of pumps,
and storage facilities. However to establish the yield, required equipments like pumps and other
accessories shall be arranged by the bore well contractor at his own cost.
The work covered in this Tender includes Mobilising necessary staff, labour, instruments,
equipment, machinery, transport etc. required to carryout the work. All necessary materials
including supervision, labour, water, power, etc., that may be required to complete the entire
work as per scope shall be provided by the Contractor at his cost. Client shall not supply any
materials or facilities at site or elsewhere. Contractor shall be entirely responsible to acquire
necessary permission to carry out the work at the site from concerned persons and authorities.
All liaisoning and required paperwork towards this shall be by Contractor. NALCO will only
provide necessary assistance.
2.2 The quoted price shall be all inclusive that is they shall include all costs towards transport of staff
and equipments, establishment at site and their expenses, supervision, labour, instruments,
statutory requirements, taxes, duties, etc.
2.3 This scope of work is to be read and interpreted in conjunction with the other sections of this
tender. It will be the bidder's responsibility to understand, interpret and grasp the scope of work.
3 SPECIAL TERMS & CONDITIONS
3.1 Site clearance, levelling etc. required for transportation of equipments and erection and dismantling
/ removal of same at each location should be carried out by the tenderer and the cost of same
should be covered by him in his quoted rates. No separate payment shall be made to him on this
account. No separate payment shall be made for construction of Bentonite slurry tanks / channels
etc.
3.2 Contractor shall confirm the subsoil data and establish his own estimate of availability of water
depth of well, yield in different seasons , quality etc. keeping in view the stipulated yield of 50 to 60
cu.m./ hr.
3.3 The site should be handed over to clients properly cleaned and free from bored muck. All such
bored muck / materials and surplus bentonite slurry shall be removed by the contractor from the site
at no extra cost to Owner.
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3.4 The bore logs based on washed samples should be maintained and submitted by the contractor,
alongwith other observations as a compiled report, in six sets.
3.5 Collection of strata samples

Strata samples, representative shall be collected for every 1.5 metre depth, both washed and
unwashed and shall be packed in plastic bags and kept for inspection by the consultant/owner.
Each such bag shall be numbered and the depth range clearly and indelibly marked.
3.6 Electric Logging

The pilot hole shall be drilled to the depth decided by the groundwater consultant and as approved
by tkIS / NALCO. As soon as this is over, an electric log with a reasonably large scale (practical)
shall be taken and a copy made available to tkIS / NALCO.
3.7 The pipes should be placed vertically in the bore hole & in plumb. Suitable guides shall be provided
at ground level, above and within the hole by the Contractor.
3.8 Compresed air shall be used by the contractor for washing of holes to remove bentonite slurry and
only then the ‘fill’ material should be placed around the pipes. Compressor shall be arranged by the
contractor with necessary accessories at his own cost.
3.9 The soundings shall be taken at intervals for the bore hole when in progress, and also during other
operations such as placement of UPVC pipes (plain / slotted) and fill materials of various grades /
and various types to know the consumption.
3.10 After completion of each Tube well, the drilling agency should submit the information as per IS 2800
(Part II), latest revision.
3.11 The drilling agency should also submit information as per Clause 12.2 of IS-2800 (Part I) after
completion of each tube well and handing over the same to clients in complete shape.
3.12 The drilling agency shall submit detailed construction programme to complete the work within the
time schedule given to him. If he is unable to maintain assured progress, he should immediately
mobilise additional machinery, equipment etc. at site to improve the progress and complete the
work in time. No extra payment will be made for any such increase in the machinery, plant and
equipment and labour.
3.13 All materials used in permanent works should meet requirements of relevant I.S. codes - with latest
revisions.
3.14 The tenderer / drilling agency should give a detailed ‘Method Statement’ explaining in detail the
“method of execution of the tubewell” he proposes to execute with his equipments for the tube well
specifications given in the tender document. He should also submit specifications of equipments he
proposes to use, give production parameters achieved by him in the past.
3.15 The tenderer should specify no. of drilling rigs and supporting equipments he proposes to mobilize
on the site to complete the work in the given time schedule.
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3.16 The tenderer / drilling agency should submit statements giving details of the similar works
satsfactorily executed by him.
3.17 The tenderer / drilling agency should give details of drilling equipments in working conditions and as
available with him, which he proposes to use for the present scope of work.
3.18 The drilling agency / contractor should give guarantee that each tube well constructed will give good
service for the “stipulated yield” of 50-60 Cu.m. per hour and should give a suitable guarantee to
cover the same and any rectification measures as and when required should be carried out by him
free of cost, and within the time schedule to be specified from time to time.
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4 TECHNICAL SPECIFICATIONS:
4.1 Method of construction (execution):

The equipment used shall be of Rotary drilling system (IS 7206-1974) or Reverse circulation rig
using Bentonite slurry which can form a membrane / mud cake on the sides of the hole for the entire
length of uncased portion. The drilling mud should be thick enough to hold the bore hole sides from
caving. It should be able to keep the cutting in suspension when circulation of slurry is suspended
for extending drill rods or for any other reason. Also it should be sufficiently thin enough to enable
efficient pumping. During the drilling process, drag bits, roller, cutter type, rock bits or any other
type as required to meet the site conditions should be used to carry out boring operations efficiently
through all types of stratas.
4.2 Bentonite Slurry: Sodium based bentonite powder used for preparation of bentonite slurry will be
tested for its liquid limit and the same should not be less than 300%. The bentonite powder is
mixed in fresh water in suitable proportions at mixing installations. The density of the slurry should
be between 1.05 to 1.10 depending on the site conditions and viscosity as tested by Marsh cone
should be approximately 35 seconds. Generally 5 to 6% bentonite solution may be found adequate.
However the same should be adjusted at the site i.e. (approx. 50 to 60 kg. bentonite per cubic
meter of theoretical based volume can be found sufficient). The bore hole should be kept filled
with bentonite slurry at all times.
4.3 The bore hole sides can also be stabilized by hydrostatic pressure of water in the hole and also due
to film of fine grained material deposits on the wall consisting of suspended clay / bentonite and silt
from subsurface formations. The work has to be carried out round the clock. The size of water tank
has to be atleast three times the volume of the hole and it should be kept full at all times.
4.4 In case of presence of boulders larger than the drill pipe, bit assembly should be pulled out and
boulders fished out by crab type (orange peel) bucket/grab.
4.5 Drilling can also be carried out by any other method, with the use of Percussion Method, Pneumatic
direct rotary drilling or rotary cum percussion Air drilling method to meet the site conditions and to
achieve the targetted boring within the given time schedule. The equipments used should meet
relevant I.S. Code requirements. Spare instruments shall be kept as standby for immediate
replacement of the damaged or non-usable instruments to avoid time delay.
4.6 550 mm dia. 5mm thick minimum M.S. conductor pipes in lengths of 2 to 3m should be driven at
the location using percussion, rotary drilling, or any other method in collapsible stratas and
thereafter 500 dia. boring should be done to required depth by any of the approved methods.
4.7 Installation of screens:

The well assembly consisting of JDW-Ribbed screen pipe and UPVC pipes as per specifications
alongwith bull nose; UPVC Reducer pipe is lowered into the well. Centralising guides are provided
in the hole. The guides shall be of strips of 25mm width, 3mm thickness and 1m long. The
assembly is held from top and not allowed to rest at the the bottom to avoid any bulking due to
excessive slenderness.If found necessary, a casing pipe is lowered till such time that the well
assembly is lowered. Then the same can be extracted.
4.8 Placement of pebbles around the well is done carefully with approx. 5 cm. dia. pipe. This pipe is
lowered in the annular space where pebbles / sand,/ clay balls are packed. Pebbles / sand / clay
balls are fed through a hopper provided at top. The feeding pipe is gradually pulled up as the
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annular space is filled up. Water is fed through the pipe to help easy flow of pebbles. Alternately
pipe can be lowered inside the well assembly and connected to a pump. A circulation of water is
established downwards in the annular space and upward through the lowered pipe. Pebbles / sand
is fed in the annular space and is carried downward by force of the water.
4.9 Clay lumps are crushed properly to form uniform size of 25 mm clay balls, to be used as packer
above 6 to 8 mm size pebble pack layer.
4.10 Pebbles packing - All gravel / pebbles (quartz, well rounded) should be packed in the tube well
as per IS-4097:1967. The diameter of same generally shall not be less than 6 to 8mm or as
specified in the provisions as per IS-2800 (Part I) should be followed:
4.11 Cement Seal - O.P.C. cement grout is used above impervious layer of 25 mm dia. clay balls to
ensure a seal so that discharge does not come out of the housing pipe and to avoid surface water
contamination.
4.12 Development:
4.12.1 The drilled well shall be developed by any method specified below or as per IS-11189:1985 inorder
to get maximum sand free yield. It should be continued till stabilization of sand and pebbles have
taken place.
Methods used : a) High velocity jetting
b) Mechanical surging
c) Compressed air
d) Over-pumping or any other approved method
4.12.2 Overpumping should be 15 to 25% higher discharge than the expected discharge from the tube
well. The final discharge should be free from sand with maximum tolerance of 20 parts of sand in
one million parts of water by volume after 20 minutes of starting the pump.
4.13 The well shall be tested for performance to give the specified yield of 50-60 M³/hr. that is, for yield
characteristics and efficiency as per provisions in IS-2800 (Part I-1991).
4.14 Disinfection Grouting & Sealing

After completion of yield test / performance the well shall be disinfected as per provisions in IS-2800
(Part I) and IS-10500and to meet acceptance of clients.
Sealing and grouting, with cement seal shall be done to ensure safe sanitary conditions as the water
will also be used for drinking purpose.
4.15 Surface Apron

An apron in concrete of grade M15 and 150 mm thick shall be provided around the well (3M x 3M)
size and sloping away from it as it protects the well from pollution caused by contaminated water
flowing back and to avoid formation of muddy pools around the well.
4.16 Taper reducer and well cap sizes should meet the requirements given in IS-2800 (Part I) 1991 and
the specifications given in the tender.
4.17 UPVC Plain casing pipes (10” & 8” O.D. or equivalent) and Ribbed screen pipes should be as per
specifications in the tender and as per relevant I.S. codes .
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4.18 Materials
All materials used in construction of the tube well should meet the relevant I.S. codes with latest
revisions and materials as accepted by consultants / clients shall only be used in permanent works.
Materials not meeting acceptance criteria should be removed from the site immediately and
replaced by materials which meets the standards and the acceptance criteria.
4.19 MEASUREMENTS
Various measurements such as tube well depth, water level, verticality and alignment, Testing of
yield and drawdown, quality of water etc.should be done as per provisions made in IS-2800 (Part II
- 1979) with revisions if any and No separate payment will be made for carrying out any tests and
corrective measures done by the contractor.
4.20 ACCEPTANCE OF WORK
The tubewell will not be accepted if :-

a) The pipes are not lowered to the depth as per casing programme.
b) The well pumps sand in whatsoever quantity.
c) The verticality tool binds anywhere in the housing or well casing.
d) There is a void in the packing of gravel.
e) The setting of conductor pipe is defective and while drilling if mud leaks through the annulus
and causes caving a surface for whatever reason.
5 QUALITY CONTROL AT SITE
5.1 The verticality of the bore should be checked before installation of screen. The verticality should not
deviate more than 10 cm per 30 M depth and deviation should be in one direction and plane only (IS
2800).
5.2 The verticality should be tested also after installation of well assembly but prior to commencement
of pebbles filling. The eccentricity is tested by Plumb test (IS 2500-1979) and if same is beyond
permissible limits, the same should be corrected by loosening soil / earth on one side and applying
jacks on other side (or by any approved method). If the bore is eccentric substantially, it may have
to be rebored. In such case all measures as may be required at site shall be carried out by the
drilling agency at no extra cost to clients / owners.
5.3 The bore hole diameter should be uniform throughout the depth, and kinks and bends if any should
be removed / rectified prior to lowering down the well pipe assembly.
5.4 No leaky joints in the PVC pipes shall be permitted and adequate care should be taken by the
contractor (to avoid same) during assembly.
5.5 The wall thicknesses and weight /M (as specified) should be uniform for all the pipes used in the
work.
5.6 Screen pipes used should have, open area, gap between the slots and the size of the slot as
specified only. In case of variance the pipes may be rejected. The contractor shall be required to
replace them immediately. No payment / compensation shall be made to the contractor on this
account.
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5.7 Screen pipes / casing pipes used should be sufficiently rigid so as not to cause any collapse due to
movement or subsidence of the soil. The contractor should take adequate measures to avoid same
at site.
5.8 Screens should not get clogged by silt and clay due to insufficient development of the well, the
contractor should ensure that Development of the well is done properly and a good backgrading is
achieved, retaining the fines behind.
5.9 The screens should be cleaned properly atleast once a year, even if the discharge has not fallen off,
hence the borewell should be flushed back by reversal of flow through the screen openings.
6 SAFETY PRECAUTIONS
The drilling agency should take all necessary precautions for the workers and staff including third
party working at the site from any accidents during execution of the work. A suitable insurance
policy should be taken by him to cover any such possibility as mentioned in the General & Special
Terms & Conditions of Contract.
The drilling agency should also take precautions so that no cavities / pockets are not formed
creating vertical downward slips along the hole, which may cause subsidence of the ground / soil or
pump house or any other structures nearby. A suitable insurance policy (including third party)
should be taken by him to cover any such event.
7 LIST OF IS CODES REFERRED & RELATED TO PRESENT SPECIFICATIONS
1. IS:2800 (Part I) : Code of Practice for Tubewell construction

2. IS:2800 (Part 2) : PART 2 TESTING
3. IS:7156 : General requirements for Reverse, Circulation Drilling Rigs
4. IS:7206 (Part I) : General Requirements for Direct Circulation Rotary Drilling
Rigs (including Amendment No.1 May 1993)
5. IS:4097 : Specifications for Gravel for Use as Pack in tube wells
6. IS:12818 : Unplasticised PVC ribbed screen casing and plain casing
pipes for bore / tube wells - specifications.
7. IS:2062 : Structural Steel (Standard quality)
8. IS:4270 : Steel tubes used for water wells
9. IS:8110 : Well screens and slotted pipes (first revision)
10. IS:9439 : Glossary of terms used in water well development
11. IS:11189 : Development of wells
12. IS:10500 : Quality of water - drinking purpose
13. IS:5120 : Tech. requirement for rotodynamic spacial purpose pumps
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8 CASING PIPES – TECHNICAL SPECIFICATIONS
8.1 10” UPVC - Plain Casing Pipe:-
Heavy duty pipe suitable for tubewells upto 450mm depth, outside dia. 280mm, wall thickness
varying from 16mm to 18mm with collapse resistance of 15.5 kg/cm² and weight 20.5 kg/m with
smooth inside surface and free of projections.
8.2 8” UPVC - Plain Casing Pipe:-
Heavy duty pipe suitable for tubewells upto 450mm depth, outside dia. 225.50mm, wall thickness
varying from 13mm to 14.20mm with collapse resistance of 15.5 kg/cm² and weight 13.20 kg/m
with smooth inside surface and free of projections.
8.3 8” UPVC - Ribbed Screen Pipe:-
Heavy duty ribbed screen pipe suitable for tubewells upto 450mm depth, outside dia. 229.02mm
(min) and 229.50mm (max), wall thickness varying from 13mm to 14.20mm and a weight of 13.2
kg/m with slots of 3mm width & 65mm length having an operative area of 13% minimum space
between slots 11mm horizontal slots.
8.4 Reducer:-
Heavy duty as per IS:12818.
8.5 Bull Nose:-
Heavy duty UPVC 200mm nominal diameter, specification same as for plain pipe with tapering
bottom and length approximately 0.5m.
8.6 Manufacturers’ original test certificate & guarantee certificate should be submitted for all UPVC
pipes and fittings.
9 BOREWELL LOCATIONS
Borewells to be located within the area demarcated for Laydown, Temporary Facilities and Labour
Colony on the east side of NALCO Plant.
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GENERAL ENGINEERING SPECIFICATION

PAINTING
Rev 01 Page 1 of 5
Finalised after NALCO's review

01 IFD 09/01/18 SPT 09/01/18 SIL/MDT 09/01/18 MBM -
and issued for engineering
00 IFR For Client review/comments 11/09/17 SPT 14/09/17 MDT 15/09/17 MBM -
Category Code: -
Barcode
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Contents:
1 Scope.................................................................................................................................................. 1
2 General ............................................................................................................................................... 3
3 Equivalent Approved Paints ............................................................................................................... 4
4 Project Specific Requirements ........................................................................................................... 4
Annexure-1 : Reference tkIS India Standards ...................................................................................................... 5
Appendix A – Painting Systems

Appendix B – Colour Coding & Lettering of Eqipment and Piping
Appendix C – Equivalent Paint Chart
Appendix D – Colour Coding for Pipelines
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1 Scope
This specification defines the general requirements for painting. Painting includes surface
preparation, clean up, supply and application of paint on external surfaces of structural, Pipelines and
Shop Fabricated Mechanical static equipments only. For structurals system 1 of Appendix A1 shall
01 be followed. For pipelines, system 2 of Appendix A1 shall be followed. Pipelines painting scope
includes only colour bands & Markings by letters & symbols as referred in section 2 & 3 of Appendix B
of this specification. For shop fabricated mechanical static equipments, system 3 (for
uninsulated) & system 4(for insulated) of Appendix A1 shall be followed.
This specification is applicable for all CS & LAS surfaces. High alloy steels are not recommended for
Painting.
This specification does not include painting for electrical items such as motors, transformers etc.
For electrical items, painting shall be as per electrical specification except colour coding. Painting for
rotating equipments and concrete surfaces is not covered in this specification.
The touchup for damaged areas where equipment painting is not originally included shall be in
painting contractor’s scope. The same shall be carried out in co-ordination with site personnel and
quantum of area for touch up, if any, is to be mutually agreed up on during execution of painting
work at site.
In case of imported items, wherever commissioning/erection or both are included in foreign vendor’s
scope, painting touch up is to be done by the foreign vendor. Otherwise, it will be done by painting
contractor as per instructions given by foreign vendor/tkIS India site office.
Internal lining and coating are not covered in this specification. Painting for underground pipelines is
also not covered in this specification.
In case of conflict between this specification and other related specifications, vendor shall notify tkIS
India.
2 General
All painting of steel surfaces (only for structurals and colour coding of pipe lines) shall be performed
in accordance with tkIS India standard UN 9257-01 Part 1 (M) "Erection – Protective Coating against
Corrosion" and manufacturer’s recommendation.
All surface preparation shall be in accordance with detailed painting systems and respective latest
Swedish Standards or IS equivalents of the same.
Quantity survey for painting shall be as per UN 9257-91.
Details of painting system along with paint system numbers are given in the Appendix ‘A1’.
Scope of painting for various equipment shall be as below:
 For package unit and package items, derusting, primer and final painting is included in
package vendor’s scope of supply.
 Surface preparation and primer painting of steel structures is included in steel fabricators
scope. Further painting is also included
included in steel
in painting fabricators's
contractor’s scope.
scope.
 Various structural to be painted as per this Technical specification are separately listed and
form part of the painting enquiry document.
 Technical requirements of Colour coding and lettering shall be as per Appendix ‘B’.
Surface preparation and identification bands of piping is included in piping fabricator’s
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 Wherever blast cleaning is not possible, consult tkIS India for alternate surface
01 preparation system
3 Equivalent Approved Paints
The paints intended for use in this specification are classified on the basis of pigments and binders.
Approved equivalent products of reputed manufacturer’s conforming to the specified paint are listed
in the equivalent paint chart - Appendix ‘C’.
4 Project Specific Requirements

All structural steelwork shall be adequately protected from atmospheric corrosion and from corrosion
resulting from the process itself, in accordance with Design Standards and Codes of Practice.
Corrosion protection shall take the form of an acceptable painting system, or hot dipped galvanising,
or the use of an acceptable grade of steel with inherent resistance to corrosion. It is a design
criterion that the corrosion protection shall provide 15 year service before requiring recoating. Paints
containing Coal Tar, Chromates or Lead are not acceptable. Paints containing High Build Epoxies,
Urethanes, and Zinc Silicate are acceptable.
All bolts, nuts and washers used for the erection of structural steelwork shall be hot-dipped
galvanised.
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Annexure-1 : Reference tkIS India Standards (attached with this GES)

Standard No. Part Title Issue Dt
UN 9257-01 1 (M) ERECTION – PROTECTIVE COATING AGAINST CORROSION 08-2008
UN 9257-91 - ERECTION – QUANTITY SURVEY OF PAINTING 04-2009

UN 9250-01 1 (M) ERECTION – WAREHOUSING 08-2008
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APPENDIX – A1
PAINTING SYSTEMS Page 1-1
01
Paint Peak to Intermediate Coats. Total DFT
Surface Prepn Primer Coats. Top Coats. Remarks & Max Operating Temp.
System Valley Pigment/Binder-Resin/ DFT microns Special Remarks.
& Finish Pigment/Binder-Resin/ DFT µm. Pigment/Binder-Resin/ DFT µm. Limits.
No Height. (mic) µm. (µm).
Zinc Dust/ Ethyl Silicate Primer as per

SSPC Paint 20 Level 2 / 1 x 75 µm (80% Epoxy Polyamide Inert Pigment / Acrylic Aliphatic PU paint
Blast zinc on dry film) Intermediate coat with with 80% gloss retention on exposure to
1000 hrs of QUV B 313 / 1 x 60 µm; % Steel Structurals. Upto 93 o C. ( Non
System 1 Cleaning to 50 %Volume Solid : Min 65, Lamellar Micaceous Iron 255 Uninsulated
Volume Solid : 58+/- 2, Galvanized )
SA 2.5 Zinc should be min 1.4 kg/ litre Oxide - Min VS 80% / 1 x 120
The product to be supplied with ASTM µm Gloss of min. 80 units @60 o gloss head
D520 Type II zinc dust.
2 x 20μm
System 2 Synthetic Enamel paint on pipes for 40 For piping
identification bands
Zinc Dust/ Ethyl Silicate Primer as per

SSPC Paint 20 Level 2 / 1 x 75 µm (80%
Blast zinc on dry film) Shop fabricated static equipment
System 3 Cleaning to 50 %Volume Solid : Min 65, 75 Uninsulated (Tanks, Vessels,
SA 2.5 Zinc should be min 1.4 kg/ litre Exchangers)Uninsulated Items.
The product to be supplied with ASTM
D520 Type II zinc dust.
Epoxy Phenolic Coating ,

Min 1 coats x 125 µm
Blast Shop fabricated itatic equipment
It shall be a two-component, amine adduct
System 4 Cleaning to 50 125 Insulated (Tanks, Vessels, Exchangers)
cured phenolic epoxy (novolac) coating
SA 2.5 Insulated Items.
(This is to avoid Corrosion under
Insulation phenomenon).
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Appendix B
COLOUR CODING & LETTERING OF
EQUIPMENT AND PIPING Rev 01 Page 1 of 5
Contents:
1 Colouring scheme shall be as follows ................................................................................................ 2
2 Procedure of Colour Coding of Pipelines ........................................................................................... 3
2.1 Application of Colour Band on uninsulated carbon steel surfaces ................................................ 3
2.2 Application of Colour Bands on galvanised steel, stainless steel surfaces and other non-
ferrous piping but excluding plastics ................................................................................................ 3
3 Marking by Lettering & Symbols ......................................................................................................... 3
3.1 Lettering ............................................................................................................................................ 3
3.2 Application of the markings .............................................................................................................. 4
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1 Colouring scheme shall be as follows

01
Sr. Description Colour Codes IS Code RAL
Colour
No. (IS 5-1978) No.
1. Machineries such as pumps, air Light Grey 631 RAL 7033

compressors, transformers, motors,
etc.
2. Stack / Chimney Silver
3. Structure (Inside plant) Dark Grey 632 RAL 7011
4. Structure (Outside including pipe Dark Grey 632 RAL 7011

rack)
5. Railing - Top Rail Black

Bottom Rail & Supports Golden Yellow 356 RAL 1003
6. Stair stops, gratings and flooring Black/as per instructions Self

of Engineer-in-charge Standard
7. Crane Girder & Supports Dark Grey 632 RAL 7011
Crane Bridge Golden Yellow / Black 356 RAL 1003

slant straps on Dark Grey
finish Paint of
Polyurethane
Hook Black Self

Standard
Pulleys Signal Red 537 RAL 3003
Machineries Light Grey 631 RAL 7033
8. Piping As per Appendix D

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Appendix B
2 Procedure of Colour Coding of Pipelines

2.1 Application of Colour Band on uninsulated carbon steel surfaces
Colour bands will be located at 15000 mm pitch. Also colour bands will be marked at
junctions, near valves, joints, service appliances, bulkheads, walls etc.
2.2 Application of Colour Bands on galvanised steel, stainless steel surfaces and other non-
ferrous piping but excluding plastics 01
First and second (if applicable) colour bands will be of 75 mm width. In case of single
colour band, the same will be at the centre of the round colour patch. In case of two
colour bands, they will be at the centre of the ground colour patch but with a gap of 75
mm between each other.
The portion required to be painted shall be degreased and roughened by 180 grit sand
paper. After roughening surfaces, wash primer will be applied. Synthetic Enamel paint
will be applied as a base colour coat after drying of the wash primer. Colour bands
coat will be put if applicable.
3 Marking by Lettering & Symbols

In addition to the colour coding according to Para 2.0 & App.D, equipment and piping will
be marked with lettering, colour bands or symbols (e.g. arrows for indicating flow
direction).
These markings will be lettering (e.g. Vessel No. identification of volume) and colour
bands (e.g. fluid marking, arrows for indicating flow direction).
Pipes of less than 3 M length shall not receive lettering, but one colour band only. Colour
bands for pipes shall be arranged maximum 1.5 M away from equipment. The blank
space between lettering and the symbols (e.g. arrows) shall be approximately 150 mm.
Table 1 Colours for Lettering and Symbols
Surface Lettering / Symbol

Yellow Black
Orange Black
Red White
Blue White
Green White
Grey Black
White Black
Black White
3.1 Lettering
Lettering for equipment shall be placed on each item at a clearly visible location. The
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letters should have the following sizes. The equipment dimensions considered below are
for the horizontal cross section.
- 50 mm or 80 mm for equipment with dimensions of <= 1 M
- 100 mm for equipment with dimensions of > 1 M to 5 M
- 300 mm for equipment with dimensions > 5 M to 15 M
- 600 mm for equipment with dimensions > 15 M to 50 M.
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Appendix B
- 900 mm for equipment with dimensions > 50 M.
Lettering for piping shall be placed at clearly visible locations near the points where the
piping leaves the ground or the pipe bridge. Decisions about any further lettering
required shall be taken on site.
The letters should have the following sizes:

- 10 mm for pipes of <= DN 25
- 20 mm for pipes of > DN 25 to DN 80
- 100 mm for pipes of > DN 1000
The blank spaces between the letters shall be approximately 10% of the letter size. The
type of letters shall be determined on site. For the colour of the letters, Table 1 shall
apply.
Lettering for tanks shall be placed at a height of approximately 4/5 of the shell height.
Lettering for horizontal vessels, spherical vessels and piping shall be placed at the height
of the centre line.
For the size of arrows for indicating flow direction the following shall apply.
Nominal Size Dimensions of Arrow in mm

DN Inch W1 W2 L1 L2
< 20 <¾ 3 9 8 20
20 To 40 ¾ to 1½ 5 15 13 35
50 To 80 2 to 3 10 30 26 65
100 To 150 4 to 6 15 45 40 100
200 To 250 8 to 10 30 90 80 200
300 To 400 12 to 16 50 150 130 325
450 To 600 18 to 24 80 240 210 525
> 600 >24 100 300 260 650
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3.2 Application of the markings
3.2.1 Prior to the application of lettering and colour bands, a surface preparation is required.
Coated surfaces shall be free from any contamination (e.g. dust, oil, grease, salts). The
surfaces should be treated with abrasive paper to improve adhesion on the marking.
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Appendix B
Surfaces of galvanised steel, alloy steel and other non-ferrous metals shall be slightly
roughened with abrasive paper.
For the materials for markings, the technical specification appendices “Painting Systems”
shall apply.
3.2.2 In case of plastic surfaces, self adhesive foils should be used for marking. Self adhesive
foils shall be applied on surface which shall be clean, smooth and free from grease.
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APPENDIX -C
EQUIVALENT PAINT CHART
PROJECT NO. 66-6695-700/MASTER 6695-EQS-G00-EC-0007
Paint Specification Paint Manufacturers
Paint Brand Name Paint Brand Name
Sr. Paint Brand Name Paint Brand Name Paint Brand Name Paint Brand Name Paint Brand Name Paint Brand Name
Pigment Binder Minimum Requirement Asian Paints / Growel (Bombay Service Requirements Remarks
No. Jotun Hempel Chembond CHUGOKU Advanced Paints Carboline
Sigma PPG Paints)
1 - Zinc Silicate Coatings to have minimum of 80% metallic Zinc on DFT by

weight of total solids. As per SSPC - Paint 20 - Level II
2 - Zinc Silicate coating is to be supplied with high-purity grade zinc dust as per Apcosil 605 / Sigmazinc Hempel Galvosil 15780
1 Zinc Dust Ethyl Silicate ASTM D520 Type II . Resist 78 NOT AVAILABLE NOT AVAILABLE ZINC -O-SIL 75 NOT AVAILABLE Carbozinc 11 E As a primer in System 1 , 2 , 3, 6 & 9
158 (Pigment 97140)
3 - Maximum lead level in zinc dust should not be more that 0.01% by weight as
per ASTM D520 Type II .
4 - Minimum Volume solid : 65%
5 - DFT Range - 60µm - 80 µm
Two component, high solids, high build
Min Volume Solid 80% and WPL of 1.8
epoxy polyamide coating with good Apcodur MIO 410 HS /
2 Lamellar MIO 1 - Lamellar Micacious Iron Oxide pigmented Penguard Midcoat MIO Hempadur Mastic 47550 KemOxy 321 HB MIO NOT AVAILABLE PENTADUR HB MIO 5569 Advoguard 2285 HS Carboguard 893 MIO As an intermediate in paint system 1 & 9
wetting properties and low temperature Sigmacover 410 MIO
2- DFT Range - 120µm - 200 µm
curing.
Two-component, high build & high solid , 1 - Minimum Volume Solid : 50 - 65 %
glossy acrylic polyurethane coating, cured 2 - Low VOC-compliance : As per EU Directive 2004/42/EC. Should be less than
with 338 g/L
aliphatic isocyanate, with good gloss and Apcothane CF 678 /
3 Inert Pigment 3- Full compliance with SSPC Paint Specification No 36 - All levels NOT AVAILABLE Hempathane 55190 KemThane 415 G NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE Carbothane 133 HB As a topcoat in paint system 1, 7 & 9
colour retention. Sigmatherm 540
4 - Gloss retention: approx. 80 gloss retention on exposure to 1000 hrs of QUV B
313
5- DFT Range - 60 - 100 µm
1 - Minimum Volume Solid : 29 %
Acrylic modified Silicone paint for heat o
2 - Continuous heat resistance 200 C Acrysil HR Finish / PENTOLITE SILICON For upto 200 DEG C Continuous operating As a high temperature topcoat in paint
4 Leafing Aluminium resistance upto 200 oC . Air drying at Solvalitt Midtherm Hempel Silvium 51570 KemGuard 250 HR SILICON AS Advotherm 3130 ZS Thermaline 1248
3- Single Pack Sigmadur 550 ACRYLIC temperature system 2
ambient temperature.
4 - DFT Range : 20 -30 µm
Aluminium pigmented heat resistant 1 - Minimum Volume Solid : 28 % Heat Resistant Silicone
Silicone paint for heat resistance upto o
2 - Continuous heat resistance 400 C Aluminium Paint / Hempel Silicone KANGAROO HHR For 400 DEG C Continuous operating As a high temperature topcoat in paint
5 Leafing Aluminium o Solvalitt KemGuard 450 HR SILICON HR SILVER Advotherm 3140 HHR carboline 4674 E
450 C . Air drying at ambient 3- Single Pack Sigmatherm 540/ Aluminium 56914 ALUMINIUM 4950 temperature system 3
temperature. 4 - DFT Range : 20 -30 µm / coat Sigmatherm 500
Aluminium pigmented heat resistant
2 - Continuous heat resistance 600 oC Apcotherm HR 600 Hempel Silicone PENTOLITE HHR For 600 DEG C Continuous operating As a high temperature topcoat in paint
6 Leafing Aluminium Silicone paint for heat resistance upto 600 Solvalitt KemGuard 600 HR SILICON HR SILVER Advotherm 3160 HHR NOT AVAILABLE
o 3- Single Pack /Sigmatherm 540 Aluminium 56914 ALUMINIUM 4951 temperature system 4
C . Air drying at ambient temperature.
4 - DFT Range : 20 -30 µm / coat
Two-component, amine adduct cured
phenolic epoxy (novolac) o Apcotherm EPN 200 Epoxy HR
2 - High temp resistance upto 260 C (Insulated)
7 Inert Pigment coating with very good adhesion and high Hempadur 85671 NOT AVAILABLE NOT AVAILABLE PENTALINE 200 NOT AVAILABLE Thermaline 450 EP For insulated services As a primer cum topcoat in paint system 5 .
3 - DFT Range : 125 µm / coat /Sigmatherm 230 (Max Temp 200 C)
temperature, water and chemical
resistance.
o
2 - Continuous heat resistance at 650 C for dry or dry/wet exposure as per
High Temperature Single component inert modified inorganic
8 modification of ASTM D 2485 Hi-Temp 1027 Jotatemp 650 Versiline CUI 56990 NOT AVAILABLE NOT AVAILABLE PENTATHERM CUI (MIO) NOT AVAILABLE Thermaline 4001
Resistant MIO copolymer MIO coating
3 - Resistant to temperature cycling in dry or wet/dry service
4 - DFT Range : 125 -150µm / coat
Two-component, amine adduct cured
phenolic epoxy o
2- Cryogenic temp resistance down to minus 196 C Apcotherm EPN 200
9 Inert Pigment coating with very good adhesion and high NOT AVAILABLE Hempadur 85671 KemOxy EPN 514 NOT AVAILABLE PENTALINE 200 NOT AVAILABLE NOT AVAILABLE For Cryogenic & insulated services As a primer coat in paint system 8 .
3 - DFT Range : 125 µm / coat /Sigmatherm 230
temperature, water and chemical
resistance.
Jotamasic 80 (alternative
Two-component polyamide epoxy . High 1 - Minimum Volume Solid : 80 % Rust-O-Cap /Sigmacover product surface tolerant PENTASEAL RUST COVER Carboguard 890 For use as a general anti-corrosive primer in
10 Inert Pigment Hempadur Mastic 47550 KemGuard 555XL NOVA 2000 Advoguard 2285 HS
Build & High Volume Solid 2 -DFT Range : 125 -200 µm / coat 620 polyamine based product with 100 high thickness paint system
80% volume solid)
1 - Minimum Volume Solid : 58 % Carboguard 893 SG

Anti Corrosive Zinc Apcodur CP 681 / GALVANITE No. For Special requirement, not assigned with
11 Two-component polyamide epoxy primer. 2 - Suitable for galvanised surface, SS, Al Penguard Primer Hempadur primer 1530C KemOxy 301G PENTASEAL UNICOAT 50 Advashield Nieblast DTM (Only For Galvsanised For SS, GI, Al.
Phosphate Sigmacover 280 200PRIMER painting systems.
3- DFT Range : 50 -60 µm / coat Surface)
>For SPLASH ZONES fabricated in Shop.
2 -DFT Range : 400-600 µm / coat
Apcotide 1200 / Hempadur Multi-strength Advashield Glass-flake >For interior lining for crude oil and fuel oil For Special requirement, not assigned with
12 Inert Chemically Amine-adduct cured epoxy coating 3- Glassflake reinforced NOT AVAILABLE KemOxy 5014 NOT AVAILABLE PENTAZONE 900GF Carboguard 690 GF
Sigmashield 880 GF 35870 Coating 511 GLF storage tanks. painting systems.
Treated Glass 4- Self-priming
Flakes 5 - High build & High Volume Solid
2 -DFT Range : 400-600 µm / coat >For SPLASH ZONES
3- Glassflake reinforced >For jetty pilings and working decks.
Apcotide 1200 / Hempadur Multi-strength Advashield Glass-flake For Special requirement, not assigned with
13 Inert Chemically Amine-adduct cured epoxy coating 4 - Suitable for early water exposure Marathon 500 KemOxy 5014 NOT AVAILABLE PENTAZONE 900GF Carboguard 690 GF >For interior lining for crude oil and fuel oil
Sigmashield 880 GF 35870 Coating 511 GLF painting systems.
Treated Glass 5 - Suitable for curing under water. storage tanks.
Flakes 6- Self-priming & surface Tolerant.
7 - High build & High Volume Solid
PENTASEAL RUST COVER
Two-component high build polyamide 1 - Minimum Volume Solid : 80 %
Anti Corrosive Zinc Rust-O-Cap /Sigmacover Penguard HSP ZP 100 or For Special requirement, not assigned with
14 epoxy primer containing zinc phosphate as 2 - Suitable for stainless steel surface Hempadur Mastic 47550 NOT AVAILABLE NOT AVAILABLE Advashield Nieblast DTM NOT AVAILABLE For use as a general anti-corrosive primer
Phosphate 620 (DFT Range 60-250 µm) PENTASEALUNICOAT 50 painting systems.
corrosion inhibiting pigment 3- DFT Range : 125-200 µm / coat
FOR SS
As a primer in premium high performance

1 - Minimum Volume Solid : 60 % Apcodur Rapid Recoat ZP
15 Inert pigment Two-component polyamide epoxy Penguard Primer Hempadur Fast dry 17410 KemOxy 301 HB UNIVAN NT PENTADUR 5521 Advoguard 1255 HB Carboguard 191 HB anti-corrosive systems. Can be a substitute
2 -DFT Range : 50 -60 µm / coat Primer / Sigmacover 240
for the inorganic zinc silicate primer
Apcodur Rapid Recoat ZP

1 - Minimum Volume Solid : 60 % For Special requirement, not assigned with
16 Redoxide Zinc Free Two-component polyamide epoxy Primer / Sigmacover 246- Penguard Primer Hempadur Primer 1530C KemOxy 301 HB UNIVAN NT PENTADUR HB RO 8530 Advoguard 1280 Carboguard 893
2 -DFT Range : 50 -60 µm / coat painting systems.
RO

Two-component, high-build, Solvent Free 2 -DFT Range : 200 -300 µm / coat Alternate to Coaltar Solvent less epoxy.
Apcoguard SF 722 This is a very good alternate to solventless
17 Inert Pigment polyamine cured 3- Flash point - 100 Deg C NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE Advoguard 3360 PHE Carboguard 703 BV Uhde uses this product for Tank internal
/Sigmaguard CSF 650 coaltar coating,
epoxy coating 4- Specific gravity: 1.3 kg/litre coating.
5- VOC : Less than 0.1 lbs/US gallon

Quick-drying, zinc phosphate pigmented 2 -DFT Range : 30 -50µm / coat Apcomin HB ZP Primer Alkyd primer . Not being specified in the
18 Zinc phosphate Pilot QD Primer Hempalin Primer NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE
Alkyd primer 3 - Approved as a low flame spread material. According to IMO resolution MSC /Sigmarine 28 current Uhde paint specs
61 (67):
Advolite 1141 BT
PENTANOL HIGH BUILD (Bitumen) & Advolite Not being specified in the current Uhde paint
19 Bituminous base paint Asian Bituminous Coating NOT AVAILABLE NOT AVAILABLE KemGuard 588 HB BITUMEN SOLUTION B NOT AVAILABLE
8022 3650 BTP (Bitumen specs
Phenolic)
507 of 1528
1.0 MTPA ALUMINA REFINERY NALCO NAL 6695-EQS-G00-EC-0007 66-6695
STREAM-5
Appendix D
COLOUR CODING FOR PIPELINES
Rev 01 Page 1 of 2
1 Colouring scheme shall be as follows 01

01
SR. FLUID GROUND FIRST IS Code RAL COLOUR SECOND IS Code RAL COLOUR
NO COLOUR COLOUR (IS 5-1978) NO. COLOUR (IS 5-1978) NO.
BAND BAND
1. Cooling water -- French Blue 166 RAL 5007 --
2. Raw water -- White Self Standard Self Standard --
3. Potable (drinking) water -- French Blue 166 RAL 5007 Canary Yellow 309 RAL 1018
4. Service water/cooling -- Canary Yellow 309 RAL 1018 --

tower make-up
5. D.M. water / process -- Light Orange 557 RAL 2000 --
water / BFpW
6. Emergency cooling -- French Blue 166 RAL 5007 Signal Red 537 RAL 3001
water
7. Plant air -- -- --
8. Instrument air -- -- --
9. L.P. Steam -- Silvery Grey 628 RAL 7001 --
10. M.P. Steam -- Red --
11. L.P. Condensate -- Sea Green 217 RAL 6017 --
12. M.P. Condensate -- Canary Yellow 309 RAL 1018 --
13. Nitrogen L.P. & H.P. -- Black Self Standard Self Standard --
Nitrogen high purity --
14. Light Orange 557 RAL 2000 --
(Pacol N2)
15. Hydrogen -- -- --
16. F.O. / LSHS -- Black Self Standard Self Standard --
508 of 1528
SR. FLUID GROUND FIRST IS Code RAL COLOUR SECOND IS Code RAL COLOUR
NO COLOUR COLOUR (IS 5-1978) NO. COLOUR (IS 5-1978) NO.
BAND BAND
17. Hot oil -- Light Brown 410 RAL 8008 --
18. LPG Liquid -- -- --
19. LPG Gas -- Canary Yellow 309 RAL 1018 --
20. N-Paraffin -- -- --
21. LAB -- -- --
22. HAB -- Black Self Standard Self Standard --
23. N. Pentane -- -- --
24. Benzene -- -- --
25. HSD -- Brilliant green 221 RAL 6001 --
26. Flare header -- -- --
27. Waste water -- -- --
28. 33% HCL -- -- --
29. 48% NaOH -- Black Self Standard Self Standard --
30. All process lines without -- -- --

insulation
All insulated process --
31. -- --
lines
32. Benzene drag -- Black Self Standard Self Standard --
509 of 1528
UHDE-STANDARD
Erection UN
9257-01
PROTECTIVE COATING AGAINST CORROSION Part 1 (M)
Page 1 of 9
[Modified: 29/08/2008]
Contents
Page
1 Scope ………………………………………………………………………………. 1
2 Technical documents …………………………………………………………….. 1
3 General requirements ……………………………………………………………. 1
4 Surface preparation ……………………………………………………………… 2
4.1 Unalloyed and low alloy steel …………………………………………………… 2
4.2 Galvanized steel ………………………………………………………………….. 3
4.3 Austenitic CrNi steel ……………………………………………………………… 4
4.4 Aluminium …………………………………………………………………………. 4
4.5 Other non-ferrous metals ………………………………………………………… 4
5 Application of the coating materials …………………………………………….. 4
5.1 General requirements ……………………………………………………………. 4
5.2 Prime coat …………………………………………………………………………. 5
5.3 Subsequent layers ……………………………………………………………….. 5
6 Checking the coating work ………………………………………………………. 6
6.1 Surface preparation ………………………………………………………………. 6
6.2 Visual check of the coating ……………………………………………………… 7
6.3 Wet film thickness ………………………………………………………………… 7
6.4 Dry film thickness ………………………………………………………………… 7
6.5 Degree of hardening ……………………………………………………………… 7
6.6 Mechanical testing (Chip testing / cross cut test)………………………………. 7
6.7 Colour of the top coat ……………………………………………………………… 8
7 Specimen surfaces ………………………………………………………………. 8
1 SCOPE
This recommendation applies to the painting (corrosion protection) of steel structures, equip-
ment, vessels, machinery and pipelines laid above ground. It contains general requirements for
surface preparation and application of coating materials. This recommendation will be supple-
mented by special instructions, if necessary.
Deviations from this recommendation shall be agreed upon in writing between the Orderer and
the Contractor.
2 TECHNICAL DOCUMENTS
The extent of work to be performed is indicated in the Bill of Material. Data regarding the sur-
face preparation and coating materials are compiled in the Appendix for “Painting Systems” in
Painting Specification.
The maximum allowable working temperatures for equipment, vessels, pipelines, etc. are indi-
cated in the equipment or piping specification.
For the treatment of the coating materials (mixing, diluting, application), the manufacturer’s
instructions shall be observed.
3 GENERAL REQUIREMENTS
For the storage of coating materials and solvents, Uhde standard UN 9250-01 Part 1(M) shall
apply. Moreover, the manufacturer’s instructions for transport and storage as well as the appli-
cable local rules for the storage of inflammable liquids (e.g. thinners) shall be observed.
© 2008 UHDE INDIA Technical discipline: MQ

510 of 1528
UHDE-STANDARD
Erection UN
9257-01
Page 2 of 9
The Contractor shall supply coating materials and solvents to the site only in hermetically
sealed and undamaged containers. The containers shall bear the manufacturer’s label. When
handling coating materials and solvents, the specified measures for the prevention of fire and
sudden deflagration, the statutory safety regulations and the manufacturer’s instructions shall
be observed. Heat, open fire and sparks shall be avoided at all events in the immediate sur-
rounding of the working place.
Solvents used shall not be detrimental to health. When solvents are used, adequate ventilation
shall be ensured. Only non-sparking tools shall be used in the vicinity of inflammable liquids or
vapours.
The surfaces to be coated shall meet the requirements specified in this recommendation. The
Contractor shall inform the site management of any preparatory work carried out improperly or
omitted by other contractors. The personnel performing the coating wok shall not walk or stand
on insulated equipment, pipes of small diameters, cable racks and the like.
The hand-wheels of valves, machinery etc. shall not be actuated. If a hand-wheel should be
actuated unintentionally, the site management shall be informed immediately.
The Contractor shall adequately secure his working area (e.g. by cordoning off) and shall mark
freshly coated equipment (e.g. by warning signs).
For coating work to be performed during plant operation, the written approval by the site man-
agement shall be obtained prior to commencement.
4 SURFACE PREPARATION
The surfaces to be coated shall be free from contamination (e.g. welding slag, welding spatter,
dust, oil, grease, salt, mill scale, laitance, rust, old coatings). Surface defects (e.g. cracks,
lamination, burrs, pitting) shall he removed by suitable methods. Sharp edges (e.g. saw cuts,
oxygen cutting) shall be adequately rounded by grinding.
Prior to any further surface preparation, oil, grease, drilling emulsions, cutting emulsions and
preservation agents shall be carefully removed by high pressure washing with mild alkaline wa-
ter detergents. The cleaned surfaces shall be washed off with drinking water.
After surface preparation, contact surfaces of structural joints (e.g. of steel structures) with
high-strength bolts shall be adequately protected until bolting.
Further surface preparation may be carried out using different methods depending on the mate-
rial of the equipment.
4.1 Unalloyed and low-alloy steel
The surfaces shall be cleaned by blasting. Unless prohibited under local rules, blasting materi-
als such as steel shot, steel grit, sand of high hardness (e.g. corundum, quartz, olivine) or slag
may be used. For blasting, dry oil-free compressed air shall be used. The mean peak-to-valley
height of the blasted surface should be 40 to 60 µm.
Table 1 Attainable peak-to-valley heights
Blasting material Grain size in mm Max. peak-to-valley height in µm

1)
Mineral material (e.g. sand, slag) 0.4 – 1.2 40 - 60
1)
Metallic material 0.2 – 1.0 40 – 60
2)
Coarse sand 1.40 70
2)
Steel shot (spherical grain) 1.20 90
2)
Steel grit (edged grain) 1.40 200
1) Continuous grading 2) Single grain size
511 of 1528
UHDE-STANDARD
Erection UN
9257-01
Page 3 of 9
If the mean peak-to-valley height exceeds the specified dry film thickness of the prime coat, the
Contractor shall inform the site management. The Contractor shall not commence with the
application of the coating materials until the Orderer has decided on an adequate increase of
the film thickness.
Unless otherwise indicated in the technical specification, steel surfaces having a maximum
allowable working temperature of ≤ 200 °C shall be blasted according to preparation grade
Sa 2 ½. In the case of a maximum allowable working temperature of > 200 °C, and in the case
of surfaces which come into permanent contact with water (e.g. underwater coating), blasting
according to preparation grade Sa 3 is required.
Table 2 Preparation grades
Preparation grade Standard designations according to

EN, DIN, ISO, SIS SSPC
Thorough wire-brushing or power tool grinding St 3 SP 3
Light blast cleaning Sa 1 SP 7
Thorough blast cleaning Sa 2 SP 6
Very thorough blast cleaning Sa 2½ SP 10
Blast cleaning to pure metal Sa 3 SP 5
SIS = Sveriges Standardiseringskommission, Sweden
SSPC = Steel Structure Painting Council, USA.
Only if approved by the site management, cleaning according to preparation grade St 3 is

allowed for field welds, connecting elements (e.g. bolts, nuts, washers) and for touching up
small areas with a maximum allowable working temperature of < 150 °C. Chemical derusting is
not permitted.
Surfaces ground to a large extent shall also be cleaned according to the preparation grade
specified or the material concerned. If zinc dust prime coats are used, the surface shall addi-
tionally be blasted to guarantee a sufficient roughness of the surfaces.
Blasting materials shall be stored in a dry place and carefully covered. Blasting work shall be
performed without impeding the activities of other contractors. After blasting, the blasting mate-
rial shall be properly removed from the cleaned surface (e.g. by vacuum cleaner, compressed
air, brush). After the work has been finished, the working area shall be cleaned and the blast-
ing material removed.
Blasting work within a plant shall be performed by suitable methods (e.g. Vacublast), using
blasting material with a low dust content, shielding, and vacuum devices, to avoid spreading of
dust as much as possible.
Prior to blasting, the surfaces that are not to be coated (e.g. markings, designation plates,
flange faces, sight glasses) shall be appropriately protected.
Whenever the development of dust and contamination has to be avoided, the wet blasting
method may be applied with the approval of the site management. Inhibitors shall be added to
the mixture of drinking water and blasting material to prevent rusting for a certain time after
blasting. The wet blasting method shall not be applied to surfaces which later come into
permanent contact with water.
At ambient temperatures of ≤ 5 °C or a relative air humidity of > 80%, blasting may only be per-
formed if appropriate protective measures (e.g. tent) are taken.
4.2 Galvanized Steel
Galvanised surfaces shall be degreased preferably by high-pressure washing with suitable wa-
ter detergents followed by rinsing with drinking water in order to remove preservation agents,
zinc salts and fluxing agent residues.
512 of 1528
UHDE-STANDARD
Erection UN
9257-01
Page 4 of 9
Surfaces which are too smooth (mean peak-to-valley height ≤ 10 µm) or heavily contaminated
shall be roughened or cleaned by sweep blasting, whichever applies. Zinc salts shall be
removed prior to sweep blasting.
Preservation agents applied after galvanisation shall be completely removed by using suitable
procedures.
4.3 Austenitic CrNi steel
The surfaces shall be degreased or preservation agent shall be removed. In case of surfaces
with a mean peak-to-valley height of ≤ 10 µm, the site management will decide whether rough-
ening by sweep blasting with a non-metallic blasting material is necessary.
4.4 Aluminium
The surfaces shall be degreased or preservation agent shall be removed. Salts shall be
removed by light grinding.
4.5 Other non-ferrous metals
The surfaces shall be degreased or preservation agents shall be removed. Salts shall be
removed by slight brushing and rinsing with drinking water. The cleaned surfaces should be
roughened by light grinding or sweep blasting with a non-metallic blasting material. Sweep
blasting shall only be performed with the approval of the site management.
5 APPLICATION OF COATING MATERIAL
5.1 General requirements
Surfaces to be coated shall be dry and free from any contamination. To prevent condensation,
the surface temperature shall be at least 3 °C above the dew point of the ambient air during
coating. A suitable instrument like sling psychrometer shall be used to measure the relative air
humidity.
To avoid defects of the coating (e.g. blisters, pores, inclusion of thinner, boiling of thinner) and
changes of the intervals between coats, the surface temperature should be in the range
recommended by the paint manufacturer during coating, hardening, and curing of the coating
materials.
Unless otherwise specified by the manufacturer, coating materials may be applied at an ambi-
ent temperature of ≥ 4 °C and a relative air humidity of 50 to 90%. Coating materials may be
applied at temperatures of < 4 °C and > 30 °C with the written approval of the manufacturer
only. In the case of certain coating materials (e.g. ethyl zinc silicate), the required time for
hardening, which depends on the air humidity, shall be observed. Two-component coating ma-
terials shall be properly mixed with motor driven mixers.
Coating work shall be interrupted when corrosive gases or dust are encountered or in the case
of fog, strong wind, rain or snow. Before recommencing the work, the coating already applied
shall be checked for damage. Damaged surfaces shall be repaired.
Vessels and pipelines should not be coated prior to the pressure test. However, if by order of
the site management, the coating is started prior to the pressure test, the welds and an area of
approx. 50 mm width on both sides of the welds shall not be coated until pressure testing is
finished.
The coating materials shall be applied with a uniform thickness. Corners, edges, bolt heads,
etc. which are not easily accessible shall be pre-coated with small brushes. Thinners shall only
be used if this is specified or recommended by the manufacturer of the coating material. Thin-
ners shall not be admixed in excess of the specified or recommended amount.
513 of 1528
UHDE-STANDARD
Erection UN
9257-01
Page 5 of 9
Suitable equipment shall be used for spray application. Compressed air spraying units may
only be employed with the approval of the site management. The spraying nozzles shall be
used in accordance with the recommendations of the paint manufacturer and employed in such
a way as to attain the required surface quality of the coating. Prime coats must not be applied
by rollers. For the application of zinc silicate prime coats, brushes shall not be used.
Certain coating material may be applied with a brush upto a dry film thickness of 70 µm. More-
over, brushes should be used if spraying would cause considerable losses (spraying mist). In
the case of coating materials based on physical drying (e.g. chlorinated rubber), brushes
should not be used because the film which is already dry might partly dissolve when the next
(wet) layer is applied.
Equipment surfaces which are not readily accessible or totally inaccessible after erection shall
be completely coated prior to erection. Items to be embedded in concrete shall be provided with
a prime coat.
Movable components of machinery, name and boiler plates, stems of valves, sight glasses, and
other items not to be coated shall be carefully covered. Coatings applied by mistake shall be
removed.
Contact surfaces of structural joints (e.g. of steel structures) with high-strength bolts shall nor-
mally not be coated, unless a suitable prime coat is specified. The external surfaces of the
joints shall not be released for coating until the bolts have been tightened and checked.
Table 3 Dew points

1)
Relative air Dew points of the ambient air in °C
Humidity Temperature of the ambient air in °C
in %
50 45 40 35 30 25 20 15 10 5 0
100 50 45 40 35 30 25 20 15 10 5 0
95 49 44 39 34 29 24 19 14 9 4.5 -0.5
90 48 43 38 33 28 23 18.5 13.5 8.5 4 -1
85 47 42 37 32 27 22.5 17.5 12.5 7.5 3 -2
80 45.5 40.5 36 31 26 21.5 16.5 11.5 6.5 2 -2.5
75 44.5 39.5 34.5 30 25 20.5 15.5 10.5 6 1 -3.5
70 43 38.5 33.5 28.5 24 19 14.5 9.5 5 0 -4
65 41.5 37 32 27.5 22.5 18 13 8.5 4 -1 -5
60 40 35.5 30.5 26.5 21.5 16.5 12 7.5 2.5 -2 -6
55 38.5 34 29 24.5 20 15.5 11.5 6 1.5 -3 -7
50 36.5 32 27.5 23 18.5 14 9.5 4.5 0 -4 -8
45 34.5 30.5 25.5 21 17 12 7.5 3 -1 -5 -9
40 32.5 28.5 24 19.5 15 10.5 6 1.5 -2.5 -6.5
35 30 26 21.5 17.5 13 8.5 4 -0.5 -4
30 28 23.5 19 15 10.5 6 2 -2 -6
25 24.5 20.5 16 12 8 3.5 0
20 21 17 13 8.5 4.5 1.5
15 16.5 12.5 8.5 4.5 0.5
10 10 6.5 2.5 -1
1) Figures rounded to 0.5 °C
514 of 1528
UHDE-STANDARD
Erection UN
9257-01
Page 6 of 9
5.2 Prime coat
For steel structures, a shop primer may be used with the approval of the Orderer. The shop
primer shall have adequate properties relating to drying, weldability and application of further
coats. In case of doubt, suitability tests shall be performed.
Surfaces cleaned according to preparation grade Sa 2 or Sa 2 ½ shall be coated within

4 hours, surfaces cleaned according to preparation grade Sa 3 shall be coated within an hour.
Cleaned surfaces on which a rust film has formed shall be re-blasted by the specified method.
Surfaces cleaned according to preparation grade St 3 shall be coated immediately. The prime
coats shall be applied with a brush.
5.3 Subsequent layers
The interval between shop coating and site coating as well as the time required for hardening
or curing specified by the manufacturer of the coating material shall be observed.
Equipment supplied with a prime coat shall be checked for damage and contamination of the
coating on site.
Damaged areas shall be repaired according to the particular painting system. The adjacent
undamaged area shall be roughened by approx. 30 mm to ensure proper adhesion of the repair
coating. Small areas may be cleaned according to preparation grade St 3. In this case, the sur-
face shall not be polished. Large areas shall be cleaned by blasting.
Prior to the application of further layers, the undamaged surfaces shall be cleaned (e.g. by
blasting with dry oil-free compressed air). Oil and grease shall be removed with suitable sol-
vents. Drinking water shall be used for rinsing.
In the case of zinc silicate coatings, the zinc salts shall be removed by proper brushing and
washing with drinking water. Large deposits of zinc salts shall be removed by additional sweep
blasting.
In the case of equipment and structures with galvanized components, the coating shall not be
applied until the surface preparation of the galvanized components has been completed.
The shades of colours of successive layers should be distinguishable to facilitate easy

checking.
6 CHECKING THE COATING WORK
The surface preparation and coating work shall be regularly checked. Tests and measurements
shall be performed prior to the final acceptance of the coating work. An acceptance certificate
covering checks, tests and measurements performed shall be prepared.
The equipment manufacturer shall be responsible for checking the coating work regularly in the
workshop if painting is included in his scope of supplies. The manufacturer of the coating ma-
terial and the Contractor for site coating may perform additional checks in the workshop to sat-
isfy themselves about the proper performance of surface preparation and coating work.
The Contractor shall be responsible for checking the coating work regularly on site. Prior to
starting his work, the Contractor shall satisfy himself about the proper condition of the coatings
applied by the manufacturers of the equipment. The site management shall be notified in writ-
ing in due time of any defects detected (e.g. inadequate film thickness, damage).
At the request of the site management, the Contractor shall apply inscriptions with the following
data to the equipment coated by him:
• Number of the painting system,

• month and year of the performance of the work,
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• type of surface preparation,

• name of Contractor’s firm.
2
This inscription shall be applied by weather-proof paint for every 5000 m of coated surface at a
clearly visible location.
6.1 Surface preparation
The preparation grade of steel surfaces should be checked according to the specified
standards. Surfaces shall be visually checked for any mill scale remnants. The assessment of
the preparation grade and the peak-to-valley height shall be done by visual comparison with a
profile comparator (e.g. Keane Tutor Profile Comparator) or by measurement with a needle
probe. The cleanliness of blast-cleaned surfaces may be checked with adhesive tape and picks
up dust or dirt particles which are clearly visible. Soluble iron salts should be identified accord-
ing to BS 5493, whenever this might have a detrimental effect on the painting system con-
cerned.
6.2 Visual check of the coating
Prior to any other test, the coating shall be subjected to a visual check. The visual check
should be limited to coating defects (e.g. spray drizzle, areas left uncoated, inclusions of dirt,
blisters, porosity, sags, tears, brush marks).
Areas in which the blasting material has remained under the coating shall be blasted again and
recoated. Defects of the coating shall be repaired by the Contractor without delay at the instruc-
tion of the Orderer.
6.3 Wet film thickness
The wet film thickness shall be measured on a random basis with a comb-type gauge within a
few seconds after applying the coating material. Comb-type gauges shall be selected in relation
to the wet film thickness. The comb-type gauge shall be firmly pressed into the wet coat per-
pendicularly to the coated surface.
6.4 Dry film thickness
The dry film thickness shall be measured after adequate hardening or curing of the coating. To
observe the specified total film thickness, the thickness of each individual layer should be
measured.
The film thickness should be measured by means of a permanent-magnetic (e.g. Mikrotest,

Elcometer) or an electro-magnetic test set (e.g. Diameter). The test set shall be regularly cali-
brated and checked for proper functioning according to the manufacturer’s instructions.
For the determination of the dry film thickness, 22 measurements shall be taken in the respec-
tive area. The lowest and the highest value shall be disregarded. The mean dry film thickness
calculated from the remaining measurements shall be higher than the specified value. 5% of
the measured values may be below the specified film thickness by ≤ 20%.
The specified film thickness shall also be attained at corners, edges, and bolt heads.
Dry film thicknesses shall not exceed the following upper limits:
• 140 µm in case of zinc dust prime coats.
• 200% of the nominal film thickness in case of one and multi-layer coating systems for al-
lowable operating temperatures of ≤ 200 C.
• 125% of the normal film thickness in case of one and multi-layer coating system for allow-
able operating temperatures of > 200 C.
Deviations in the film thicknesses of the individual layers of a coating system may be set off:
• if justified in individual cases and with approval of the site management.
• If upper limits as mentioned above will not be exceeded.
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6.5 Degree of hardening
If required, the degree of hardening of two-component coating materials, zinc silicates and ep-
oxy resins can be determined with the aid of solvents (e.g. methyl ethyl ketone). When a piece
of cloth saturated with solvent is rubbed over the coating, the coating shall not soften and dis-
colour. Details of the test procedure shall be agreed upon by the Contractor, the site manage-
ment and the manufacturer of the coating material in due time.
6.6 Mechanical testing (chip testing / cross cut test)
Both procedures allow a limited evaluation of the following quality criteria:
• Adhesive strength of the coating.

• Elasticity of the coating (e.g. brittleness due to wrong mix proportions in the case of two
component coating materials).
• Proper composition of coats.
• Proper surface preparation.
Damaged areas in which mechanical testing was performed shall be repaired according to the
particular painting system.
6.7 Colour of top coat
The colour of the top coat shall be checked by comparison with a colour chart (e.g. RAL 840
HR, Munsell Book of Colors). Slight deviations of the colour from the colour chart are permissi-
ble.
7 SPECIMEN SURFACES
Specimen surfaces of approximately 1 m2 should be prepared for the determination of the

causes of defects at the coating that might occur within the guarantee period.
The surface preparation and coating of the specimen surfaces shall correspond to the particular
painting system. One specimen surface should be prepared for each coated surface less than
2
or equal to 10000 m . In the case of finish-coated equipment and steel structures, the speci-
men surfaces shall also be prepared in the manufacturer’s workshop.
Representatives of the Contractor, of the manufacturer of the coating material and of the
Orderer shall witness the preparation of the specimen surfaces.
The locations of the specimen surfaces shall be selected on the basis of the following criteria:
• Appropriate consideration of the principal wind direction and solar radiation,

• representative mean strain of the component,
• existing protection against abnormal operating conditions of the plant,
• consideration of large-size equipment and small structures in correct proportion,
• existing protection against dripping water and accumulation of water,
• good access,
• existing protection against mechanical strains (e.g. caused by foot traffic).
The preparation of specimen surfaces shall be recorded. The specimen surfaces shall be num-
bered with weather-proof paint.
In the case of corrosion damage at coatings in the area of the nearest specimen surface which
do not occur on the specimen surface, the Contractor shall be liable for rectifying the damage.
If the same or similar type of damage is found on the nearby specimen surface, the manufac-
turer of the coating material shall be responsible for rectifying the damage.
If for whatever reason, the specimen surface cannot be taken for the evaluation of the causes
of the damage, the next nearby specimen surface shall be taken instead.
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During the guarantee period, the specimen surfaces shall meet the following quality require-
ments:
• Degree of corrosion ≤ Ri 1 according to DIN 53210 / ISO 4628,

• no peeling,
• no blisters,
• no cracks.
In connection with the preparation of specimen surfaces, the site management can require the
determination of the yield of the coating materials. The coating materials shall be taken from
lead-sealed containers.
Reference Standards
Uhde Standards:
UN 9250-01 Part 1(M) Erection; Warehousing
DIN Standards:
DIN 53210 Designation of degree of rusting of paint surfaces
EN ISO Standards:
EN ISO 12944-4 Paints and varnishes; Corrosion protection of steel structures by protective
paint systems; Types of surface and surface preparation
Other Standards:
ISO 4628-1 Paints and varnishes; Evaluation of degradation of paint coatings;
Designation of intensity, quantity and size of common types of defect;
General principles and rating schemes
BS 5493 Code of practice for protective coating of iron and steel structures against
corrosion
RAL 840 HR Chart of RAL Colours
US Code Munsell Book of Colours
SIS 05 59 00 Preparation of steel substrates before application of paints and related
products
ISO 8501 Visual assessment of surface cleanliness
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Montage; Aufmaß von Korrosionsschutzarbeiten Supersedes UN 9257-91 Part 1, 01-06
Contents
Page
1 Scope .................................................................................................................................................................... 1
2 Units, Abbreviated Terms ................................................................................................................................... 1
2.1 Units....................................................................................................................................................................... 1
2.2 Abbreviated Terms................................................................................................................................................. 2
3 Technical documents .......................................................................................................................................... 2
4 General notes to quantity surveying.................................................................................................................. 2
5 Quantity survey of steel structures.................................................................................................................... 2
6 Quantity survey of process equipment.............................................................................................................. 4
6.1 General notes ........................................................................................................................................................ 4
6.2 Round vessels ....................................................................................................................................................... 4
6.2.1 Circular surfaces .................................................................................................................................................... 5
6.2.2 Oval surfaces ......................................................................................................................................................... 5
6.2.3 Cylindrical shell surfaces ....................................................................................................................................... 5
6.2.4 Conical surfaces .................................................................................................................................................... 5
6.2.5 Spherical surfaces ................................................................................................................................................. 6
6.2.6 Composite surfaces ............................................................................................................................................... 7
6.3 Rectangular vessels............................................................................................................................................... 7
6.3.1 Rectangular surfaces ............................................................................................................................................. 7
6.3.2 Trapezoidal surfaces.............................................................................................................................................. 8
6.3.3 Pyramidal surfaces ................................................................................................................................................ 8
6.3.4 Composite surfaces ............................................................................................................................................... 9
6.4 Equipment.............................................................................................................................................................. 9
6.5 Machinery .............................................................................................................................................................. 9
6.6 Ducts, chutes ....................................................................................................................................................... 10
7 Quantity survey of piping.................................................................................................................................. 11
7.1 General notes ...................................................................................................................................................... 11
7.2 Straight pipes ....................................................................................................................................................... 11
7.3 Fittings ................................................................................................................................................................. 11
7.3.1 Elbows ................................................................................................................................................................. 11
7.3.2 Tees..................................................................................................................................................................... 12
7.3.3 Reducers ............................................................................................................................................................. 12
7.4 Flanges ................................................................................................................................................................ 12
7.5 Valves .................................................................................................................................................................. 12
7.6 Pipe supports ....................................................................................................................................................... 12
8 Quantity survey of materials............................................................................................................................. 13
9 Damages to pre-coated surfaces...................................................................................................................... 14
9.1 Examples for damages ........................................................................................................................................ 14
Reference standards ......................................................................................................................................................... 15
Amendments ...................................................................................................................................................................... 15
1 Scope
This Uhde Standard (UN) applies to the design and construction of industrial and chemical plants. It contains
statements for quantity surveying of areas protected by coatings.
2 Units, Abbreviated Terms

2.1 Units
Table 1. Units
General SI-units
Dimensions mm
UF 19 ST-F01 M01 D 06-04
Weights kg, t
Weight of sections kg/m
Surface calculation coefficient m²/t
14.05.09 Kuhnke 25.05.09 Jakob 19.05.09 Fellner 26.05.09 Dr. Lazaridis

Date Prepared Date Checked Date Standardization Date Approved
© 2009 Uhde GmbH

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2.2 Abbreviated Terms

A = surface
AS = surface of supporting structures
b, B = width
d, D = outside diameter
h, H = height
l, L = length
r, R = radius
s, S = side length of a cone
U = circumference
3 Technical documents
The technical documents provided (e.g. quantity take-offs, isometrics, parts lists, drawings, technical specifi-
cations) shall be binding for the quantity survey, on the precondition that the services were performed in con-
formance with these documents. If such documents contain no compilations of quantities they shall be com-
piled based on the technical documents. If no documents exist about the items in question the service con-
cerned shall be measured during or after execution. This also applies if the execution deviates from the tech-
nical documents.
Modifications made without the approval of the site management shall be excluded from the measurement.
4 General notes to quantity surveying

The services and their estimated scope are described in the bill of quantities. These descriptions shall always
be understood as complete services including the necessary auxiliary services. Auxiliary services
(e.g. storage of painting materials, provision of scaffolding, cleaning of the surfaces to be painted) shall only
be included in the quantity survey if they are listed as individual items in the bill of quantities.
The quantity survey shall be prepared for each plant unit. Side calculations shall be attached to the quantity
survey.
Surfaces of fasteners (e.g. bolts, nuts, rivets, washers) shall not be measured. The areas covered by the fas-
teners and the holes required for the fasteners are considered by the stipulations of sections 5 to 7.
5 Quantity survey of steel structures

Quantity survey of steel structures shall be performed according to parts lists or based on the weight installed.
According to parts lists the quantities shall be measured in terms of m² by using the values of Table 2 and
Table 3. They shall be adapted accordingly, if others than DIN sections are used.
Individual lengths shall be determined to an accuracy of 0.1 m. The quantity survey shall only include the pain-
ted surfaces of the sections.
UF 19 ST-F01 M01 D 06-04
Figure 1. Uncoated surfaces of steel sections

Raised pattern plates (e.g. checkered plates) shall be considered as plates with a flat surface.
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If the quantity survey bases on the weight installed, the individual weights shall be determined to an accuracy
of 0.01 t. The following values shall be used for computing the surfaces:
• 15 m²/t for heavy structures (weight of sections > 60 kg/m),
• 22 m²/t for medium-weight structures (weight of sections > 30 to 60 kg/m),
• 28 m²/t for light structures (weight of sections > 10 to 30 kg/m),
• 40 m²/t for very light structures (weight of sections ≤ 10 kg/m).
Anchoring elements, fasteners, shims and uncoated items shall not be measured.
Table 2. Surfaces of I-beams in m²/m
DIN 1025-1 DIN 1025-2 DIN 1025-3 DIN 1025-4 DIN 1025-5
Section symbol HE-B HE-A HE-M
I I PB I PBI I PBv I PE
80 0.304 0.328
100 0.370 0.567 0.561 0.619 0.400
120 0.439 0.686 0.677 0.738 0.475
140 0.502 0.805 0.794 0.857 0.551
160 0.575 0.918 0.906 0.970 0.623
180 0.640 1.04 1.02 1.09 0.698
200 0.709 1.15 1.14 1.20 0.768
220 0.775 1.27 1.26 1.32 0.848
240 0.844 1.38 1.37 1.46 0.922
260 0.906 1.50 1.48 1.57
270 1.04
280 0.966 1.62 1.60 1.69
300 1.03 1.73 1.72 1.83 1.16
320 1.09 1.77 1.76 1.87
320/305 1.78
330 1.25
340 1.15 1.81 1.79 1.90
360 1.21 1.85 1.83 1.93 1.35
380 1.27
400 1.33 1.93 1.91 2.00 1.47
450 1.48 2.03 2.01 2.10 1.61
500 1.63 2.12 2.11 2.18 1.74
550 1.80 2.22 2.21 2.28 1.88
600 2.32 2.31 2.37 2.01
650 2.42 2.41 2.47
700 2.52 2.50 2.56
800 2.71 2.70 2.75
900 2.91 2.90 2.93
1000 3.11 3.10 3.13
UF 19 ST-F01 M01 D 06-04
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Table 3. Surfaces of channels / Z-bars / T-bars and angles in m²/m

DIN 1026-1 DIN 1027 EN 10055 EN 10056-1
Section
symbol Section Equal Section Unequal
Channel Z-bar T-bar
symbol angle symbol angle
30 0.174 0.198 0.114 20 × 20 0.077
30 × 15 0.103 25 × 25 0.097
35 0.133 30 × 30 0.116 30 × 20 0.097
40 0.199 0.225 0.153 35 × 35 0.136
40 × 20 0.142 40 × 20 0.117
40 × 40 0.155
50 0.232 0.253 0.191 40 × 25 0.127
50 × 25 0.181 45 × 45 0.174 45 × 30 0.146
60 0.215 0.282 0.229 50 × 50 0.194 50 × 30 0.156
65 0.273 60 × 30 0.175
60 × 60 0.233
70 0.268 60 × 40 0.195
80 0.312 0.339 0.307 65 × 65 0.252 65 × 50 0.224
100 0.372 0.397 0.383 70 × 70 0.272 70 × 50 0.235
120 0.434 0.454 0.459 75 × 75 0.291 75 × 50 0.244
140 0.489 0.511 0.537 80 × 40 0.234
80 × 80 0.311
160 0.546 0.569 80 × 60 0.274
180 0.611 0.626 90 × 90 0.351
200 0.661 0.683 100 × 50 0.292
220 0.718 100 × 100 0.390 100 × 65 0.321
240 0.775 100 × 75 0.341
260 0.834 120 × 120 0.469 120 × 80 0.391
280 0.890 125 × 75 0.392
300 0.950 130 × 130 0.508
320 0.982 135 × 65 0.392
350 1.05 150 × 75 0.441
380 1.11 150 × 150 0.586 150 × 90 0.469
400 1.18 150 × 100 0.489
160 × 160 0.625
180 × 180 0.705
200 × 100 0.587
200 × 200 0.785
200 × 150 0.687
250 × 250 0.962
6 Quantity survey of process equipment

6.1 General notes
Painted surfaces of individual items of equipment and machinery shall be determined to an accuracy of
0.5 m². Cut-outs and openings of > 0.5 m² shall not be measured, i.e. they shall be regarded as non-coated
surfaces. Cut-outs and openings of ≤ 0.5 m² shall be disregarded for the quantity survey, i.e. they shall not be
deducted.
Painted insulation claddings shall be computed from the outer dimensions of the equipment or machinery,
increased by the insulation thickness.
Piping pertaining to equipment or machinery shall be measured according to section 7. Surfaces of supporting
structures, reinforcing members made of steel sections and the like shall be measured according to section 5.
For determining the surfaces, the formula given in sections 6.2 to 6.6 shall be used or adapted accordingly.
UF 19 ST-F01 M01 D 06-04
The abbreviations used in the formula are specified in section 2.2.
Surfaces of nozzles, manholes, vessel flanges and supporting brackets shall not be measured.
6.2 Round vessels

Quantities shall be measured in terms of m² with reference to the actual dimensions. The following formulae
are applicable to the various surfaces.
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6.2.1 Circular surfaces
A = 0.25 · π · D2
Figure 2. Circular surfaces

Conical heads and covers with angles of inclination ≤ 10° as well as dished heads shall also be considered as
circular surfaces.
As regards tanks and vessels on foundations, the bottom head surfaces shall only be included in the quantity
survey if they will be painted on site.
6.2.2 Oval surfaces
A=π·R·r
Figure 3. Oval surfaces

6.2.3 Cylindrical shell surfaces
A = π · D· H
Figure 4. Cylindrical shell surfaces

The height of conical heads and covers with angles of inclination ≤ 10° as well as of dished heads shall be
considered as cylindrical height.
6.2.4 Conical surfaces

Conical shell surfaces shall be considered as such whenever the angle of inclination is > 10°. The following
formulae apply to regular and irregular conical shell surfaces:
ratio D : d ≥ 10 Regular cone Irregular cone

A = 0.5 · π · D · S
S= 0.25 ⋅ D 2 + H2
UF 19 ST-F01 M01 D 06-04
ratio D : d < 10
A = 0.5 · π · (D + d) · S
0.25 ⋅ (D − d) + H2
2
S=
Figure 5. Conical surfaces

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Conical transitions of cylindrical shells with different diameters, where H ≤ 1 m and D : d ≤ 1.5 shall be consid-
ered as cylindrical shell surfaces.
Conical or pyramidal transitions from circular to angular cross sections, with D : b resp. D : l ≥ 10 and B : d
resp. L : d ≥ 10 shall be considered as a cone or a pyramid (see section 6.3.3). If the ratio is < 10, the quantity
survey shall be as for a truncated cone shell. The circumference of the rectangle shall be converted to a di-
ameter DT or dT.
A = 0.5 · π · S · (d + dT) dT = 0.64 · (b + l)
0.25 ⋅ (D − dT ) + H2
2
S=
A = 0.5 · π · S · (DT + d) DT = 0.64 · (B + L)
0.25 ⋅ (DT − d) + H2
2
S=
Figure 6. Transition surfaces
6.2.5 Spherical surfaces
A = π · D2
Figure 7. Spherical tank
The following applies to calottes (e.g. as tank roof):
A=2·π·R·H
H=R– R 2 − 0.25 ⋅ D 2
Figure 8. Tank roof with spherical surface

UF 19 ST-F01 M01 D 06-04
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6.2.6 Composite surfaces

For computing the total surface, use shall be made of the formula according to sections 6.2.1 through 6.2.5.
Verhältnis D : D ≤ 1.5
A = 0.25 · π · (D2 + d2) + π · D · H + π · d · h + 2 · π · D · L
Figure 9. Composite surfaces of cylindrical vessels (example)
Cut-outs in the skirt shall be taken into account as described in section 6.1.
A = 0.25 · π · D2 + π · D · H + 0,5 · π · D · S + AS
Figure 10. Composite surfaces of cylindrical vessels (example)
The cover surface A = 0.25 · π · D2 is omitted in the case of open vessels.
6.3 Rectangular vessels

Quantities shall be measured in terms of m² with reference to the actual dimensions. The following formulae
are applicable to the various surfaces.
6.3.1 Rectangular surfaces
A=L·B
Figure 11. Rectangular surfaces
Pyramidal covers with angles of inclination of ≤ 10° shall also be considered as rectangular surfaces.
UF 19 ST-F01 M01 D 06-04
As regards vessels on foundations, the bottom head surfaces shall be included in the quantity survey if they
will be painted on site. Cut-outs, openings, corners and the like of > 0.5 m² shall not be measured.
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6.3.2 Trapezoidal surfaces
A = 0.5 · H · (L + S)
Figure 12. Trapezoidal surfaces
6.3.3 Pyramidal surfaces

Pyramidal shell surfaces shall be considered as such whenever the angle of inclination is > 10°. The following
applies to regular and irregular pyramidal shell surfaces:
Front view Side view

ratio L : l or B : b ≥ 10
A=B·S+L·s
S= 0.25 ⋅ L2 + H2
s= 0.25 ⋅ B 2 + H2
Figure 13. Pyramidal surfaces
ratio L : l or B : b < 10
A = S · (B + b) + s · (L + l)
S= 0.25 ⋅ (L − l)2 + H2
s= 0.25 ⋅ (B − b)2 + H2
Figure 14. Surfaces of truncated pyramids
In the case of irregular pyramids and truncated pyramids, for S and s a mean value shall be determined.
Pyramidal transitions of different rectangles, where H ≤ 1 m and L : I or B : b ≤ 1.5, shall be considered as

rectangular surfaces.
UF 19 ST-F01 M01 D 06-04
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6.3.4 Composite surfaces

For determining the total surface, use shall be made of the formula according to sections 6.3.1 through 6.3.3.
Front view Side view
A = L · B + 2 · H · (L + B) + B · S + L · s + AS
Figure 15. Composite surfaces of rectangular vessels
The cover surface A = L · B is omitted in the case of open vessels.
6.4 Equipment
Quantities shall be measured in terms of m² with reference to the actual dimensions.
For the quantity survey, the individual equipment shall be divided into individual surfaces. The formula given in
sections 6.2 and 6.3 shall be used accordingly.
A = sum of all individual surfaces + A S
6.5 Machinery
Quantities shall be measured in terms of m² with reference to the largest dimensions.
For determining the largest dimensions, installed piping, electrical items, and instruments shall not be taken
into account.
The following applies to machinery and motors, which are mounted on a common base plate:
A = 2.5 · L · B + 1.8 · H · B + 1.8 · H · L
Figure 16. Surfaces of pumps and blowers

UF 19 ST-F01 M01 D 06-04
Machinery, gears, motors and the like without a common base plate shall be measured individually. The fol-
lowing note applies to each item:
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A = 1.8 · L · B + 1.8 · H · B + 1.8 · H · L
Figure 17. Surfaces of compressors and turbines
Cranes shall be compartmentalised into their components. Crane girders and end carriages shall be meas-
ured according to section 5. Crabs shall be considered as machines according to section 6.5 (machines with-
out common base plate).
Figure 18. Surfaces of cranes
Belt conveyors shall be measured according to section 5. Other conveying facilities (e.g. bucket elevators,
feed screws) shall be measured according to sections 6.4 and 6.5.
6.6 Ducts, chutes

Quantities shall be measured in terms of m² with reference to the outer dimensions.
Circular or angular ducts, chutes and the like shall be divided such that the formula according to sections 6.2
and 6.3 can be used.
The length of corner pieces and bends is deemed to be the length of the centreline.
A = (2 · B + 2 · L) · (H1 + H2 + H3 + 0,5 · π · R + H4 + 1,2 m)

UF 19 ST-F01 M01 D 06-04
Figure 19. Surfaces of ducts (example)
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The (sheet metal) flanges shall be considered as 0.15 m of straight duct or chute length. For internals
(e.g. gate valves, butterfly valves), their outer dimensions shall apply. Operating elements (e.g. levers) shall
not be measured.
In case of open channels or ducts the cover surface will be omitted. For the example above the first multiplica-
tion factor for the area calculation shall then be reduced to (B + 2 · L).
7 Quantity survey of piping

7.1 General notes
For the quantity survey, the values of Table 4 are binding. Parts not included in this table (e.g. caps, wel-
dolets) shall not be measured.
Classification of the piping into the corresponding nominal diameters shall be based on the outside pipe
diameter d.
Cut-outs and openings (e.g. for pipe nozzles) shall be included in the quantity survey.
Prefabricated piping (e.g. rubber-lined piping) shall be measured as field-fabricated piping.
Painted insulation claddings shall be computed from the outer pipe dimensions, increased by the insulation
thickness s. For simplifying the quantity survey, d + 2 · s may be replaced by the nearest larger (standard)
pipe outside diameter.
7.2 Straight pipes

Quantities shall be measured in terms of m with reference to the outside pipe diameter d.
Figure 20. Quantity survey of piping (example)
Straight pipe lengths shall be measured up to connecting welds of flanges, elbows, valves, reducers, tees, etc.
Referring to isometric drawings, the accuracy of the determination of lengths is given by the computer pro-
gramme.
If the quantity survey is performed on site, individual straight lengths shall be determined to an accuracy of 0.05 m.
7.3 Fittings
7.3.1 Elbows
Quantities shall be measured in terms of numbers with reference to the outside pipe diameter d, the standard
radius (based on the nominal size DN), and the elbow angle. For the surface per piece the values of Table 4
shall apply.
UF 19 ST-F01 M01 D 06-04
One-piece elbows with elbow angles differing from 90° shall be considered in case of:
• < 60° as ½ piece,
• ≥ 60° to 115° as 1 piece,
• > 115° to 160° as 1 ½ piece,
• > 160° as 2 pieces.
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7.3.2 Tees
Quantities shall be measured in terms of numbers with reference to the outside pipe diameter d. For the sur-
face per piece the values of Table 4 shall apply.
Only weld-in Tees shall be included in the quantity survey. Classification of the Tees shall be based on the
largest outside pipe diameter d.
7.3.3 Reducers
Quantities shall be measured in terms of numbers with reference to the outside pipe diameter d. For the sur-
face per piece the values of Table 4 shall apply.
Classification of the reducers shall be based on the larger outside pipe diameter d.
7.4 Flanges
Quantities shall be measured in terms of numbers with reference to the nominal diameter DN. For the surface
per piece the values of Table 4 shall apply.
The term “flanges” shall be deemed to include all types of flanges (e.g. welding neck flanges, lap joint flanges,
blind flanges) irrespective of their nominal pressure. The values of Table 4 are based on the maximum (stan-
dard) nominal pressure and include an extra charge for the shape of the flange.
7.5 Valves
Quantities shall be measured in terms of numbers with reference to the nominal diameter DN. For the surface
per piece the values of Table 4 shall apply.
The term "valves" shall be deemed to include all flanged components (e.g. check valves, gate valves, control
valves, sight glasses, strainers, level indicators), irrespective of their installed length and including their oper-
ating elements (hand wheels, levers).
Valves with DN > 500 shall be measured individually at site, because of their type-specific size of surface
areas. For computing the surface, the following formula (for a cuboid) shall be used:
A = 3 · L · D + 2 · L · H + 2 · D · H + D2
Figure 21. Quantity survey of a valve
Butterfly valves without flanges, valves with welding and with threaded ends shall be considered as
0.8 pieces.
7.6 Pipe supports

Quantities shall be measured according to section 5. If the quantity survey is based on weight, the value of
33 m²/t shall be used for computing the surfaces.
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Table 4. Surfaces of piping components
Nominal Outside Surfaces

size diameter Flanged Welded
Pipe 90° elbow Reducer Tee Flange
valve valve
DN D 1.5 DN 2.5 DN all PN all PN all PN
DIN ANSI DIN ANSI m²/m m²/St m²/St m²/St m²/St m²/St m²/St m²/St
8 ¼" 13.5 13.7 0.04 0.01 0.01 0.01 0.01 0.03 0.06 0.05
10 ⅜" 17.2 17.1 0.05 0.01 0.01 0.01 0.01 0.03 0.08 0.06
15 ½" 21.3 21.3 0.07 0.01 0.01 0.01 0.01 0.04 0.10 0.08
20 ¾" 26.9 26.7 0.08 0.01 0.01 0.01 0.01 0.05 0.12 0.10
25 1" 33.7 33.4 0.11 0.01 0.01 0.01 0.01 0.07 0.16 0.12
32 1¼" 42.4 42.2 0.13 0.01 0.02 0.01 0.01 0.08 0.20 0.15
40 1½" 48.3 48.3 0.15 0.02 0.03 0.01 0.02 0.10 0.23 0.18
50 2" 60.3 60.3 0.19 0.03 0.04 0.01 0.03 0.12 0.29 0.22
65 2½" 76.1 73 0.24 0.04 0.07 0.01 0.05 0.15 0.36 0.27
80 3" 88.9 88.9 0.28 0.06 0.10 0.02 0.06 0.18 0.45 0.34
90 3½" 101.6 101.6 0.32 0.08 0.13 0.03 0.08 0.20 0.52 0.39
100 4" 114.3 114.3 0.36 0.10 0.16 0.03 0.10 0.23 0.59 0.45
125 5" 139.7 141.3 0.44 0.14 0.24 0.05 0.15 0.28 0.76 0.56
150 6" 168.3 168.3 0.53 0.21 0.35 0.07 0.22 0.33 0.93 0.69
200 8" 219.1 219.1 0.69 0.36 0.59 0.12 0.38 0.43 1.28 0.94
250 10" 273 273 0.86 0.55 0.92 0.19 0.59 0.54 1.69 1.22
300 12" 323.9 323.8 1.02 0.78 1.29 0.26 0.82 0.64 2.11 1.51
350 14" 355.6 355.6 1.12 0.94 1.56 0.32 0.99 0.70 2.43 1.72
400 16" 406.4 406.4 1.28 1.22 2.04 0.42 1.30 0.80 2.91 2.04
450 18" 457 457 1.44 1.55 2.58 0.52 1.64 0.90 3.43 2.38
500 20" 508 508 1.60 1.91 3.18 0.65 2.03 1.01 3.98 2.74
600 24" 610 610 1.92 2.75 4.59 0.94 2.92 1.21
700 28" 711 711 2.23 3.74 6.24 1.27 3.97 1.41
750 30" 762 762 2.39 4.30 7.16 1.46 4.56 1.51
800 32" 813 813 2.55 4.89 8.15 1.66 5.19 1.61
900 36" 914 914 2.87 6.18 10.31 2.10 6.56 1.81
1000 40" 1016 1016 3.19 7.64 12.73 2.59 8.11 2.01
1100 44" 1118 1118 3.51 9.25 15.42 3.14 9.82 2.21
1200 48" 1219 1219 3.83 11.00 18.33 3.73 11.67 2.41
1300 52" 1321 1321 4.15 12.92 21.53 4.39 13.71 2.61
1400 56" 1422 1422 4.47 14.97 24.95 5.08 15.88 2.81
1500 60" 1524 1524 4.79 17.19 28.65 5.84 18.24 3.02
1600 64" 1626 1626 5.11 19.57 32.62 6.64 20.76 3.22
1700 1727 5.43 22.08 36.80 7.50 23.42 3.42
1800 72" 1829 1829 5.75 24.76 41.27 8.41 26.27 3.62
1900 1930 6.06 27.57 45.95 9.36 29.26 3.82
2000 80" 2032 2032 6.38 30.56 50.94 10.38 32.43 4.02
2100 2134 6.70 33.71 56.18 11.45 35.77 4.22
2200 2235 7.02 36.98 61.63 12.55 39.23 4.42
2300 2337 7.34 40.43 67.38 13.73 42.90 4.63
2400 2438 7.66 44.00 73.33 14.94 46.68 4.83
8 Quantity survey of materials

UF 19 ST-F01 M01 D 06-04
The yield of the painting material shall be decisive for the determination of the quantities (in kg or litres) con-
sumed. The actual yield shall be determined from the theoretical yield (in m²/l or m²/kg) specified by the paint-
ing material suppliers plus an extra charge for losses during application (e.g. surface irregularities, differing
peak-to-valley heights, subgrade unevenness, mixture losses due to limited pot life, application method, ex-
cessive layer thickness).
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The following extra charges on the theoretical yield are admissible for losses:
• 60 % for the first prime coat (directly after surface preparation),
• 80 % for inorganic zinc prime coats,
• 30 % for one-pack prime and top coats,
• 40 % for two-pack prime and top coats.
For the determination of the quantities of solvents applies:

• for painting material quantities ≤ 100 litres thinner: 10 % cleaner: 20 %
• for painting material quantities > 100 to 1000 litres thinner: 5% cleaner: 10 %
• for painting material quantities > 1000 litres thinner: 2% cleaner: 8%
9 Damages to pre-coated surfaces

Damages to pre-coated surfaces might be caused by others during shipment, loading and erection. the extent
of those damages shall be listed prior to commencement of the painting works.
If the ratio of damaged surfaces will be above 10% of the painted surface in total, the relevant component
shall completely be repainted. In that case the quantity survey shall be executed according to sections 5, 6 or 7.
In case the ratio of damaged surfaces will be beneath 10%, the touch-up works shall be brought to account in
the following manner:
For the evaluation of the touch-up area a line shall de drawn around each damage / scratch with an offset of
20 cm. The enveloping line depicts the touch-up area. The calculation of its surface area may be executed in
simplified terms by transforming it into equivalent rectangular areas. An area with the overlap of different
damages shall only once be included. The minimum size of a touch-up area will be 0.2 m².
In order to minimize time and effort the total number of the touch-up areas multiplied by the minimum size may
be brought to account as an alternative.
The validation for touch-up areas should be put into effect with the unit rate for touch-up work. In case no such
unit rate has been agreed upon, the unit rate for the relevant complete system will then also be valid for touch-
up work.
Areas for quantity survey shall be detected with an accuracy of 0.1 m².
9.1 Examples for damages
1.4 m × 0.4 m = 0.56 m²
rounded to 0,6 m²
Figure 22. Long scratches

UF 19 ST-F01 M01 D 06-04
0.4 m × 0.4 m = 0.16 m²
validation 0,2 m² (minimum size)
Figure 23. Spot-shaped scratches
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1.4 m × 0.4 m + 0.6 m × 0.4 m = 0.8 m²
Figure 24. Overlap of two scratches
Reference standards
DIN standards
DIN 1025-1 : 2009-04 Hot rolled I-beams; Narrow flange I-sections, I-serie; Dimensions, masses,
sectional properties
DIN 1025-2 : 1995-11 Hot rolled I-beams; Wide flange I-beams, IPB-serie; dimensions, masses,
sectional properties
DIN 1025-3 : 1994-03 Hot rolled I-beams; wide flange I-beams, light pattern, IPBl-serie; dimen-
sions, masses, sectional properties
DIN 1025-4 : 1994-03 Hot rolled I-beams; wide flange I-beams heavy pattern, IPBv-serie; dimen-
sions, masses, sectional properties
DIN 1025-5 : 1994-03 Hot rolled I-beams; medium flange I-beams, IPE-serie; dimensions,
masses, sectional properties
DIN 1026-1 : 2009-04 Hot rolled steel channels; Taper flange steel channels; Dimensions, masses
and sectional properties
DIN 1027 : 2004-04 Steel bars; Hot rolled round edge Zeds; Dimensions, weights, tolerances,
static values
EN standards
EN 10055 : 1995-12 Hot rolled steel equal flange tees with radiused root and toes; Dimensions and
tolerances on shape and dimensions
EN 10056-1 : 1998-10 Structural steel equal and unequal leg angles; Dimensions
Amendments
In comparison with UN 9257-91 Part 1 : 2001-06 edition, the following amendments have been made
− The tables 2 through 4 have been revised according to the new Standards, now being valid.
− Section 9 "Damages to pre-coated surfaces" has now been included.
UF 19 ST-F01 M01 D 06-04
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[Modified: 29/08/2008]
Contents
Page
1 Scope ……………………………………………………………………………………. 1
2 Facilities …………………………………………………………………………………. 1
3 Receipt of material ……………………………………………………………………… 1
4 Storage of material ……………………………………………………………………… 4
5 Preservation …………………………………………………………………………….. 7
6 Issue and return of material …………………………………………………………… 8
1 Scope
This standard applies to the administration of the site warehouse and to the storage of equip-
ment. It contains generally applicable requirements which will be supplemented by special in-
structions, if necessary.
Deviations from this standard shall be agreed upon in writing.
2 Facilities
The warehouse usually comprises open-air storage facilities (with or without fencing, with roof)
and temporary storage rooms (e.g. lockable, heated, cool, dry).
The size of areas for the open-air storage facilities and storage rooms shall be determined on
the basis of the scope of supplies. If approved by the client, plant buildings (e.g. storage facili-
ties) may also be used for the storage of equipment. The type and quantity of warehouse
equipment (e.g. shelves, wire mesh boxes, fire-extinguishers, fork lifts, light cranes) shall be
determined sufficiently in advance of the commencement of site activities.
Depending on the prevailing weather conditions, the areas of the open-air storage facilities
shall be connected to a drainage system. The areas for the open-air storage facilities and stor-
age rooms shall be selected with a view to precluding flooding.
3 Receipt of material
Care shall be taken when unloading and transporting any packages and items of equipment.
The symbols for handling and storage marked on the packages and items of equipment shall
be observed at all events.
1, This side up 5. Use no hooks 9. Clamp here

2. Fragile, handle with care 6. Centre of gravity 10. Do not use forklift truck here
3. Keep dry 7. Sling here
4. Keep away from heat 8. No hand truck here
Figure 1. Symbols for the handling of equipment
© 2008 UHDE INDIA Technical discipline: MQ

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Roofed storage Storage in closed rooms
Storage at ambient temperatures of > 0 °C Storage in air-conditioned rooms
Figure 2. Symbols for the storage of equipment
Lifting tackle (e.g. ropes, chains, shackles, cross-beams) shall be selected with due regard to
the centre of gravity and shape of the equipment to be lifted. The lifting tackle shall not be sub-
jected to loads exceeding their maximum permissible carrying capacity. The maximum permis-
sible carrying capacity is shown in the relevant load tables. In the case of multi-line lifting
tackle, only two lines shall be assumed to carry the load if it cannot be assured that the load is
distributed uniformly amongst all the lines. For asymmetrically arranged lifting tackle or loads
with an asymmetrical centre of gravity, the non-uniform load distribution shall be observed. The
angle subtended by the rope lines or chains shall not exceed 120°.
Ropes and chains shall only be fastened to the points (e.g. lifting clips, lifting lugs, trunnions,
eyebolts) provided for such purpose. If no sling points have been provided or marked, the at-
tachment method shall be agreed with the site management. Nozzles, shaft ends and other
protruding parts of the equipment shall not be used as sling points. Unprotected wire ropes or
steel chains shall not come into contact with bare steel surfaces and austenitic CrNi steel.
Cross-beams should be used for lifting vertical vessels of > 2 m diameter. Special care shall be
taken to prevent distortions when raising vessels delivered in a horizontal position. Synthetic
fibre belts of approx. 100 mm width should be used for lifting plastic vessels. Wire ropes shall
only be used for plastic vessels which are provided with lifting lugs or eyebolts.
Ropes and chains shall neither be knotted nor placed across sharp edges. The rope end at-
tachments and chain end links shall comply with the applicable standards. Wire ropes shall be
protected from moisture and shall be greased regularly. Synthetic fibre ropes shall be stored in
dry places with sufficient ventilation. Chains shall always be kept clean. Under adverse condi-
tions (e.g. impact loads, temperatures < 0 °C), the maximum carrying capacity of chains shall
be reduced accordingly. The chain manufacturer’s instructions shall be observed.
The lifting tackle shall be inspected regularly for damage. Wire ropes shall be deemed unserv-
iceable if any of the following defects are detected:
• Many visible wire fractures,

• A broken wire strand,
• Clustering,
• Loose external strands,
• Pinching, kinks and knots,
• Corrosion pits,
• Damage or extremely worn rope end attachments,
• Damage due to contact with items conducting electric current.
Chains shall be deemed unserviceable if any of the following defects are detected:
• Elongation of the chain or a chain link by > 5%,

• Decrease of nominal thickness of a chain link by > 10%,
• Deformation or fracture of a chain link,
• Cracks in a chain link,
• Damage due to contact with items conducting electric current.
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Natural or synthetic fibre ropes shall be deemed unserviceable if any of the following defects
are detected:
• Breakage of one strand,

• Mechanical damage, extreme wear or loose strands,
• Damage due to storage in moist places or exposure to corrosive media,
• Multiple yarn breakages,
• Loose splices.
Lifting hooks shall be deemed unserviceable if any of the following defects are detected:
• Cracks (particularly transverse cracks) in the shank, collar, thread or hook jaw,
• Wear of hook jaw by > 5%,
• Severe deformation of the hook jaw,
• Defective hook safety catch.
3.1 Inspection of incoming material
The receipt of material at the site shall be confirmed to the head office by a notification of re-
ceipt of material. If the client has to acknowledge the receipt of material, a “Erection: Ware-
housing; Material receiving report” (Uhde form UF 9250-21) shall be issued.
The equipment received shall be checked in accordance with the “Construction: Warehousing;
Requirements for material receiving inspection” (Uhde form UF 9250-22). The scope and time
of the checks shall be governed by the type and storage period of the equipment. The checks
shall be performed in sufficient time before erection of the equipment. The following checks
should be performed immediately upon receipt of the packages:
• Checking the packing lists against the number of packages received,

• Checking the outside packing for damage,
• Checking the inside packing (e.g. welded plastic sheets) for damage,
• Checking damaged packages for completeness and damage to the contents,
• Checking any protective inert-gas fillings.
Damage in transit shall be reported without delay to the insurance department at the head of-
fice, using special forms. In the event of severe damage, an average adjuster shall be con-
sulted.
The following checks may be performed at a later date, after the packages have been opened.
• Checking the contents for completeness,

• Checking the outer condition of the individual components (e.g. corrosion protection, preser-
vation),
• Checking the technical details.
The performance of the specified checks shall be recorded (e.g. in the warehouse file card-
index). Any defects detected shall be recorded in a “Construction: Warehousing; Deficiency
report” (Uhde form UF 9520-23).
Any missing items of equipment shall be replaced by re-ordering. In the case of defective
equipment, the site management shall decide whether the defects are still permissible or
whether repair can be performed on site. The site management shall make arrangements for
the return of any non-specification-grade items of equipment.
3.2 Warehouse file card-index
All movements of material (receipt, place of storage, issue, return) shall be recorded on appro-
priate warehouse file cards. On large sites, the warehouse file card-index can be computer-
ized.
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4 Storage of material
4.1 General notes
The items of equipment shall be stored in accordance with the technical specification “Erection:
Storage of material and equipment” (Uhde form UF 9250-01) or in accordance with the manu-
facturer’s instructions either outdoors, indoors, in cooled or in dry rooms. Adequate protection
shall be ensured against pilfering, inclement conditions (e.g. moisture, rain, snow, sandstorm,
insects), soiling (e.g. by bird droppings, dust, tar), static and dynamic loads. In the event of
prolonged storage periods and extreme ambient conditions (high or low temperature, corrosive
atmosphere), special protective measures can be specified by the site management.
The storage temperatures depend on the type of storage facility. In open-air storage facilities
(open-air or roofed), the storage temperatures are governed by weather conditions. In closed
storage rooms without special requirements, a storage temperature between 5 °C and 35 °C
should be maintained. Special requirements as regards storage temperatures are indicated in
sections 4.2 to 4.8.
All items of equipment are marked with a TON (Technical Organization Number) or a part num-
ber. If necessary, this marking shall be touched up with weather-proof paint on receipt of the
material or during storage.
If tarpaulins are specified for covering the equipment in the open-air storage facilities, these
shall be of flame-resistant material (without PVC components). The tarpaulins shall be an-
chored carefully and arranged in such a manner as to permit proper drainage of surface water
and air circulation underneath the tarpaulins. For protecting equipment (e.g. with soft-rubber
lining) against UV radiation, tarpaulins impervious to light or plastic sheets of red or orange col-
our shall be used.
Equipment of austenitic CrNi steel shall be protected from direct contact with unalloyed steel or
low-alloy steel, detrimental influences (e.g. corrosive gas, sea air), metal dust (e.g. steel, tin,
zinc, copper) and from zinc-based coating materials. Items of austenitic CrNi steel shall only
be cleaned with demineralized water.
Protective coverings (e.g. covers, caps) shall not be removed from flanges and from machined,
rubber-lined or bare surfaces. Missing or damaged protective coverings shall be replaced.
Caps made of PVC should not be used.
Welding filler metals shall be stored at temperatures of ≥ 20 °C and a relative air humidity of ≤
60%.
Protective inert-gas fillings (e.g. of heat exchangers or transformers) shall be checked regularly
for pressure drop. The efficiency of the dessicant shall be checked regularly in the case of
equipment (e.g. instruments, electrical equipment) provided with bags of dessicant. The instruc-
tions on the bags containing the dessicant shall be observed.
The open storage areas and the storage rooms shall be selected such that they cannot be
flooded. The said areas shall be connected to a drainage system depending on the ambient
weather.
Storage rooms, in which combustible materials are stored, shall be provided with an adequate
number of fire extinguishers. The local fire regulations shall be observed.
Items of equipment which have to be checked and maintained regularly during storage shall be
provided with suitable record cards.
The site management shall be informed immediately if deficiencies or damage are detected
during storage. The site management will then decide about the measures required (repair, re-
ordering).
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4.2 Steel structures, vessels, and machinery
Steel structures, vessels, machinery and the like should be stored outdoors on timber blocks of
approximately 150 mm thickness. Placing the equipment on unprotected, bare or machined
surfaces as well as on flanges is not permitted. Care shall be taken not to damage nozzles,
shaft ends or other protruding parts.
Vessels, machinery and other equipment shall be stored in their “operating position” on a plane
surface and shall be supported by an adequate number of timber beams. Vertical vessels with
a height of > 5 m may be stored horizontally.
Rolled plates (e.g. for site-welded tanks) should be stored upright. For plates stored in horizon-
tal position, provision shall be made for adequate support. Care shall be taken not to damage
the machined plate edges.
If specified by the manufacturer, the shafts of machinery and electric motors shall be turned
regularly by several degrees.
Oil and grease shall be prevented from entering the equipment and machinery which will come
into contact with oxygen during operation.
4.3 Rubber-lined and plastic equipment
Rubber-lined equipment and plastic equipment shall be stored with special care. The equip-
ment shall be stored on a soft underlay to preclude any distortion. It shall be protected against
knocks, impacts and low temperatures. Impact-sensitive rubber linings and plastic equipment
shall be checked for cracks prior to erection.
Rubber-lined equipment, particularly with soft-rubber lining, shall be protected against exces-
sive heat (e.g. due to solar radiation or heating elements) and UV radiation (due to solar radia-
tion and artificial lighting). Plastic sheets of blue colour shall not be used for covering the rub-
ber-lined surfaces. The formation of ozone or high oxygen concentrations (e.g. due to fluores-
cent lighting) shall be prevented wherever rubber-lined equipment is stored.
Equipment with hard-rubber linings or brittle special material shall be protected from severe dif-
ferences in temperature. The temperature within rubber-lined equipment should not drop below
minus 10 °C if the hardness of the rubber lining is > 75 shore D and not below –20 °C if the
hardness of the rubber lining is ≤ 75 Shore D. At temperatures of < 0 °C, the equipment shall
be stored free of any stress.
At temperatures of < 0 °C, utmost care should be exercised when unloading and transporting
rubber-lined equipment.
Rubber lined items shall be checked for corrosion at the edges of the rubber lining.
4.4 Piping components
Pipes, spools, fittings, elbows flanges and valves should be stored outdoors on timber blocks of
approx. 150 mm thickness or on timber pallets. Flange faces shall not be damaged. Valves
shall be stored in the “closed” position. For the storage of piping components, section 4.1 shall
also apply analogously.
The piping components shall be stored separately by material groups. The marking of the pip-
ing components shall be checked on receipt of the material to avoid any mix-up at a later stage.
Pipes maybe stacked to a height of approx. 1.5 m if properly secured. In the case of pipes
≥ DN 500, only two pipes should be stacked one upon the other. The storage area should be
plane to ensure uniform support over the entire pipe length. A sufficient number of timber
planks shall be placed between the individual pipe layers.
Safety valves, control valves, bolts, nuts, washers, gaskets and other hardware shall be stored
indoors. Temporary storage of these items outside the storage rooms is not permitted.
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4.5 Electrical equipment and instrumentation
Transformers for outdoor service, cable supports, cable drums and sectional steel for fixtures
may be stored outdoors. With the exception of cable drums, this equipment should be stored on
timber blocks of approx. 150 mm thickness or on timber pallets.
Other electrical, measuring and control equipment should be stored in dry and well ventilated
rooms on timber pallets or on shelves. The storage temperature should be ≥ 10 °C. If specified
by the manufacturer, equipment (e.g. switch boards, transformers) or parts thereof (e.g. termi-
nal boxes of high-voltage motors) shall be heated during storage.
A crane or a fork lift shall be used for un-loading the cable drums. Cable coils shall not be
thrown. Cable coils shall be stored lying flat. The sealing caps provided at the cable ends shall
be checked for proper condition and, if necessary, repaired.
Switch boards, distribution boards, control panel sections and the like shall be stored on level
surfaces and handled with such lifting and handling equipment that will not cause damage (e.g.
distortion). During storage and transportation, the surfaces of the equipment shall be protected
by plastic sheets against soiling and scratching.
Transformers with insulating fluid shall be checked for proper condition on receipt at the site. In
the case of transformers with complete filling and installed expansion vessel, the air dehumidi-
fier shall be checked for proper functioning. The nozzle on the expansion vessel of small trans-
formers shall be open. The moisture indicator shall be checked regularly. The colour change of
the indicator from blue to pink indicates that the relative humidity in the transformer housing has
risen unduly.
Storage batteries shall be stored in accordance with the manufacturer’s instructions. Batteries
filled with the electrolyte shall be recharged at least once in every 6 months.
Tubes for instrument process lines, pneumatic impulse lines and instrument-air lines as well as
the related hardware (e.g. unions, valves) shall be stored on shelves or on timber pallets, sepa-
rated by material groups. Transport of tube bundles shall be effected in such a way that the
bundles do not sag excessively, thus becoming distorted or bent. The tube bundles shall be not
pulled over the ground. Tube coils shall not be thrown and not stacked to a height of > 1 m. The
tube ends shall be protected from the ingress of foreign matter.
Instruments shall be stored on shelves. The original packing shall only be removed at the
place of installation. Caps, covers, plugs and the like on instruments and valves shall not be
removed until immediately prior to installation. Missing or damaged caps, covers and plugs
shall be replaced.
4.6 Insulation material
Insulation material and sheet-metal may be stored outdoors if soiling and ingress of moisture
can be prevented. Insulation material in unpacked state and hardware shall be stored indoors.
Shells and slabs shall be stored horizontally on a plane underlay. Sheet-metal reels and metal
plates shall be stored on timber pallets.
Insulation materials shall be stored as per instruction by manufacturer or as follows: PU foam

components shall be stored at temperatures between 10 °C and 15 °C. The foaming agent
shall be stored at a temperature of < 22 °C. The individual components shall be stored sepa-
rately from one another.
4.7 Coating materials
Coating materials shall be stored at temperatures between 5 °C and 30 °C in dry and well venti-
lated rooms. The instructions of the manufacturers shall be observed. Any rise in temperature
(e.g. by solar radiation) of the coating material shall be prevented.
The statutory regulations governing the storage of inflammable coating materials and auxiliary
materials shall be observed.
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4.8 Other materials
Bricks (for refractory linings), packing materials, catalysts and the like should be stored accord-
ing to the manufacturer’s instructions.
Polyester resins (e.g. for glass-fibre-reinforced plastic pipes) shall be stored at temperatures
between 15 °C and 20 °C in well ventilated rooms. Glass fibre mats shall be kept in a dry place
and protected from moisture. Accelerators and catalysts shall be stored separately from one
another and from resins. Any explosion hazards shall be taken into account when storing ac-
celerators and catalysts.
Rubber lining material shall be stored at temperatures between 6 °C and 10 °C. The rubber
reels shall be jacked up at both ends of the mandrel to preclude contact with the ground. Any
missing or damaged mandrels shall be replaced. Rubber reels shall not be stacked.
Rubber lining material shall be protected against direct solar radiation and UV radiation accord-
ing to section 4.3. The formation of ozone or high oxygen concentrations (e.g. due to fluores-
cent lighting) shall be prevented in the storage room. Plastic sheets of blue colour shall not be
used for covering the rubber reels.
Baled conveyor belts, which are to be stored for a prolonged period, shall be jacked up and
turned from time to time to prevent the belt plies from becoming distorted as a result of the
dead weight of the belt bale.
Solvents, fuels, lubricants and corrosive chemicals shall not be stored close to rubber-lined
equipment, rubber sheets and the like and shall not come in contact with rubber.
Lubricants (oil and grease), insulating fluids for transformers and insulating oils shall be stored
indoors in the original containers. Oils and insulating fluids shall be protected against moisture
and water. Oil drums shall be stored with the bungs down.
Special measures are usually required for the storage of chemicals. Particular attention shall
be paid to :
• Statutory regulations,
• Maximum shelf life,
• Flammability,
• Chemical reactivity,
• Explosion hazard,
• Formation of toxic vapours,
• Maximum storage temperatures.
5 Preservation
The preservation of items of equipment shall be checked at regular intervals and touched-up, if
necessary. The manufacturer’s instructions for the application of preservation agents shall be
observed. Unless otherwise specified, the preservation agents may be selected according to
table 1. The branded products indicated in table 1 may be substituted by equivalent products
of other manufacturers.
540 of 1528
UHDE-STANDARD
Erection
UN
9250-01
Part 1 (M)
WAREHOUSING
Page 8 of 8
Table 1. Preservation agents
Preservation agents Application

1)
Tectyl 506 Valves, gliding surfaces, bearings, guide pins, keys,
Covering with oiled paper Outside surfaces of gears, are metal parts
1)
Tectyl 846 Compressors, rotors, unalloyed steel piping
1) 1)
Tectyl 511 M , Tectyl 506 Inside surfaces of crank cases, oil tanks, oil filters, oil
lubricated bearings and gears
Covering with oiled paper Casings, bearings caps, valve bodies
Anti-corrosion oil (e.g. Shell Eusin Instruments, electrical appliances
2) 1)
I OW , 20 W Valvoline )
Collordal molybdenum disulphide, Spindles, spindle bushings, couplings, bearings
vaseline
Dessicants (e.g. silica gel) Interior of compressors, casings.
1) Branded product of Valvoline Oel GmbH & Co., Hamburg, Germany
2) Branded product of Shell AG, Hamburg, Germany.
6 Issue and return of material
Material shall be issued against store issue forms which are to be signed by the area superin-
tendent in charge.
If fairly large quantities are required at a time (e.g. material for complete pipelines), advance
notice shall be given to permit the necessary preparations for the issue of this material to be
made, thus avoiding waiting periods.
In cooperation with the area superintendents in charge, the warehouse superintendent shall
regularly check whether material bottlenecks are likely to occur. Material bottlenecks shall be
reported to the head office immediately so that the problem can be solved by priority expediting
or procurement of supplementary material. In the case of large sites, material planning (e.g. for
piping) can be performed with the aid of a site computer.
When the stocks of bulk material (e.g. pipes, fittings, valves, bolts, cables) have decreased to a
certain level (e.g. 5%), a check shall be made to determine whether the stock in hand will be
sufficient for the remaining work.
If the quantity of material taken from the warehouse proves to be larger than required, the ma-
terial in excess shall either be returned to the warehouse or set off against the next issue of
material. The returned material shall be recorded as incoming material in the warehouse file
card-index. Cutting spoil (e.g. from pipes, cables) remains the property of the Orderer. The site
management will decide whether cutting spoil can still be used or is to be considered as scrap.
Cutting spoil shall be stored separately by material type in an area designated by the site man-
agement.
Reference standards
Uhde standards:
UF 9250-01 Erection: Storage of material and equipment

UF 9250-21 Erection: Warehousing; Material receiving report
UF 9250-22 Construction: Warehousing; Requirements for material receiving inspection
UF 9250-23 Construction: Warehousing; Deficiency report
541 of 1528
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NALCO NAL 6695-PIP-G00-EC-0009 66-6695
REFINERY STREAM-5
Technical specification for Weigh Bridge
Rev 02 Page 1 of 9
00 Issued for tender 07-03-18 RNJ 07-03-18 PRM 07-03-18 LNN / SJP -
Category Code: -
Barcode
Page 1 of 10
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TABLE OF CONTENT
1.0 INTENT OF SPECIFICATION.................................................................................................................... 3

2.0 INSTRUCTION TO BIDDERS .................................................................................................................... 3
3.0 RESPONSIBILITIES................................................................................................................................... 4
4.0 BIDDER’S SCOPE OF SUPPLY & SERVICES ........................................................................................ 4
5.0 SPARE PARTS & SPECIAL TOOLS ......................................................................................................... 5
6.0 SCOPE MATRIX OF WORK ...................................................................................................................... 6
7.0 GENERAL DESIGN CONDITIONS............................................................................................................ 6
8.0 ERECTION, TESTING, COMMISSIONING AND PERFORMANCE GUARANTEE.................................. 7
9.0 INSTRUMENTATION / AUTOMATIC CONTROLS ................................................................................... 7
10.0 SURFACE PREPRATION AND PAINTING ............................................................................................... 8
11.0 PERFORMANCE-MECHANICAL GUARANTEE ....................................................................................... 8
12.0 OPERATION AND MAINTENANCE .......................................................................................................... 9
13.0 CODES AND STANDARDS ....................................................................................................................... 9
Annexures :
Annexure I : Data Sheet
Page 2 of 10
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1.0 INTENT OF SPECIFICATION
1.1 The scope of this specification covers the Design, Detail engineering, Fabrication, Supply of materials,
Inspection, Testing, Painting, pre-commissioning, Mechanical completion, Trial run, Erection &
Commissioning at site and Performance Guarantee of ONE NO. OF PITLESS TYPE TRUCK WEIGH
BRIDGE with all components / Accessories as per requirement set forth in this specification, Drawings &
other reference documents to achieve a guaranteed and coordinated commercial operation of the same to
the entire satisfaction of the client. This Specification defines the minimum mandatory requirement for
supply and installation of the equipment.
1.2 Bidder is responsible to comply with the requirements specified in this document and also as per the
relevant standard, Indian, International and OSHA Standards. Wherever such standard is not available,
Bidder must comply with good engineering practice which is followed internationally.
1.3 It is not the intent to specify completely herein, all aspects of design and construction of equipment.
Nevertheless, the equipment shall conform in all aspects to high standard of engineering, design and
workmanship and shall be capable of performing in continuous commercial operation in a manner
acceptable to the owner.
2.0 INSTRUCTION TO BIDDERS
2.1 Bidders shall submit their technical bid in full compliance with the requirement of this specification, and the
requirement of the corresponding Material Requisition (MR) and its’ attachments.
2.2 Bidders are requested to carefully examine and understand the specifications and seek clarifications, if
required, to ensure that they have understood the specification. The Bidder’s offer should not carry any
section like clarification, interpretation and/or assumption. However, if the bidder feels that, in his opinion,
certain features brought-out in his offer are superior to what has been specified in this specification, these
may be highlighted separately.
2.3 Under no circumstances, the equipment as specified herein shall be made as an alternative offers i.e. the
equipment specified shall be made as base offer. In case all the above requirements are not complied
with, the offers may be considered incomplete.
2.4 If any provision of this specification departs from the bidder‘s usual construction sufficiently to materially
increase the cost of equipment, without (in bidder’s opinion) providing a corresponding increase in quality;
or if the bidder considers that the usual construction would provide better quality, the bidder shall call this
to the attention of the Purchaser by submitting an alternative bid, in which case adequate technical
information, operating feedback, etc. are to be enclosed with the offer, to enable the Purchaser to assess
the superiority and reliability of the alternatives offered. Without above document bidder’s alternative offer
will not be considered.
2.5 In event of any conflict in the Specification / Clause / Standards mentioned, stringent specification / Clause
standard shall be considered.
Page 3 of 10
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3.0 RESPONSIBILITIES
3.1 Bidder is responsible to ensure that all the equipment supplied under this package are complete with all
respect for safe and smooth functioning as per the technical and guarantee requirement.Stable operation
shall be ensured, throughout capacity range.
3.2 Bidder is responsible for application of and adherence to any and all statutory requirements, standards
and design codes. Nevertheless, these regulations and specifications do not release the Bidder from
his responsibility for his scope of supplies.
4.0 BIDDER’S SCOPE OF SUPPLY & SERVICES
4.1 The BIDDER’s scope of Supply for One no. of Truck Weigh bridge package shall include but not limited
to design, engineering, supply, transportation, third party inspection, Erection, commissioning and
performance guarantee test and shall be performed in compliance to the specified requirements below. It
shall also include all items and services but not limited to the following, along with necessary fittings,
fixtures and ancillaries, bolts, nuts, gaskets, hold-down clips etc. as detailed in various parts/sections of
the specification. Bidders shall consider all components to ensure complete and satisfactorily operable
equipment. All items shall be included which are required to run the equipment as per guaranteed
parameters unless otherwise specifically has been asked to exclude the same.
4.2 Following is the equipment in Successful Bidder’s scope, unless otherwise specified elsewhere:
Sr.No. Ton No. Equipment description Qty. (Nos.)

1 NIL Truck Weigh Bridge – 60 T capacity, 18 x 3 m 1
4.3 The Weigh Bridge shall be installed to check the Incoming and Outgoing Trucks / Trailers to and from the
plant.
4.4 The Detailed scope for each Weigh Bridge is as under:

a) Compression type Digital Loadcell of suitable capacity: 8 Nos
b) Loadcell Mounting Assembly: 8 Sets
c) Master Junction Boxes, Die cast Aluminium, IP 65: 1 No.
d) Termination Junction Box, FRP, IP 65: 1 No.
e) Interconnecting cables between the Weighbridge and Weigh bridge control room: 30 m ( Multi-core, 1.5
Sq.mm, multistrand, shielded Armoured cable). These cables shall be suitable for area having Rodents
and Water logging.
f) Weighing scale terminal Electronics ( Indicator): 1 No.
g) Mild Steel Fabricated Platform of size 18m x 3 m, pitless type design, 60 t capacity.
h) Accessories Like GI Conduits, Fastners, earthing Strip, spike buster etc.
i) 1 KVA UPS with 30 min. Backup.
j) PC, INTEL, dual core processor, 500 GB HDD, 2 GB RAM (minimum), DVD Drive, Operating System
with Window- 7(Licensed) (professional) or Latest Version along with media Kit
k) 17’’ colour Monitor, USB type Keyboard, Optical Mouse.
l) Windows based standard Weighbridge management software
m) Hydraulic Jack for Lifting the structure for Loadcell replacement.
n) Load cell dust protection system if required.
o) Lightning protection If required.
p) Jumbo display and com. converter
Page 4 of 10
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Rev 02 Page 5 of 9
4.5 Connectivity arrangement for data transfer to user ERP system shall be provided by contractor.
4.6 The structure of the text file for tare wt. & gross wt. which are to be transferred from weigh bridge
computer to servers.
4.7 Standard PC Software Specifications / Reports

Platform : Windows based
Standard Reports : Ticket printing
a. Daily Transaction report
b. Various MIS reports such as Vehicle wise, Challan wise,
Customer wise, Product wise, Truck wise, Operator / Shift wise
Features : a. Flexible Reports can be exported to Excel
b. Direct Masters updation from transaction screen
c. Ticket Print Control as per selected Paper Size
4.8 Modalities for on line data transfer for Truck Weigh Bridges
a) All other relevant data to be incorporated in weigh bridge software such as Customer code, grade code
destination code etc. will be communicated to successful bidder.
b) Truck wise Excise duty Tax Invoice
c) The weighment software shall incorporate features to generate Truck wise Excise duty Tax Invoice for
dispatches.
4.9 The successful Bidder shall take the responsibility of all the Testing and Inspections at their / their sub
vendors works to be conducted in manner as specified in this specification.
4.10 Calibration of weigh bridge for accurate weight measurements, statutory approval such as approval from
local Weights & Measures Authority, Government and other authorities, if any, (OIML R60, NTEP
approval, Factory Mutual approval, CE Approval ) which is mandatory shall be arranged and obtained by
the bidder before putting the weigh bridge in operation.
4.11 Transportation of all equipment packed for transportation from the manufacturing place to the specified
destination site inclusive of all intermediate handling.
4.12 All type of nuts, bolts, fasteners including foundation bolts.
4.13 Supply, Erection, inspection, testing, start-up of the equipment, performance and guarantee tests.
4.14 Supply & Administering first and all fill of lubricants, touch up paints
4.15 Commissioning and taking-over/repair work if any, to meet the requirements of the guarantee.
5.0 SPARE PARTS & SPECIAL TOOLS
BIDDER shall include and provide the following spare parts for all the equipment under scope of supply:
5.1 Any special tools and tackles if required for servicing of the equipment shall be included as Part of
equipment supply. The tools shall be supplied in a steel toolbox.
5.2 5 t capacity hydraulic Jack shall be supplied as special tool for replacement / maintenance of load cells.
5.3 Commissioning and start up spares shall be included as part of supply( Mechanical, Electrical and C&I
Items )
Page 5 of 10
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5.4 Recommended spare parts required for 1 years of normal & trouble free operation.
5.5 Mandatory spares for WEIGH BRIDGE shall be supplied as under :
• Load cell: 2 Nos.

• Weight indicator: 1 No.
• Jumbo Display: 1 No.
6.0 SCOPE MATRIX OF WORK
The scope of work shall include all items and services as detailed in various parts/ sections of this
specification. Bidder shall consider all components required to ensure complete and operable equipment /
system. Major scope is listed as under:
All statutory compliance for the start-up of weigh bridge and renewal of statutory compliance
( ex. Stamping etc )shall be in bidders scope.
7.0 GENERAL DESIGN CONDITIONS
7.1 Capacity of Weigh Bridges shall be 60 T Size shall be 18 m x 3 m.
7.2 The weigh bridge shall be electronic type and shall be as per latest international standards.
7.3 The platform for the weigh bridge shall be of robust construction. The girders shall be constructed of rolled
steel sections and shall be strong enough to withstand full static load. Suitable arrangement shall be
provided to restrict horizontal movement of the platform. The top of the platform shall be covered with
roughened steel plate of adequate strength. The floor shall be slightly elevated for easy drainage of rain
water.
7.4 The weigh bridge shall be fitted with suitable no. of high precision, DIGITAL load cells for sensing load and
converting it to proportional electric signal. The load cell mounting shall be fitted below the platform in
such a manner that no horizontal load is transmitted to it. The load cell shall be impervious to harsh
environment in dust, dirt, water etc. requiring practically no maintenance and cleaning. Ambient condition
compensating device shall be provided. Provision shall be made to neutralize the change of error caused
due to application of transverse force on the load cells. The protection class of load cells shall be IP 68.
7.5 The electric signal from load cell shall be carried to the signal conditioner & control console through cable
where it will be converted to respective reading of weight in digital display Indicators.
7.6 The electronic system shall include a temperature compensating circuit so that the accuracy of the
equipment is least affected due to change in ambient temperature. The ACCURACY of the Electronic
system shall be mentioned in the NAME PLATE.
7.7 The weighing system shall be provided with fault signal device which will give signal in case of a fault
developed in the electrical & electronic circuit of the weigh bridge. Arrangement shall also be provided by
which the operational accuracy of the circuit can be checked & calibration can be done by including
electrical simulation in the circuit.
7.8 The control console shall be desk mounted and located in the control room near the weigh bridge. The
supply and installation of cables between load cells and control console are in the scope of bidder.
7.9 The load cell shall be suitable to withstand at least 150 % overload (without electrical damage) and shall
be hermetically sealed. Load cell also shall be suitable for destructive load of >300%.
7.10 The weigh bridge control console shall have lockable glass door & shall be dust and Vermin proof. It also
shall have splash proof front panel. Page 6 of 10
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REFINERY STREAM-5
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7.11 The control panel for Weigh Bridge shall be made of sheet steel, desk mounted dust and vermin proof
construction and shall be provided with necessary control switch. The weigh bridge panel shall be
provided with necessary auto zero and auto tare facility. The display shall be of LED type.
7.12 Approved makes for Structural steel shall be TATA, JINDAL, JSW or ESSAR.
8.0 ERECTION, TESTING, COMMISSIONING AND PERFORMANCE GUARANTEE
Installation of complete weigh bridge with all necessary accessories, as applicable. Stage wise
supervision of Civil work.
8.1 Installation & alignment of indicator weigh bridge and related all items as per Specifications.
8.2 Material identification shall be carried out by bidder as applicable.
8.3 Arrangement of necessary labours as required for Erection, commissioing and stamping.
8.4 Carrying all materials from from owners’s store to the Site
8.5 Arrangement of construction power, water , tools and taclkes as required for construction.
8.6 Testing & commissioning of system include following jobs:
1. Checking & alignment of indicator with the weigh bridge.

2. Checking & ensuring that all parts & bearings etc. are properly lubricated / fitted.
3. Structural parts shall be checked for their dimensional accuracy specially at the joining areas.
4. No load checking of weigh bridge.
5. Performance test of entire weigh bridge with rated load.
9.0 INSTRUMENTATION / AUTOMATIC CONTROLS
9.1 Bidder shall carry out design and Engineering of all automation / controls for entire system as per the
applicable codes / Engineering standards. Also shall be designed ,supplied and installed as a complete
package including instruments, operator panel, switch panel, weighing system units and system PLC to
handle the requirements of controlling the process and signal interchange with the station units.
9.2 Design and all the documents generated by bidder are subjected to review / approval by CLIENT /
CONSULTANT.
9.3 Operator panel shall be provided including switches, push-buttons, signal lamps etc. for system starting,
actuating, alarms, emergency stop etc.
9.4 Scope of work shall include design ,supply and installation of all instruments & sensors along with one
Industrial PC (windows based) to be stationed in the control room connected through Ethernet
connection for inventory, counting, monitoring, reporting and maintenance purposes.
9.5 All instruments shall be designed with minimum protection class of IP 65.
9.6 All control cables from the station shall be terminated at single location in junction box within the skid.
9.7 The Control unit loading station shall be completely assembled, tubes connected and wires linked to the
internal switch box.
9.8 Instruments and control system shall be designed based on engineering standards as per project
requirements and site conditions.
9.9 All hardware & software (Including PLC and visualization systems) shall be provided with latest &
compatible versions.
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10.0 SURFACE PREPRATION AND PAINTING
Surface preparation and Painting shall be as per Manuafcturer’s standard.
11.0 PERFORMANCE-MECHANICAL GUARANTEE
11.1 The manufacturer shall guarantee the capacity, and Trouble free operation.
11.2 It is Bidder’s ‘responsibility to establish performance of Weigh Bridge to the entire Satisfaction of
Purchaser.
11.3 No load trials: there shall not be any undue friction, vibration or display of any unfavourable
characteristics.
11.4 A performance test shall be conducted for the equipment at the designed capacity and specified figure
for guarantee shall be ascertained. Any modification required meeting the guarantee consumption
figures or from operation point of view shall be done at bidder’s cost.
11.5 Repair work if system / Equipment fail to meet guaranteed requirements.
11.6 Bidder shall, with all possible speed, rectify all defects arising from defective design, materials or
workmanship of the BIDDER or his SUB-BIDDER or from any act of omission of the BIDDER that may
appear during a period, called the WARRANTY Period.
11.7 Bidder shall guarantee that all equipment / components, as applicable shall be new and free from any
defect or fault or deficient in design, material, workmanship, construction and manufacture. Remaining
conditions shall be as per commercial purchase order.
11.8 Design of all equipment shall be such that it will operate 8000 hours per year minimum.
11.9 In the event of a defect in design or materials or workmanship, bidder will repair or replace the defective
item without any charge to the Client towards labour, traveling expenses incurred, materials or any other
expense, incurred by bidder directly or indirectly (through his sub- bidder). Such repair or replacement
shall be to the satisfaction of the CLIENT
11.10 The bidder's proposed method of correction shall attempt to minimize the operating downtime. Items
replaced under this warranty are warranted free from defects in workmanship and material during main
guarantee.
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12.0 OPERATION AND MAINTENANCE
Operation & maintenance manuals shall be submitted as a part of final documentation before dispatch of
the equipment.
The manual are expected to contain, but not limited to the following –
1. A detailed functional description of the equipment and recommended mode of operation.
2. All normal and sequential steps in the operating procedure must be identified and sufficient explanation
given so that operating and maintenance training can be undertaken for starting, stopping, for normal
and emergency conditions.
3. Identification of abnormal operation accompanied by a recommended list of corrective action to be

taken.
4. Cross sectional drawings of various sub-assemblies along with material of construction as well as
quantities of various parts used and various clearances between moving and stationary parts.
5. Procedure for assembly and disassembly.
6. Preventive and predictive maintenance and recommended schedule for maintenance.
7. Do’s and Don’ts
8. Lubrication details – consumption, type, schedule of lubrication for various parts.
9. Various statutory requirement/documents.
13.0 CODES AND STANDARDS
The design, manufacture, inspection and testing of the Weigh Bridge shall comply with all the currently
applicable statues, regulations and safety codes in the locality where the equipment is to be installed.
The equipment shall confirm to the latest edition of the following standards & codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance, shall also be accepted.
IS 9281 Part I-II : Electronic Weighing Systems, Parts I-IV

Part III
Part IV
Page 9 of 10
550 of 1528
Plant Customer Location Page
UAN 66-6695-700 1
1 MTPA ALUMINA NALCO DAMANJODI
TON
DATA SHEET FOR TRUCK WEIGH BRIDGE ITEM
Truck Weigh Bridge
Rev Rev Rev. 00
1 GENERAL DATA 61 TRANSMITTER / INDICATOR
2 Site Location Damanjodi 62 Principal of operation Microprocessor based
3 Type of Weigh Bridge (1) PIT-LESS type 63 Model no.
4 type of Weigh Bridge (2) Road Weighbridge 64 Display Digital Display, 7 Digits
5 Type of bridge construction Antiskid Steel Platform 65 Protection class IP 65
6 66 Housing material Die Cast Aluminium
7 DESIGN DATA 67
8 Design Capacity MT 60 68 DATA STORAGE
M
MODBUS RS485 with
Platform Size m X m 18 x 3 Interfaces for external connectivity
ne
necessary connectors
9 69
10 Quantity nos. 1 70 S
Sr. no.
11 Frequency of working 24 hrs/day 71 Date
Da & Time
12 Applicable Standard IS 9281 PART I-IV 72 Pr
Product code
13 Area of installation SAFE, Dusty 73 Cu
Customer code
14 Area Classification General Purpose 74 Tr
Truck Registration no.
Vehicle Management
15 Power Supply 110 VAC 75 Gr
Gross Weight
software (min. requirement)
16 230 VAC 76 Ta
Tare Weight
17 TECHNICAL DATA 77 Ne
Net Weight
18 Number of Load cells nos. 8 78 Da
Daily Report
19 Min. Readout on Display 79 W
Weight Totaliser
20 Minimum Increment rating 80
21 Overall Weigh Accuracy 81
22 Max. Allowed Tolerance 82
23 Distance from Platform to Control Room 30 m max 83 INSTRUMENTATION
24 Maximum Speed of vehicle pass over 10 km/hr 84
25 Weighing Range 0-60 MT 85 PC, INTEL, dual core processor,
50
500 GB HDD, 2 GB RAM, DVD
26 LOAD CELLS 86 Personal Computer (PC) Dr
Drive, OS, 17" Colour Monitor,
27 Make and Model no. 87 Keyboard, Mouse. Or latest version
28 Type of Load cell 88
29 Protection class 89 Printer A4, LaserJet
A4
30 Sealing Type 90 fro Load cell / Transmitter to
from
Cables Pa
Panel/Indicator
31 Rated capacity of each Load cell 91
32 Safe Overload of each Load cell 92 Uninterrupted Power Supply minimum 30 min. Backup
m
33 Ultimate Overload of each Load cell 93 Power Supply One point supply
O
34 MOC of Load cell 94 Over Capacity Annunciation
35 Operating Nominal temp. range 95
36 Compensated temp. range 96 ADDITIONAL SCOPE
37 Load cell accuracy 97 Structure and Support
38 Zero Balance 98 Foundation / Anchor Bolts & Hardware
39 Hysteresis 99 Painting as per UIPL specs./ MFR's std.
40 Non-Linearity 100 Calibration and Commissioning
41 Repeatability 101 Special Tools and Tackles if any
42 Creep after 30 minutes 102 Commissioning Spares
43 103 1 Years Operational Spares
44 JUNCTION BOX 104 Supervision of Erection/Commissioning
45 Material of construction 105 Erection & commissioning
46 Protection class 106 Documentation
47 Glands for cable entry 107
48 Type of platform 108 GUARANTEES
49 109 Design Capacity MT 60
50 110 Accuracy Kg ±20
51 111
52 REMARKS / NOTES
53 a. Bidder to fill blank details
54
55
56
57
58
59
60
2018 tKIS-INDIA FORM_WEIGH BRIDGE_DS_R0
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REFINERY STREAM-5
PIPING SPECIFICATION
Rev 02 Page 1 of 2
REVISED AS PER CLIENT’S

02 IFR 23.01.18 PTE 23.01.18 SHK 23.01.18 NNG -
COMMENTS AND RE-ISSUED
01 IFR REVISED AND RE-ISSUED FOR 13.10.17 PTE 13.10.17 SHK 13.10.17 NNG -
REVIEW
00 IFR FIRST ISSUE 28.09.17 PTE 28.09.17 SHK 28.09.17 NNG -
Category Code: -3
Barcode
552 of 1528
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REFINERY STREAM-5
Rev 02
00 Page 2 of 2
CONTENTS :
PART 1 General
PART 2 Fluid List
PART 3 Branch Table
PART 4 Piping Classes
PART 5 Miscellaneous
- Insulation Thicknes Tables
- Testing & Test System
ANNEXURE I - Dimensional details of special Tapers.

ANNEXURE II - Dimensional Details of Paddle spacer and blanks for flanges to B16.47A.
ANNEXURE III - General engineering spec for start up strainer & spacer.
ANNEXURE IV - Dimensional details of steel adaptor.
ANNEXURE V - Standard drawings for metallic piping fabrication & welding.
ANNEXURE VI - Master abbreviation list.
553 of 1528
Projectnumber : 66-6695-700
Piping Specification
General Rev. Date
First Issue
:
:
22.01.18
28.09.17
Print Date : 23.01.2018
Print Time : 17:07
PIPING
SPECIFICATION
Nalco
66-6695
Part 1
LG-PIP-01 STATUS: IFR
46-7519-10/IRP4.0-MU1/RS10/1996-12/00
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Piping Specification Part : 1
Page : 1
General Rev. Date
First Issue
:
:
22.01.18
28.09.17
Print Date : 23.01.2018
Print Time : 17:07
CLIENT : NALCO TITLE OF DOCUMENT : PIPING SPECIFICATION

SITE : DAMANJODI ORISSA DATE OF FIRST ISSUE : 28/09/2017
PROJECT : ALUMINA REFINERY(STREAM-5)
.--------.----------.---------------.---------------.---------------.--------------------------------------------------.
! REV. ! DATE ! PREPARED ! CHECKED ! APPROVED ! REMARK !
! ! ! DATE / SIGN ! DATE / SIGN ! DATE / SIGN ! !
!--------+----------.---------------+---------------+---------------+--------------------------------------------------!
! 0 ! 28/09/17 ! PTE ! SHK ! NNG ! FIRST ISSUE !
! ! ! 28/09/17 ! 28/09/17 ! 28/08/17 ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
! ! ! ! ! ! !
! 1 ! 13/10/17 ! PTE ! SHK ! NNG ! REVISED AND RE-ISSUED FOR REVIEW !
! ! ! 13/10/17 ! 13/10/17 ! 13/10/17 ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
! ! ! ! ! ! !
! 2 ! 23/01/18 ! PTE ! SHK ! NNG ! REVISED AS PER CLIENT’S COMMENTS AND RE-ISSUED !
! ! ! 23/01/18 ! 23/01/18 ! 23/01/18 ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
! ! ! ! ! ! !
! ! ! ! ! ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
! ! ! ! ! ! !
! ! ! ! ! ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
! ! ! ! ! ! !
! ! ! ! ! ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
! ! ! ! ! ! !
! ! ! ! ! ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
! ! ! ! ! ! !
! ! ! ! ! ! !
! ! ! ! ! ! !
!--------‘----------‘---------------‘---------------‘---------------‘--------------------------------------------------!
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C O N T E N T
-------------
.----------.-----------.------------------------------------------------------------------------------------------------.
! PART ! PAGE ! !
!----------+-----------+------------------------------------------------------------------------------------------------!
! 1 ! ! GENERAL !
! ! ! !
! ! ! 1. CONTENT !
! ! ! 2. PIPE LINE DESIGNATION !
! ! ! 3. GENERAL NOTES TO PIPING SPECIFICATION !
! ! ! 4. SPECIAL REQUIREMENTS !
! ! ! 5. LIST OF APPLICABLE STANDARDS !
! ! ! 6. SERVICE CATEGORY/NDT REQUIREMENTS !
! ! ! !
! 1b ! ! PIPING CLASSES !
! ! ! !
! 2 ! ! LIST OF FLUIDS !
! ! ! !
! ! ! !
! 3 ! ! BRANCH TABLE !
! ! ! !
! ! ! !
! ! ! !
! 4 ! ! PIPING CLASSES !
! ! ! ============== !
! ! ! PIPING CLASS A !
! ! ! PIPING CLASS B !
! ! ! PIPING CLASS C !
! ! ! PIPING CLASS D !
! ! ! PIPING CLASS E 2 !
! ! ! PIPING CLASS F !
! ! ! PIPING CLASS G !
! ! ! PIPING CLASS H !
! ! ! PIPING CLASS J !
! ! ! PIPING CLASS K !
! ! ! PIPING CLASS L !
! ! ! PIPING CLASS M !
! ! ! PIPING CLASS N !
’----------’-----------’------------------------------------------------------------------------------------------------’
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.----------.-----------.------------------------------------------------------------------------------------------------.
! PART ! PAGE ! !
!----------+-----------+------------------------------------------------------------------------------------------------!
! ! ! PIPING CLASS P !
! ! ! PIPING CLASS R !
! ! ! PIPING CLASS S !
! ! ! PIPING CLASS X !
! ! ! PIPING CLASS Y !
! ! ! PIPING CLASS Z !
! ! ! PIPING CLASS XX00 2 !
! ! ! !
! ! ! !
! ! ! !
! 5 ! ! MISCELLANEOUS !
! ! ! ============= !
! ! ! INSULATION SPECIFICATION !
! ! ! PRESSURE TESTING OF PIPELINES !
! ! ! !
! ! ! !
! ! ! !
! ! ! !
’----------’-----------’------------------------------------------------------------------------------------------------’
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L I N E D E S I G N A T I O N
------------------------------
...................................................... FLUID CODE

.
. ................................................ PIPING NUMBER .... 232 = PROCESS UNIT CODE
. . (KEY NO.) 0013 = LINE NUMBER
. .
. . ........................................ DIAMETER, NOMINAL IN MM
. . .
. . .
. . . ..................................... PIPING CLASS
. . . .
. . . .
. . . . ................................. TYPE OF INSULATION
. . . . .
. . . . .
. . . . . ............................ INSULATION THICKNESS
. . . . . .
. . . . . .
---- -------- --- - -- --
MIS1 232-0013 - 200 A - HC - 30
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GENERAL NOTES TO THIS PIPING SPECIFICATION

------------------------------------------
1. BALL VALVES SHALL HAVE LONG PATTERN DESIGN, UNLESS OTHERWISE SPECIFIED.
2
2. BALL VALVES SPECIFIED WITH REDUCED BORE(RB) SHALL BE OF SINGLE REDUCED BORE.
3. BALL VALVES WILL BE SOFT (PTFE) SEATED, UNLESS OTHERWISE SPECIFIED.
4. REINFORCEMENT PAD AT LOCATIONS SHOWN IN ISOMETRICS SHALL BE PROVIDED. THE DIAMETER OF

PAD SHALL BE TWICE THE OUTSIDE DIAMETER OF BRANCH PIPE, UNLESS OTHERWISE SPECIFIED.
THICKNESS OF PAD SHALL BE SAME AS THE RUN PIPE, UNLESS OTHERWISE SPECIFIED.
5. USE OF 1 1/4", 2 1/2", 3 1/2", 5", 7", 9", 22", 26", 28", 34" NOMINAL DIAMETER LINES
SHALL BE AVOIDED AS FAR AS POSSIBLE.
6. FOR 1 1/2" AND BELOW LINES, MINIMUM WALL THICKNESS SHALL BE NOT LESS THAN SCHEDULE XS IN
CASE OF CARBON STEEL PIPES; AND NOT LESS THAN SCHEDULE 40S IN CASE OF STAINLESS STEEL
PIPES. FOR ALL OTHER SIZES, MINIMUM WALL THICKNESS SHALL BE NOT LESS THAN SCHEDULE STD IN
CASE OF CARBON STEEL PIPES; AND NOT LESS THAN SCHEDULE 5S IN CASE OF STAINLESS STEEL
PIPES.
7. ALL PISTON CHECK VALVES SHALL BE WITHOUT SPRING AND SHALL BE ERECTED ONLY ON HORIZONTAL LINES
UNLESS SPECIFIED.
8. NO COMPONENTS FORMED FROM ALUMINIUM, ZINC, COPPER AND THEIR ALLOYS ARE TO BE USED. MATERIALS
CONTAINING ASBESTOS FIBRES SHALL NOT BE USED. GREY CAST IRON SHALL NOT BE USED.
9. FLANGE GUARDS SHALL BE PROVIDED AT EVERY FLANGE JOINT WITHOUT EXCEPTION FOR ALL APPLICABLE
SERVICES AS INDICATED BY THE FLUID LIST.
10. THIS PIPING SPECIFICATION IS GENERATED FROM THE BASIS GIVEN BY ALCAN IN DOC. NO:
Z02-000-7-SP-014 - BASIS FOR PIPING MATERIAL SPECIFICATIONS. FOR STEAM APPLICATION PIPE
CLASSES ARE GENERATED AS PER IBR REQUIREMENTS.
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SPECIAL REQUIREMENTS
--------------------
1. COOLING WATER AND VACUUM SERVICE (PIPE CLASS ’B’):
- PIPING 750NB OR GREATER IS NOT PERMITED FOR VACUUM(VC) FLUID SERVICE.
2. FRESH CAUSTIC SERVICE (PIPE CLASS ’C’):
- For PIPE 1050NB AND 1200NB THE MAXIMUM DISATNCE OF STRAIGHT PIPE
(STRAIGHT DISTANCE BETWEEN WELDS OF ELBOWS AND/OR FLANGE) IS 11.0M AND 9.0M RESPECTIVELY.
3. CONCENTRATED SULPHURIC ACID SERVICE (PIPE CLASS ’D’):
- CONCENTRATED SULPHURIC ACID IS A POWERFUL OXIDANT AND DESSICANT AND CAN CAUSE SERIOUS BURN ON
THE SKIN.
- IN CASE OF HYDROTESTING OF PIPE SYSTEMS, AFTER TESTING ALL PIPING SHALL BE THOROUGHLY DRAINED AND
THEN DRIED WITH HOT DRY AIR UNTIL ALL THE MOISTURE HAS BEEN REMOVED.
- PIPING SYSTEMS SHOULD NOT HAVE BLOCKED IN ACID FOR LONG TIME WITHOUT PRESSURE RELIEF DEVICE,
OTHERWISE HYDROGEN GENERATED BY CORROSION COULD DEVELOP DANGEROUS PRESSURES. ACCUMULATION OF
HYDROGEN IN PIPING IS A POTENTIAL EXPLOSION HAZARD. IN CASE OF INTERMITTANT TRANSFER OF ACID,
AFTER EACH TRANSFER ALL PIPING SHALL BE THOROUGHLY DRAINED AND THEN DRIED WITH HOT DRY AIR.
- USE OF FLANGE JOINTS IS TO BE MINIMISED.
4. SCALING AND SLURRY SERVICE (PIPE CLASS ’F’):
- WELD PENETRATIONS SHALL BE GROUND FLUSH WHERE POSSIBLE. IF GRINDING IS NOT POSSIBLE, MAXIMUM
ACCEPTABLE WELD PENETRATION SHALL NOT EXCEED 1mm. TIG ROOT RUNS MAY BE SPECIFIED.
- FOR FULID CODE FV(ONLY) AND PIPE OF 750NB, 900NB, 1050NB and 1200NB, THE MAXIMUM DISATNCE OF STRAIGHT
PIPE(STRAIGHT DISTANCE BETWEEN WELDS OF ELBOWS AND/OR FLANGE) IS 7.0M, 5.0M, 4.0M and 9.0M RESPECTIVELY.
- IF CAUSTIC CLEANING IS USED, TEMPERATURE OF CLAENING CAUSTIC IS TO BE <=85 DEG.C AND CONCENTRATION
<=160 GPL FREE CAUSTIC AS NA2CO3.
5. SCALING AND HIGHLY ABRASIVE SLURRIES (PIPE CLASS ’G’):
- FOR ’LM’ SERVICE (MILK OF LIME) ALL PIPE RUNS SMALLER THAN DN 200 SHALL BE IN 6m FLANGED SECTIONS. ALL
MANUALLY OPERATERED VENT AND DRAIN CONNECTIONS SHALL BE DN 50.
- IN SLURRY APPLICATIONS, WELD PENETRATIONS SHALL BE GROUND FLUSH WHERE POSSIBLE. IF GRINDING IS NOT
POSSIBLE, MAXIMUM ACCEPTABLE WELD PENETRATION SHALL NOT EXCEED 1mm. TIG ROOT RUNS MAY BE SPECIFIED.
- STRESS RELIEVING SHALL BE CARRIED OUT FOR ALL WELDS FOR DIS2,DLS2,DSS2 & MIS2 SERIVCES.
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- FOR LM FLUID SERVICE ONLY,IF CAUSTIC CLEANING IS USED, TEMPERATURE OF CLAENING CAUSTIC IS TO BE
<=85 DEG.C AND CONCENTRATION <=160 GPL FREE CAUSTIC AS NA2CO3.
6. STRONG CAUSTIC CLEANING LIQUOR SERVICE (PIPE CLASS ’H’):
- STRESS RELIEVING SHALL BE CARRIED OUT FOR ALL WELDS IN ALL SERVICES.
- ANGLE VALVE AND BAYONET VALVES SHOULD ONLY BE USED FOR TANK CONNECTIONS AND SCALING APLLICATION
THAT AFFECT THE GATE VALVE OPERATION AND THE VALVE AT CLEANING CAUSTIC CONNECTION SHOULD BE AS PER
THE PROCESS PIPELINE SPECIFICATION.
7. HIGH PRESSURE SLURRY SERVICE (PIPE CLASS ’J’):
- WELD PENETRATIONS SHALL BE GROUND FLUSH WHERE POSSIBLE. IF GRINDING IS NOT POSSIBLE, MAXIMUM
ACCEPTABLE WELD PENETRATION SHALL NOT EXCEED 1mm. TIG ROOT RUNS MAY BE SPECIFIED.
8. ACID CLEANING SERVICE (SCALING SERVICE) (PIPE CLASS ’K’):

- IN SLURRY APPLICATIONS, WELD PENETRATIONS SHALL BE GROUND FLUSH WHERE POSSIBLE. IF GRINDING IS NOT
POSSIBLE, MAXIMUM ACCEPTABLE WELD PENETRATION SHALL NOT EXCEED 1mm. TIG ROOT RUNS MAY BE SPECIFIED.
9. STRONG CAUSTIC LIQUORS (PIPE CLASS ’L’):
- PIPING SYSTEM SHALL BE SUBJECTED TO ACID CLEANING.
10. LOW SCALING LIQUOR SERVICE (PIPE CLASS ’M’):
- IF CAUSTIC CLEANING IS USED, TEMPERATURE OF CLEANING CAUSTIC IS TO BE <=85 DEG.C AND CONCENTRATION
11. STRONG AND HIGH TEMPERATURE CAUSTIC SERVICE (PIPING CLASS ’N’)
- ALL WELDED DUPLEX STEEL COMPONENTS SHALL BE PASSIVATED IN CONFORMANCE WITH ASTM A380 AND ASTM A967 AS
APPLICABLE.
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12. FLASH VAPOUR SERVICE(PIPING CLASS ’P’)

15. SLURRY TRANSPORTAION (RED MUD) (PIPING CLASS ’R’)
- THIS SPEC. HAS BEEN DESIGNED IN ACCORDANCE WITH B31.4. THE STRINGENT REQUIREMENTS FOR DESIGN,
CONSTSTRUCTION AND TESTING UNDER THIS CODE HAS BEEN FULLY RECOGNISED AND APPLIED.
2 - THE FABARICATION SHOULD BE ACCORDING TO B31.4.
16. SUPERNATANT LIQUOR SERVICE(PIPING CLASS ’S’)
17. STEAM SERVICE
- USE PIPE CLASS ’Y’ FOR CL 300 IBR SERVICES AND PIPE CLASS ’Z’ FOR CL 600 IBR SERICES. 2
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STANDARDS
----------------------------------------------------------------------------------------------------------------------
DESIGNATION STANDARD
----------------------------------------------------------------------------------------------------------------------
1. DESIGN
1.1 WALL THICKNESS ASME B31.3(2016) / ASME B31.1(2016)/ASME B31.4(2016)/IBR

1.2 BRANCH CALCULATION ASME B31.3(2016) / ASME B31.1(2016)/ASME B31.4(2016)/IBR 2
1.3 OTHER DESIGN REQUIREMENTS ASME B31.3(2016) / ASME B31.1(2016)/ASME B31.4(2016)/IBR
2.0 DIMENSIONS
PIPES ASME B36.10M/ASME B36.19M/API 5L

ELBOWS ASME B16.9/ASME B16.11
REDUCERS ASME B16.9/ASME B16.11
TEES ASME B16.9/ASME B16.11
CAPS ASME B16.9/ASME B16.11
THREADED AND SOCKET WELD FITTINGS ASME B16.11
FLANGES ASME B16.5/ASME B16.47 SERIES A
GASKETS ASME B16.20/ASME B16.21
STUD BOLTS ASME B18.2.1
NUTS ASME B18.2.2
SPECTACLE BLIND ASME B16.48/6695-PIP-G00-TB-0003
OLETS MSS-SP-97
SWAGE MSS-SP-95
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STANDARD
---------------------------------------------------------------------------------------------------------------------
DESIGNATION STANDARD
----------------------------------------------------------------------------------------------------------------------
3. DESIGN MANUFACTURING STANDARDS FOR VALVES
- GATE VALVES API 602 / API 600
- GLOBE VALVES BS EN ISO 15761 / BS 1873
- BUTTERFLY VALVES API 609
- CHECK VALVES API 594 / BS 1868 / MFG STD
- BALL VALVES API 608
- DIAPHRAGM VALVES BS EN 13397

- ANGLE SLURRY VALVE MFG STD
- ANGLE CHECK VALVE MFG STD
- ANGLE BAYONET VALVE MFG STD
- ANGLE 3-WAY VALVE MFG STD
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SERVICE CATEGORY/NDT REQUIREMENTS
STAINLESS STEEL
-----------------------------------------------------------------------------------------------------------
CATEGORY EXTENT OF NDT EXAM. OF COMPLETE WELDS IN %
----------------------------------------------------------------------------------------------
TYPE OF CONNECTION VISUAL XRT MPT DPT REMARKS
-----------------------------------------------------------------------------------------------------------
B.W. 100 20 - -
NF S.W/F.W 100 - - 20 1)
B.C 100 - - 100 3) 2)
-------------------------------------------------------------------------------------------------------------
NOTE: 1.ONLY FOR ROOT RUN 2.FOR ROOT AND FINAL RUN 3.FOR VENT & DRAIN LINES NDT REQUIREMENT IS NOT
APPLICABLE.
LEGEND: NDT:NON DESTRUCTIVE TEST , DPT:DYE PENETRANT TEST, MPT:MAGNETIC PARTICLE TEST
XRT:X-RAY EXAM/GAMMA-RAY, BW:BUTT WELD, SW:SOCKET WELD
FW:FILLET WELD, BC:BRANCH CONNECTION
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SERVICE CATEGORY/NDT REQUIREMENTS
CARBON STEEL
------------------------------------------------------------------------------------------------------------
CATEGORY EXTENT OF NDT EXAM. OF COMPLETE WELDS IN %
---------------------------------------------------------------------------------------------
TYPE OF CONNECTION VISUAL XRT MPT DPT REMARKS
------------------------------------------------------------------------------------------------------------
B.W 100 10 - -
NF S.W/F.W 100 - - -
B.C 100 - - 100 1) 2)
------------------------------------------------------------------------------------------------------------
NOTE: 1.AS PER IBR(FOR IBR PIPECLASS)2.FOR ROOTRUN AND FINAL RUN
LEGEND:NDT: NON DESTRUCTIVE TEST, DPT:DYE PENETRANT TEST, MPT:MAGNETIC PARTICLE TEST
XRT: X-RAY EXAMINATION/GAMMA-RAY B.W:BUTT WELD SW:SOCKET WELD
FW: FILLET WELD, B.C:BRANCH CONN.
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HYDROTEST VENT-DRAIN TYPE

--------------------------
A - FLANGE-BLIND FLANGE OF 25NPS. 2
C*- NIPPLE AND THREADED CAP OF 20NPS. AFTER HYDROTEST IS OVER, THE CAP SHALL BE SEAL WELDED.
E - HYDROSTATIC TEST VENTS SHALL BE 20NPS CLASS 3000 SOCKET WELD HALF COUPLING, NIPPLE, VALVE AND THREADED CAP.
AFTER SATISFACTORY COMPLETION OF PRESSURE TESTING THE VALVE AND ITS DOWNSTREAM NIPPLE SHALL BE REMOVED
AND THE THREADED CAP SHALL BE SEAL WELDED ON TO EXSISTING NIPPLE.
F - HYDROSTATIC TEST VENTS SHALL BE 20NPS CLASS 6000 THREADOLET, NIPPLE, VALVE AND PLUG.
AFTER SATISFACTORY COMPLETION OF PRESSURE TESTING THE VALVE SHALL BE REMOVED AND THE PLUG SHALL BE SEAL
WELDED INTO THREADOLET.
CG*- NIPPLE AND THREADED CAP OF 50NPS. AFTER HYDROTEST IS OVER, THE CAP SHALL BE SEAL WELDED. 2
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Piping Classes Print Date : 22.01.2018
Print Time : 13:45
Piping Class Material Corr. Allowance Nominal Pressure Facing

A A53 GR.B (GALV) 2.50MM 150 RF
B A106 GR.B/A53GR.B/API-5LGR.B 2.00MM 150 RF
C A106GR.B/A53GR.B/API-5LGR.B 2.00MM 150 RF
D A106 GR.B 2.00MM 150 RF
2
E A 312 TP316L 0.0 MM 300 RF
F A106 GR.B/A53 GR.B/API-5LGR.B 2.00MM 150 RF
G A106 GR.B/A53 GR.B/API-5LGR.B 3.0-5.0MM 150 RF
H A106 GR.B(STRESS RELIEVED) 2.00MM 150 RF
J A106GR.B(STRESS RELIEVED) 3.00MM 300 RF
K A106GR.B(STRESS RELIEVED) 2.00MM 150 RF
L A106GR.B(STRESS RELIEVED) 2.00MM 300 RF
M A106GR.B/A53GR.B/API-5LGR.B 2.00MM 150 RF
N DUPLEX SS (UNS S31803) 0.00MM 300 RF
P A106GR.B/A53GR.B 2.00MM 300 RF
R API-5L GR.X52 1.50MM 600 RF
S A106GR.B/A53GR.B 2.00MM 300 RF
X A106GR.B/A672GR.B60 CL32 2.00MM 150 RF
2
XX00 STANDARD PIPING SPECIALS
Y A106GR.B/A672GR.B60 CL32 (IBR) 2.00MM 300 RF
Z A106GR.B/A672GR.B60 CL32 (IBR) 2.00MM 600 RF
46-7519-10/IRP4.0-MU1/RS11/1996-12/00
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UAN : 66-6695-700
Piping Specification :
:
Rev.Date : 22.01.18
List of Fluids First Issue : 28.09.17
Date : 22/01/18
Time : 15:44
PIPING
SPECIFICATION
Nalco
66-6695
PART 2
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List of Fluids Date : 22/01/18
Time : 15:44
Fluid Tracer/ Paint Test Vent / Insul. Category acc. Corros. Oper. Oper. Design Design DN Piping
Heating Sys. Sys. Drain Type To allow. press. temp. press. temp. class
Code Designation Details 4) 3) 1) 2) ASME B31.3 mm KPag Deg.C KPag Deg.C Max.
AFR Anti Foam Agent CN02 C* NF 2 120 30 1360 60 1200 B
AIR Air (High Volume) CN50 C* NF 2 850 40 1360 60 1200 B
AIR1 Caustic Laden Air CN04 C* HC NF 2 Atm 85 1500 150 1200 F

PP
ALE Alkaline Effluent CN04 C* HC NF 2 900 120 1500 150 1200 F
ALE1 Alkaline Effluent CN02 C* NF 2 670 40 1360 70 1200 B
APS Agglomeration Precipitation CN04 C* HC NF 2 900 120 1500 150 1200 F

Slurry
CFL Caustification Overflow CN04 C* HC NF 2 900 98 1500 150 1200 F

PP
CGM Crystal Growth Modifier CN02 C* NF 2 500 50 1360 80 1200 B
CLL Caustic Cleaning Liquor 5) CN04 C* HC NF 2 980 85 1500 115 600 H

PP
CLU Caustic Cleaning Liquor Used5) CN04 C* HC NF 2 740 85 1500 115 600 H
PP
CON Live Steam Condensate CN09 C* HC NF 2 1300 181 4265 300 750 Z
medium pressure
CON1 Live Steam Condensate CN05 C* HC NF 2 580 158 1375 300 750 Y
Low Pressure
CRS CaustificationReactor Slurry5) CN04 C* HC NF 2 490 98 1500 150 1200 F

REMARK: 1) Refer ’Hydrotest Vent-Drain Type’ in Part 1 - General 2) PP=Personal Protection, HC=HEAT CONSERVATION,
2 D=Steam Tracing
3) Test System Details refer part 5 4) Painting system as per Painting Specification
5) Flange guard to be provided 6) Continuity strip required
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Time : 15:44
PP
CSA Sulphuric Acid 98 % CN01 C* NF 2 180 30 1200 60 250 D

Concentration 5)
CSR Coarse Seed Reslurry 5) CN04 C* HC NF 2 1130 65 1500 150 1200 F

PP
CSS Coarse Seed Slurry 5) CN04 C* NF 2 180 53 1500 150 1200 F
CW Cooling Tower Water CN02 C* NF 2 600 45 1360 75 1200 B
DFS Deliquoring Filter Slurry CN04 C* NF 2 900 53 1500 150 1200 F
DFW Product Dewatering Filter CN04 C* HC NF 2 1070 91 1500 150 1200 M

Filtrate PP
DIS1 Digestion Slurry CN04 E HC NF 2 710 143 1500 175 1200 F
DIS2 Digestion Slurry 5) CN04 E HC NF 3-5 710 80 1500 150 1050 G

PP
DIS4 Digestion Slurry 5) SN01 E HC NF 0 710 155 2500 200 600 N
DLS1 Diluted Slurry 5) CN04 C* HC NF 2 330 106 1500 150 1200 F

PP
DLS2 Diluted Slurry 5) CN04 C* HC NF 3-5 330 106 1500 150 1050 G
PP
DSA Sulphuric Acid Up To 10 % 2 SN03 A NF 0 625 44 1500 75 300 E

Concentration 5)
2
D=Steam Tracing
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DSS1 Desilication Slurry 5) CN04 C* HC NF 2 490 96.5 1500 150 1200 F

PP
DSS2 Desilication Slurry 5) CN04 C* HC NF 3-5 490 97.2 1500 150 1050 G
PP
DSS3 Desilication Slurry 5) CN08 C* HC NF 3 1450 95.7 4500 130 600 J

PP
DSS4 Desilication Slurry Acid CN04 C* HC NF 2 490 98 1500 150 600 K

Cleaned 5) PP
DW Domestic (Potable) Water CN04 C* NF 2.5 600 30 1500 60 150 A
FCL Fresh Caustic 5) CN03 C* NF 2 500 30 1375 200 1200 C
FDW Fine Seed Dewatering Slurry CN04 C* NF 2 HOLD 53.7 1500 150 1200 M
FL Flocculent CN02 C* HC NF 2 510 74.5 1360 105 1200 B

PP
FO Fuel Oil 5) CN06 C* NF 2 HOLD 50 1600 120 600 X
FSF Fine Seed Filtrate CN04 C* NF 2 50 53.7 1500 150 1200 M
FSS Fine Seed Slurries CN04 C* HC NF 2 810 65.6 1500 150 1200 F
PP
FTS Red Mud Thickner Underflow CN04 C* HC NF 2 1000 101 1500 150 1200 F
PP
FV Flash Vapour (Scaling) CN52 C* HC NF 2 170 137 1500 170 1200 F

D=Steam Tracing
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FV1 Flash Vapour (Non Scaling) CN51 C* HC NF 2 170 137 1375 200 1200 C
FV2 Flash Vapour CN53 C* HC NF 2 1130 188 4265 230 600 P

(Scaling&Non-Scaling)
FW Fresh Water CN02 C* NF 2 600 30 1360 60 1200 B
FWS Washer Underflow CN04 C* HC NF 2 950 81.5 1500 150 1200 F

PP
GW1 Pump Gland Packing Water CN02 C* NF 2 HOLD 50 1360 70 1200 B
GW2 Pump Gland Packing Water CN07 C* HC NF 2 HOLD HOLD 4265 230 600 P
(High Pressure) PP
HDRM High Density Red Mud Slurry CN11 F HC NF 1.5 HOLD HOLD 9200 90 400 R
PP
HFL Hydrate Filtration Liquor CN04 C* HC NF 2 640 62.2 1500 150 1200 F
PP
HS Hydrate Slurry 5) CN04 C* HC NF 2 1005 64.2 1500 150 1200 F

PP
HTL Hydrate Thickener Liquor CN04 C* HC NF 2 HOLD HOLD 1500 150 1200 F
PP
HW Hosing (Industrial) Water CN02 C* NF 2 HOLD 50 1360 80 1200 B
IA Instrument Air CN52 C* NF 2.5 620 40 1500 70 150 A
INH Inhibitor CN02 C* NF 2 120 30 1360 60 1200 B

D=Steam Tracing
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IPW Instrument Purging Water CN02 C* NF 2 HOLD 50 1360 80 1200 B
LDO Light disel Oil 5) CN06 C* NF 2 HOLD 50 1600 120 600 X
LM Milk of Lime CN04 CG* HC NF 3-5 1170 95 1500 150 1050 G

PP
2
MIS1 Mill Pulp Injection Slurry 5) CN04 C* HC NF 2 600 76.4 1500 150 1200 F
PP
MIS2 Mill Pulp Injection Slurry 5) CN04 C* HC NF 3-5 600 76.4 1500 150 1050 G
PP
MIS3 Mill Pulp Injection Slurry 5) CN08 C* HC NF 3 1640 106 4500 140 600 J
PP
MPS Mid Precipitation Slurry CN04 C* HC NF 2 200 70 1500 150 1200 F

PP
ODS Oxalate Disposal Slurry CN04 C* HC NF 2 700 80 1500 150 1200 F

PP
OFS Oxalate Fine Seed Slurry CN04 C* HC NF 2 HOLD HOLD 1500 150 1200 M
PP
OFW Oxalate Fine Seed washed CN04 C* HC NF 2 HOLD HOLD 1500 150 1200 M
PP
OS Oxalate Slurry CN04 C* HC NF 2 HOLD HOLD 1500 150 1200 M

PP
PA Plant air CN50 C* NF 2 700 40 1360 70 1200 B

D=Steam Tracing
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Rev.Date : 22.01.18
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PC Process (Flash) Condensate CN07 C* HC NF 2 420 188 4265 230 600 P
PC1 Process (Flash) Condensate CN03 C* HC NF 2 450 128 1375 200 1200 C
PDS Product Dewatering Slurry CN04 C* NF 2 HOLD 53.8 1500 150 1200 F
PFF Product Deliquoring Filtrate CN04 C* NF 2 50 53.8 1500 150 1200 F
PFS Product Deliquoring Filter CN04 C* HC NF 2 HOLD HOLD 1500 150 1200 F
Slurry PP
PGL1 Pregnant Liquor 5) CN04 C* HC NF 2 590 101 1500 150 1200 F

PP
PGL2 Pregnant Liquor 5) CN04 C* HC NF 2 590 101 1500 150 600 K

PP
PHS Product Hydrate Slurry CN04 C* NF 2 720 53.8 1500 150 1200 F
POS Precipitators Pump Off Slurry CN04 C* NF 2 HOLD 55 1500 150 1200 F
PSS Sump Pump Slurry CN04 C* HC NF 2 550 102 1500 150 1200 F
PP
PW Process Water CN02 C* NF 2 600 30 1360 60 1200 B
RW Raw Water CN02 C* NF 2 600 30 1360 60 1200 B
SCF Seed Cyclone feed CN04 C* NF 2 50 53.7 1500 150 1200 F
SEL1 Strong Evaporation Liquor CN04 C* HC NF 2 1400 85 1500 150 1200 F

PP
D=Steam Tracing
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Project No. : 66-6695-700
Page : 7
Rev.Date : 22.01.18
Time : 15:44
SEL2 Strong Evaporation Liquor CN04 C* HC NF 2 1400 80.2 1500 150 600 K
PP
SFL1 Strong Digestion Feed Liquor CN04 E HC NF 2 400 80.2 1500 150 1200 F
PP
SFL2 Strong Digestion Feed Liquor CN04 E HC NF 2 400 92.4 1500 150 600 K
PP
2
SFL3 Strong Digestion Feed Liquor CN08 E HC NF 2 1870 105 4500 120 600 L
SFL4 Strong Digestion Feed Liquor SN02 E HC NF 0 1500 179 2500 210 600 N
SLP Low Pressure Steam CN05 C* HC NF 2 580 167 1375 300 750 Y
SMP Medium Pressure Steam CN09 C* HC NF 2 1300 220 4265 300 750 Z
SNL1 Supernatant Liquor CN04 C* NF 2 580 30 1500 150 1200 M
SNL2 Supernatant Liquor CN10 C* NF 2 1770 30 4800 75 600 S
SPL1 Spent Liquor 5) CN04 C* HC NF 2 800 77.1 1500 150 1200 F

PP
SPL2 Spent Liquor 5) CN04 C* NF 2 800 55.3 1500 150 600 K
TCA Filter Aid CN04 C* HC NF 2 HOLD 100. 1500 150 1200 F

PP
TRL Thickener overflow "turbid" CN04 C* HC NF 2 HOLD 101. 1500 150 1200 F
liquor 5) PP
D=Steam Tracing
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Page : 8
Rev.Date : 22.01.18
Time : 15:44
Code Designation Details 4) 3) 1) 2) ASME B31.3 mm KPag Deg.C KPag Deg.C Max. 2
VC Vacuum CN50 C* NF 2 -60 50 1360 80 750 B
WCL Weak Caustic Liquor 5) CN04 C* PP NF 2 HOLD 62.3 1500 150 1200 M
95.7
WL Weak Liquor CN04 C* HC NF 2 300 96.3 1500 150 1200 F

(1st Washer O/Flow) 5) PP
D=Steam Tracing
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Print Date : 22.01.2018
Print Time : 13:55
PIPING
SPECIFICATION
Nalco
66-6695
Part 3
46-7519-10/IRP4.0-MU1/RS31/1996-12/00
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25 UT UT __ __ __ __ __
40 UT UT UT __ __ __ __
50 UT UT UT UT __ __ __
80 UT UT UT UT UT __ __
100 UT UT UT UT UT UT __
150 US US US US US US ET
ET = BW-TEE US = THREADOLET CLASS 3000 UT = SCREWED-TEE,CL 3000
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25 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __ __ __ __
200 LW LW LW WH * ET ET ET __ __ __ __ __ __ __ __ __ __
250 LW LW LW WH * ET ET ET ET __ __ __ __ __ __ __ __ __
300 LW LW LW WH * * ET ET ET ET __ __ __ __ __ __ __ __
350 LW LW LW WH * * * ET ET ET ET __ __ __ __ __ __ __
400 LW LW LW WH * * * ET ET ET ET ET __ __ __ __ __ __
450 LW LW LW WH * * * * ET ET ET ET ET __ __ __ __ __
500 LW LW LW WH * * * * * * * ET ET ET __ __ __ __
600 LW LW LW WH * * * * * ** ** ** ** ET ET __ __ __
750 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ET __ __
900 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ET __
1050 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** ET
1200 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** **
** = STUB IN REINFORCEMENT * = STUB IN WITHOUT PAD ET = BW-TEE

LQ = SOCKET TEE, CL.3000 LW = HALF COUPLING SW, CL.3000 WH = WELDOLET SCH STD
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20 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __ __ __ __
200 LW LW LW WH * ET ET ET __ __ __ __ __ __ __ __ __ __
500 LW LW LW WH * * * * * * * ET ET ET __ __ __ __
600 LW LW LW WH ** ** * ** ** ** * ** ET ET ET __ __ __
750 LW LW LW WH * * ** * * * * * * * * ET __ __
900 LW LW LW WH * * ** * * * ** * ** ** ** ** ET __
1050 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** ET
1200 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** **

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350 __
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750 __
900 __
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Pipe 20 40 80 150 250
DN 25 50 100 200
20 LQ __ __ __ __ __ __ __ __
25 LQ LQ __ __ __ __ __ __ __
40 LQ LQ LQ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __
80 LW LW LW ET ET __ __ __ __
100 LW LW LW ET ET ET __ __ __
150 LW LW LW WH ET ET ET __ __
200 LW LW LW WH * ET ET ET __
250 LW LW LW WH * ET ET ET ET
* = STUB IN WITHOUT PAD ET = BW-TEE LQ = SOCKET TEE, CL.3000

LW = HALF COUPLING SW, CL.3000 WH = WELDOLET SCH STD
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Main Branch Pipe DN

Pipe 15 25 50 100 200 300
DN 20 40 80 150 250
15 LQ __ __ __ __ __ __ __ __ __ __
20 LQ LQ __ __ __ __ __ __ __ __ __
25 LQ LQ LQ __ __ __ __ __ __ __ __
40 LQ LQ LQ LQ __ __ __ __ __ __ __
50 LW LW LW ET ET __ __ __ __ __ __
80 LW LW LW LW ET ET __ __ __ __ __
100 LW LW LW LW ET ET ET __ __ __ __
150 LW LW LW LW W9 ET ET ET __ __ __
200 LW LW LW LW W9 W9 ET ET ET __ __
250 LW LW LW LW W9 W9 ET ET ET ET __
300 LW LW LW LW W9 W9 W9 ET ET ET ET
ET = BW-TEE LQ = SOCKET TEE, CL.3000 LW = HALF COUPLING SW, CL.3000

W9 = WELDOLET SCH 10S
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20 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __ __ __ __
200 LW LW LW WH * ET ET ET __ __ __ __ __ __ __ __ __ __
500 LW LW LW WH * * * * * * * ET ET ET __ __ __ __
600 LW LW LW WH ** ** ** ** ** ** ** ** ** ET ET __ __ __
750 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ET __ __
900 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ET __
1050 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** ET
1200 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** **

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Pipe 20 40 80 150 250 350 450 600 900
DN 25 50 100 200 300 400 500 750 1050
20 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __ __ __ __
150 LW LW LW WM ET ET ET __ __ __ __ __ __ __ __ __ __ __
200 LW LW LW WM * ET ET ET __ __ __ __ __ __ __ __ __ __
250 LW LW LW WM * ET ET ET ET __ __ __ __ __ __ __ __ __
300 LW LW LW WM * * ET ET ET ET __ __ __ __ __ __ __ __
350 LW LW LW WM * * * ET ET ET ET __ __ __ __ __ __ __
400 LW LW LW WM * * * ET ET ET ET ET __ __ __ __ __ __
450 LW LW LW WM * * * * ET ET ET ET ET __ __ __ __ __
500 LW LW LW WM * * * * * * * ET ET ET __ __ __ __
600 LW LW LW WM ** ** ** ** ** ** ** ** ** ET ET __ __ __
750 LW LW LW WM ** ** ** ** ** ** ** ** ** ** ** ET __ __
900 LW LW LW WM ** ** ** ** ** ** ** ** ** ** ** ** ET __
1050 LW LW LW WM ** ** ** ** ** ** ** ** ** ** ** ** ** ET

LQ = SOCKET TEE, CL.3000 LW = HALF COUPLING SW, CL.3000 WM = WELDOLET SCH XS
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DN 25 50 100 200 300 400 500
20 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __
200 LW LW LW WH * ET ET ET __ __ __ __ __ __ __
250 LW LW LW WH * ET ET ET ET __ __ __ __ __ __
300 LW LW LW WH * * ET ET ET ET __ __ __ __ __
350 LW LW LW WH * * * ET ET ET ET __ __ __ __
400 LW LW LW WH * * * ET ET ET ET ET __ __ __
450 LW LW LW WH * * * * ET ET ET ET ET __ __
500 LW LW LW WH * * * * * * * ET ET ET __
600 LW LW LW WH * * * * * * * * * ET ET

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DN 25 50 100 200 300 400 500
20 LT __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LT LQ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LT LQ LQ __ __ __ __ __ __ __ __ __ __ __ __
50 LV LW ET ET __ __ __ __ __ __ __ __ __ __ __
80 LV LW LW ET ET __ __ __ __ __ __ __ __ __ __
100 LV LW LW ET ET ET __ __ __ __ __ __ __ __ __
150 LV LW LW WM ET ET ET __ __ __ __ __ __ __ __
200 LV LW LW WM ** ET ET ET __ __ __ __ __ __ __
250 LV LW LW WM ** ET ET ET ET __ __ __ __ __ __
300 LV LW LW WM ** ** ET ET ET ET __ __ __ __ __
350 LV LW LW WM ** ** ** ET ET ET ET __ __ __ __
400 LV LW LW WM ** ** ** ET ET ET ET ET __ __ __
450 LV LW LW WM ** ** ** ** ET ET ET ET ET __ __
500 LV LW LW WM ** ** ** ** ** ** ** ET ET ET __
600 LV LW LW WM ** ** ** ** ** ** ** ** ** ET ET
** = STUB IN REINFORCEMENT ET = BW-TEE LQ = SOCKET TEE, CL.3000

LT = SOCKET TEE,6000# LV = HALF COUPLING SW,CLASS 6000 LW = HALF COUPLING SW, CL.3000
WM = WELDOLET SCH XS
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DN 25 50 100 200 300 400 500
20 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __
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40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __
200 LW LW LW WH * ET ET ET __ __ __ __ __ __ __
250 LW LW LW WH * ET ET ET ET __ __ __ __ __ __
300 LW LW LW WH * * ET ET ET ET __ __ __ __ __
350 LW LW LW WH * * * ET ET ET ET __ __ __ __
400 LW LW LW WH * * * ET ET ET ET ET __ __ __
450 LW LW LW WH * * * * ET ET ET ET ET __ __
500 LW LW LW WH * * * * * * * ET ET ET __
600 LW LW LW WH * * * * * * * * * ET ET

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DN 25 50 100 200 300 400 500
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40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __
200 LW LW LW WH ** ET ET ET __ __ __ __ __ __ __
250 LW LW LW WH ** ET ET ET ET __ __ __ __ __ __
300 LW LW LW WH ** ** ET ET ET ET __ __ __ __ __
350 LW LW LW WH ** ** ** ET ET ET ET __ __ __ __
400 LW LW LW WH ** ** ** ET ET ET ET ET __ __ __
450 LW LW LW WH ** ** ** ** ET ET ET ET ET __ __
500 LW LW LW WH ** ** ** ** ** ** ** ET ET ET __
600 LW LW LW WH ** ** ** ** ** ** ** ** ** ET ET

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DN 25 50 100 200 300 400 500 750 1050 2
20 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __ __ __ __
200 LW LW LW WH * ET ET ET __ __ __ __ __ __ __ __ __ __
500 LW LW LW WH * * * * * * * ET ET ET __ __ __ __
600 LW LW LW WH ** ** ** ** ** ** ** ** ** ET ET __ __ __
750 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ET __ __
900 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ET __
1050 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** ET
1200 LW LW LW WH ** ** ** ** ** ** ** ** ** ** ** ** ** **

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20 __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
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40 __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LW __ __ ET __ __ __ __ __ __ __ __ __ __ __
80 LW __ __ ET ET __ __ __ __ __ __ __ __ __ __
100 LW __ __ ET ET ET __ __ __ __ __ __ __ __ __
150 LW __ __ WA ET ET ET __ __ __ __ __ __ __ __
200 LW __ __ WA * ET ET ET __ __ __ __ __ __ __
250 LW __ __ WA * * ET ET ET __ __ __ __ __ __
300 LW __ __ WA * * * ET ET ET __ __ __ __ __
350 LW __ __ WA ** ** ** ** ET ET ET __ __ __ __
400 LW __ __ WA ** ** ** ** ** ET ET ET __ __ __
450 LW __ __ WA ** ** ** ** ** ** ET ET ET __ __
500 LW __ __ WA ** ** ** ** ** ** ** ET ET ET __
600 LW __ __ WA ** ** ** ** ** ** ** ** ET ET ET

LW = HALF COUPLING SW, CL.3000 WA = WELDOLET SCH 40S
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50 LW LW ET ET __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __
100 LW LW LW ET ET ET __ __ __ __ __ __ __ __ __
150 LW LW LW WH ET ET ET __ __ __ __ __ __ __ __
200 LW LW LW WH ** ET ET ET __ __ __ __ __ __ __
500 LW LW LW WH ** ** ** ** ** ** ** ET ET ET __
600 LW LW LW WH ** ** ** ** ** ** ** ** ** ET ET

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20 __ __ __ __ __ __ __ __ __ __ __ __
25 __ __ __ __ __ __ __ __ __ __ __ __
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50 UH __ __ ET __ __ __ __ __ __ __ __
80 UH __ __ ET ET __ __ __ __ __ __ __
100 UH __ __ ET ET ET __ __ __ __ __ __
150 UH __ __ WH ET ET ET __ __ __ __ __
200 UH __ __ WH ** ET ET ET __ __ __ __
250 UH __ __ WH ** ** ET ET ET __ __ __
300 UH __ __ WH ** ** ET ET ET ET __ __
350 UH __ __ WH ** ** ** ET ET ET ET __
400 UH __ __ WH ** ** ** ET ET ET ET ET
** = STUB IN REINFORCEMENT ET = BW-TEE UH = THREADOLET, CL.6000

WH = WELDOLET SCH STD
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200 LW LW LW WH ** ET ET ET __ __ __ __ __ __ __
500 LW LW LW WH ** ** ** ** ** ** ** ET ET ET __
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15 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
20 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __
50 LW LW LW ET ET __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW LW ET ET __ __ __ __ __ __ __ __ __ __
100 LW LW LW LW WH ET ET __ __ __ __ __ __ __ __ __
150 LW LW LW LW WH ET ET ET __ __ __ __ __ __ __ __
200 LW LW LW LW WH * ET ET ET __ __ __ __ __ __ __
250 LW LW LW LW WH * ET ET ET ET __ __ __ __ __ __
300 LW LW LW LW WH * * ET ET ET ET __ __ __ __ __
350 LW LW LW LW WH * * * ET ET ET ET __ __ __ __
400 LW LW LW LW WH * * * ET ET ET ET ET __ __ __
450 LW LW LW LW WH * * * * ET ET ET ET ET __ __
500 LW LW LW LW WH * * * * * * * ET ET ET __
600 LW LW LW LW WH * * * * * ** ** ** ** ET ET

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:
:
22.01.18
28.09.17
Piping Class: Y Print Date : 22.01.2018
Print Time : 13:58

Pipe 15 25 50 100 200 300 400 500 650 on Page
DN 20 40 80 150 250 350 450 600 700 2
15 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
20 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LQ LQ LQ ET ET __ __ __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW LW ET ET __ __ __ __ __ __ __ __ __ __ __ __
100 LW LW LW LW ET ET ET __ __ __ __ __ __ __ __ __ __ __
150 LW LW LW LW ** ET ET ET __ __ __ __ __ __ __ __ __ __
200 LW LW LW LW ** ** ET ET ET __ __ __ __ __ __ __ __ __
250 LW LW LW LW ** ** ** ET ET ET __ __ __ __ __ __ __ __
300 LW LW LW LW ** ** ** ** ET ET ET __ __ __ __ __ __ __
350 LW LW LW LW ** ** ** ** ** ET ET ET __ __ __ __ __ __
400 LW LW LW LW ** ** ** ** ** ** ET ET ET __ __ __ __ __
450 LW LW LW LW ** ** ** ** ** ** ** ET ET ET __ __ __ __
500 LW LW LW LW ** ** ** ** ** ** ** ** ET ET ET __ __ __
600 LW LW LW LW ** ** ** ** ** ** ** ** ** ET ET ET __ __
650 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ET ET ET __
700 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ** ET ET ET
750 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ** ** ET ET

LW = HALF COUPLING SW, CL.3000
46-7519-10/IRP4.0-MU1/RS31/1996-12/00
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:
:
22.01.18
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Piping Class: Y Print Date : 22.01.2018
Print Time : 13:58

Pipe 750 from Page
DN 1
15 __
20 __
25 __
40 __
50 __
80 __
100 __
150 __
200 __
250 __
300 __
350 __
400 __
450 __
500 __
600 __
650 __
700 __
750 ET

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Page : 1
First Issue
:
:
22.01.18
28.09.17
Piping Class: Z Print Date : 22.01.2018
Print Time : 13:58

Pipe 15 25 50 100 200 300 400 500 650 on Page
DN 20 40 80 150 250 350 450 600 700 2
15 LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
20 LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
25 LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __
40 LQ LQ LQ LQ __ __ __ __ __ __ __ __ __ __ __ __ __ __
50 LQ LQ LQ ET ET __ __ __ __ __ __ __ __ __ __ __ __ __
80 LW LW LW LW ** ET __ __ __ __ __ __ __ __ __ __ __ __
100 LW LW LW LW ** ** ET __ __ __ __ __ __ __ __ __ __ __
150 LW LW LW LW ** ** ** ET __ __ __ __ __ __ __ __ __ __
200 LW LW LW LW ** ** ** ** ET __ __ __ __ __ __ __ __ __
250 LW LW LW LW ** ** ** ** ** ET __ __ __ __ __ __ __ __
300 LW LW LW LW ** ** ** ** ** ** ET __ __ __ __ __ __ __
350 LW LW LW LW ** ** ** ** ** ** ** ET __ __ __ __ __ __
400 LW LW LW LW ** ** ** ** ** ** ** ** ET __ __ __ __ __
450 LW LW LW LW ** ** ** ** ** ** ** ** ** ET __ __ __ __
500 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ET __ __ __
600 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ** ET __ __
650 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ** ** ET __
700 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ** ** ** ET
750 LW LW LW LW ** ** ** ** ** ** ** ** ** ** ** ** ** **

46-7519-10/IRP4.0-MU1/RS31/1996-12/00
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Page : 2
First Issue
:
:
22.01.18
28.09.17
Piping Class: Z Print Date : 22.01.2018
Print Time : 13:58

Pipe 750 from Page
DN 1
15 __
20 __
25 __
40 __
50 __
80 __
100 __
150 __
200 __
250 __
300 __
350 __
400 __
450 __
500 __
600 __
650 __
700 __
750 ET

46-7519-10/IRP4.0-MU1/RS31/1996-12/00
603 of 1528
Piping Classes Rev. Date

First Issue
:
:
22.01.18
28.09.17
Print Date : 22.01.2018
Print Time : 14:42
PIPING
SPECIFICATION
Nalco
66-6695
Part 4
46-7519-10/IRP4.0-MU1/RS40/1996-12/00
604 of 1528
Page : 1
Piping Class: A
Nalco Print Date : 23.01.2018
Print Time : 17:14
Fluid code:
DW IA
Basic Material: A53 GR.B (GALV) Facing: RF Corrosion allowance: 2.50MM
Rating: Temperature CEL: -29 38 93 149 204
Class 150 Pressure KPag: 1965,31 1965,31 1802,51 1644,63 1378,85
Piping Schedule
B36.10M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3
Thk 3,73 3,91 4,55 5,08 5,54 7,62 8,56 7,11
Sch XS XS XS XS XS XS XS STD
2 Rating DN
Pipe Designation Class from to M a t e r i a l Standard End Connection Note
P PGWA06 PIPE, ERW, CS, GALV 15 100 A53 GR.B GALV B36.10M TBE, NPT(M), SCH XS, B 1.20.1
P P WA06 PIPE,ERW,CS GALV 2 150 150 A53 GR.B GALV B36.10M BW ENDS,SCH STD
Fittings
E UE A11 ELB, 90 DEG,LR, CS GALV 3000 20 100 A105N GALV B16.11 SCRD,NPT(F), B1.20.1
E E WA05H ELB,90 DEG,LR, CS GALV 150 150 A 234 GR.WPB-W GALV B16.9 BW ENDS,SCH STD
EF UF A11 ELB, 45 DEG,LR, CS GALV 3000 20 100 A105N GALV B16.11 SCRD,NPT(F), B1.20.1
EF EFWA05H ELB,45 DEG,LR, CS GALV 150 150 A 234 GR.WPB-W GALV B16.9 BW ENDS,SCH STD
R UO A11 RCPL, CS GALV 3000 20 100 A105N GALV B16.11 SCRD,NPT(F), B1.20.1
R EOWA05H CON RED, CS GALV 150 150 A 234 GR.WPB-W GALV B16.9 BW ENDS,SCH STD
RE EXWA05H ECC RED, CS GALV 150 150 A 234 GR.WPB-W GALV B16.9 BW ENDS,SCH STD
T UT A11 TEE, CS GALV 3000 20 100 A105N GALV B16.11 SCRD,NPT(F), B1.20.1 1
T ETWA05H TEE, CS GALV 150 150 A234 GR.WPB-W GALV B16.9 BW ENDS,SCH STD 1
T UH A11 THREDOLET, CS GALV 3000 150 150 A105N GALV MSS-SP-97 SCRD,NPT (F) 1
C UK A11 CAP, CS, GALV 3000 20 100 A105N GALV B16.11 SCRD,NPT(F), B1.20.1
C EK A05H CAP, CS GALV 150 150 A234 GR.WPB GALV B16.9 BW ENDS, SCH STD
US US A11 HEX HEADED PLUG, CS GALV 3000 20 100 A105N GALV B16.11 SCRD,NPT(M)B1.20.1
N PN A06 NIPPLE, 100MM LONG,CS GALV 20 50 A53 GR.B GALV B36.10M TBE,SCH XS,NPT TO B1.20.1
NA PN A06A NIPPLE, CS, 100MM GALV 100 100 A53 GR.B GALV B36.10M POE/TOE,SCH XS,NPT TO B1.20.1
MU UU A11 UNION, CS GALV 3000 20 100 A105N GALV MSS SP-83 SCRD,NPT(F), B1.20.1
Revision Date Name Checked Description Revision Date Name Checked Description
A
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Print Time : 17:14
Rating DN
Flanges Designation Class from to M a t e r i a l Standard End Connection Note
F FGDA10 THREADED FLG, CS GALV 150 20 100 A105N GALV B16.5, RF SCRD, NPT(F),B1.20.1
F FSDA10 SO FLG, CS GALV 150 150 150 A105N GALV B16.5, RF
FB FBDA10 BF, CS GALV 150 20 150 A105N GALV B16.5, RF
Bolts
B B 131 SBOLT 20 250 A193GR.B7/A194GR.2H B18.2.1/B18.2.2
Gaskets
G D 069 FLAT RING GASKET 150 20 250 CNAF ,BS7531 GR.X B16.21/B16.5
2
Others
WB WBD130G SBLD, CS GALV 150 20 150 A515 GR.70 GALV B16.48, RF FOR RF FLGS,B16.5
WA WALA11 ADAPTOR, CS, GALV, FLGD 150 50 50 A105N, GALV PINLES-PIP-6265 FLGD TO B16.5 x SCRD(F)B1.20.1
WHA WH 001 RUBBER HOSE (AIR) 150 15 50 SYNTHETIC RUBBER MFG STD FOR QRC WSX361G,WSX361,WSD360
WHL WH 002 RUBBER HOSE (LIQUID/WATER) 150 15 50 NATURAL RUBBER MFG STD QRC WSX361LG,WSX361L,WSD360L
WSA WSX361G QRC (UTIL. AIR) 3000 15 50 SS304 MFG STD SCRD ENDS
WSL WSX361LG QRC (LIQUID/WATER) 3000 15 50 SS304 MFG STD SCRD ENDS
2 2
Rating DN M a t e r i a l
Valves Designation Class from to Body Body Seat Packing Standard End Connection Note
VA VBF101 BUTTERFLY VALVE, CS, LO 2 150 80 150 A216 GR.WCB PTFE PTFE API 609/CATG. B FOR RF FLGS,B16.5 11
VG VGA802 GATE VALVE, CS,HO 800 20 40 A105N SS 304 PTFE API 602 SCRD,NPT(F),B1.20.1
VG VGA101 GATE VALVE, CS,HO 150 50 150 A216 GR.WCB TRIM NO.8 PTFE API 600 FLGD, B16.5, RF
VK VBL802 BALL VALVE, CS,FB, LO 2 800 15 40 A105N PTFE PTFE API 608 SCRD,NPT(F),B1.20.1
VK VBL101 BALL VALVE, CS,FB, LO 150 50 150 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF
V VGL802 GLOBE VALVE, CS,HO 800 20 40 A105N SS 304 PTFE BS EN ISO 15761 SCRD,NPT(F),B1.20.1
V VGL101 GLOBE VALVE, CS, HO 150 50 150 A216 GR.WCB TRIM NO.8 PTFE BS 1873 2 FLGD, B16.5, RF
VC VCK802 SWING CHECK VALVE,CS 800 20 40 A 105N SS 304 BS EN ISO 15761 SCRD,NPT(F),B1.20.1 21
VC VCK104 DUAL PLATE CHK VALVE,CS 150 50 150 A216 GR.WCB SS 304 PTFE API 594 DOUBLE FLANGED,B16.5,RF 21
VYA YH 130 START-UP STRAINER,CS 150 50 100 A515 GR.70 PINLES-PIP-6235 FOR RF FLGS,B16.5 16
2
Notes
11 - LUG TYPE 1 - FOR TYPE OF BRANCH REFER PART3
A
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Piping Class: A
Print Time : 17:14
Notes
16 - SS INTERNALS 21 - INSTALLED IN HORIZONTAL OR
VERTICAL POSITION WITH UPWARD
FLOW
A
46-7519-10/IRP4.0-MU1/RS81/2010-11/02
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Page : 4
Piping Class: B
Print Time : 17:14
Fluid code:
AFR AIR ALE1 CGM CW FL FW GW1 HW INH IPW PA PW RW VC
Basic Material: A106 GR.B/A53GR.B/API-5LGR.B Facing: RF Corrosion allowance: 2.00MM
Piping Schedule
B36.10M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2
Thk 3,73 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53 9,53
Sch XS XS XS XS STD STD STD STD STD STD STD STD STD STD
CONTINUE DN 500,0 600,0 750,0 900,0 1050,0 1200,0
OD 508,0 609,6 762,0 914,4 1066,8 1219,0
Thk 9,53 9,53 9,53 9,53 9,53 9,53
Sch STD STD STD STD STD STD
Rating DN
P PB 130M PIPE,SMLS,CS 15 40 A106 GR.B B36.10M PBE, SCH XS
P P W060H PIPE,ERW,CS 50 600 A53 GR.B B36.10M BW ENDS,SCH STD
P P W064H PIPE,SAW,CS 750 1200 API-5L GR.B B36.10M BW ENDS,SCH STD
Fittings
E LE 141 ELB,90 DEG, CS 3000 20 40 A105 B16.11 SW ENDS
E E W060H ELB,90 DEG,LR, CS 50 1200 A234 GR.WPB-W B16.9 BW ENDS,SCH STD
EF LF 141 ELB,45 DEG, CS 3000 20 40 A105 B16.11 SW ENDS
EF EFW060H ELB,45 DEG,LR, CS 50 1200 A234 GR.WPB-W B16.9 BW ENDS,SCH STD
T ED 060H WELDOLET, CS 100 1200 A105 MSS SP-97 BW ENDS, SCH STD 1
T EG 130 STUB IN 200 600 SAME AS PIPE 1
T EG 130A STUB IN WITH REINFORCEMENT PAD 600 1200 SAME AS PIPE 1
R EO 130MA CON REDUCING SWAGE, CS 20 40 A106 GR.B MSS SP-95 PBE, SCH XS
R EOW060H CON RED, CS 50 1200 A234 GR.WPB-W B16.9 BW ENDS,SCH STD
RE EX 130MA ECC REDUCING SWAGE, CS 20 40 A106 GR.B MSS SP-95 PBE, SCH XS
RE EXW060H ECC RED, CS 50 1200 A234 GR.WPB-W B16.9 BW ENDS,SCH STD
B
46-7519-10/IRP4.0-MU1/RS81/2010-11/02
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Page : 5
Piping Class: B
Print Time : 17:14
Rating DN
Fittings Designation Class from to M a t e r i a l Standard End Connection Note
T LT 141 TEE, CS 3000 20 40 A105 B16.11 SW ENDS 1
T ETW060H TEE, CS 50 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH STD 1
C LK 141 CAP, CS 3000 20 40 A105 B16.11 SW ENDS
C EK 060H CAP, CS 50 1200 A234 GR.WPB B16.9 BW ENDS, SCH STD
CX UK 141 CAP, CS 3000 20 20 A105 B16.11 SCRD,NPT(F)B1.20.1 8A
M LM 141 FCPL, CS 3000 20 40 A105 B16.11 SW ENDS
NA PN 130M NIPPLE,100MM LONG, CS 20 40 A106 GR.B B36.10M PBE, SCH XS
NB PN 130MA NIPPLE,100MM LONG, CS 20 40 A106 GR.B B36.10M POE X TOE,XS
NC PN 130MX NIPPLE,100MM LONG, CS 20 40 A106 GR.B B36.10M TBE, SCH XS
T LV 141 HCPL, CS 3000 50 1200 A105 B16.11 SW ENDS 1
Flanges
F F D140M WN FLANGE, CS 150 20 40 A105 B16.5,RF BW ENDS, SCH XS
F FSD140H SLIP ON FLANGE, CS 150 50 600 A105 B16.5,RF
F F D140HA WN FLANGE, CS 150 750 1200 A105 B16.47,SR-A,RF BW ENDS, SCH STD
FA F D140H WN FLANGE, CS 150 50 600 A105 B16.5,RF BW ENDS, SCH STD 44A
FB FBD140 BLIND FLANGE,CS 150 20 600 A105 B16.5,RF
FB FBD140A BLIND FLANGE,CS 150 750 1200 A105 B16.47,SR-A,RF
FM FMD141H WN ORIFICE FLANGE SET , CS 300 50 600 A105 B16.36 BW ENDS, SCH STD
Bolts
2 B B 131 SBOLT 20 1200 A193GR.B7/A194GR.2H B18.2.1/B18.2.2
BB B 131 SBOLT 20 600 A193GR.B7/A194GR.2H B18.2.1/B18.2.2 43
Gaskets
G D 069A FLAT RING GASKET 150 750 1200 CNAF ,BS7531 GR.X B16.21/B16.47A
GA D 070 FLAT RING GASKET 300 20 600 CNAF ,BS7531 GR.X B16.21/B16.5 43
Others
WB WBD130 SBLD, CS 150 20 250 A515 GR.70 B16.48, RF FOR RF FLGS,B16.5
WB WUD130 PADDLE SPACER & BLANK, CS 150 300 600 A515 GR.70 B16.48,RF FOR RF FLGS,B16.5
B
46-7519-10/IRP4.0-MU1/RS81/2010-11/02
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Page : 6
Piping Class: B
Print Time : 17:14
Rating DN
Others Designation Class from to M a t e r i a l Standard End Connection Note
WB WUD130A PADDLE SPACER & BLANK, CS 150 750 1200 A515 GR.70 MFG STD FOR RF FLGS B16.47 SR-A
WA WAX144 ADAPTOR,CS 3000 25 25 A105 PINLES-PIP-6265 FOR SW ENDS VALVES,B16.11
2
WA WAD140 ADAPTOR,FLGD, CS 150 50 50 A105 PINLES-PIP-6265 RF, FLG, B16.5
WHA WH 001 RUBBER HOSE (AIR) 150 15 50 SYNTHETIC RUBBER MFG STD FOR QRC WSX361G,WSX361,WSD360
WSA WSX361 QRC (UTILITY AIR) 3000 15 40 SS304 MFG STD SW ENDS
WSA WSD360 QRC (UTILITY AIR) 150 50 50 SS304 MFG STD FLGD END,B16.5,RF
WSL WSX361L QRC (LIQUID/WATER) 3000 15 40 SS304 MFG STD SW ENDS
WSL WSD360L QRC (LIQUID/WATER) 150 50 50 SS304 MFG STD FLGD END,B16.5 RF
VA VBF101 BUTTERFLY VALVE, CS, LO 150 50 150 A216 GR.WCB PTFE PTFE API 609/CATG. B FOR RF FLGS,B16.5 44
VA VBF102 BUTTERFLY VALVE, CS, GO 150 200 600 A216 GR.WCB PTFE PTFE API 609/CATG. B FOR RF FLGS,B16.5 44
VA VBF103 BUTTERFLY VALVE, CS, GO 150 750 1200 A216 GR.WCB PTFE PTFE API 609/CATG. B FOR RF FLGS,B16.5 44
VG VGA801 GATE VALVE, CS,HO 800 20 40 A105 TRIM NO.8 GRPH API 602 SW ENDS
VG VGA102 GATE VALVE, CS,GO 150 300 600 A216 GR.WCB TRIM NO.8 PTFE API 600 FLGD, B16.5, RF
VK VBL801 BALL VALVE,CS,RB,LO 800 20 40 A105 PEEK GRPH API 608 SW ENDS 13
VK VBL101 BALL VALVE, CS,FB, LO 150 50 150 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF 13
VK VBL108 BALL VALVE, CS,FB, GO 150 200 450 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF 13
V VGL101 GLOBE VALVE, CS, HO 150 50 250 A216 GR.WCB TRIM NO.8 PTFE BS 1873 FLGD, B16.5, RF
V VGL801 GLOBE VALVE, CS,HO 800 15 40 A105 TRIM NO.8 PTFE BS EN ISO 15761 SW ENDS, B16.11
2
VC VCK801 SWING CHECK VALVE,CS 800 20 40 A105 TRIM NO.8 BS EN ISO 15761 SW ENDS 21
VC VCK104 DUAL PLATE CHK VALVE,CS 150 50 600 A216 GR.WCB SS 304 PTFE API 594 DOUBLE FLANGED,B16.5,RF 21
VY Y D130 Y TYPE STRAINER, CS 150 80 80 A216 GR.WCB MFG STD FLGD, B16.5, RF 16
VY YSD130 T TYPE STRAINER, CS 150 400 400 A234 GR.WPB MFG STD. FLGD B16.5,RF 16
Notes
13 - FOR FLOCCULENT SER. USE ONLY 21 - INSTALLED IN HORIZONTAL OR 44A - FOR BUTTERFLY VALVE.
BALL VALVE. VERTICAL POSITION WITH UPWARD 44 - LUG TYPE. USE WITH WELD NECK
16 - SS INTERNALS FLOW FLANGE ONLY.
1 - FOR TYPE OF BRANCH REFER PART3 43 - FOR CL 300 CONNECTION ONLY. 8A - FOR HYDROSTATIC TEST VENTS.
B
46-7519-10/IRP4.0-MU1/RS81/2010-11/02
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Page : 7
Piping Class: C
Print Time : 17:14
Fluid code:
FCL FV1 PC1
Basic Material: A106GR.B/A53GR.B/API-5LGR.B Facing: RF Corrosion allowance: 2.00MM
Piping Schedule 2
B36.10M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2
Thk 3,73 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53 9,53
CONTINUE DN 500,0 600,0 750,0 900,0 1050,0 1200,0
OD 508,0 609,6 762,0 914,4 1066,8 1219,0
Thk 9,53 9,53 12,7 12,7 12,7 12,7
Sch STD STD XS XS XS XS
Rating DN
P P W060H PIPE,ERW,CS 2 50 600 A53 GR.B B36.10M BW ENDS,SCH STD
P P W064M PIPE,SAW,CS 750 1200 API-5L GR.B B36.10M BW ENDS,SCH XS
Fittings
E E W060M ELB,90 DEG,LR, CS 750 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
EF EFW060M ELB,45 DEG,LR, CS 750 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
C
46-7519-10/IRP4.0-MU1/RS81/2010-11/02
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Page : 8
Piping Class: C
Print Time : 17:14
Rating DN
R EOW060MB CON RED, CS 750 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
RE EXW060MB ECC RED, CS 750 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
T ETW060M TEE, CS 750 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
C EK 060M CAP, CS 750 1200 A 234 GR.WPB B16.9 BW ENDS,SCH XS
Flanges
F FWD140M SW FLG, CS 150 20 40 A105 B16.5,RF SW ENDS,SCH XS
F F D140H WN FLANGE, CS 150 50 600 A105 B16.5,RF BW ENDS, SCH STD
F F D140MA WN FLANGE, CS 150 750 1200 A105 B16.47,SR-A,RF BW ENDS, SCH XS
Bolts
2
Gaskets
G DU 451 SP WD GASKET 150 20 600 SS 316L/FLX GRPH B16.20/B16.5
G DU 451A SP WD GASKET 150 750 1200 SS 316L/FLX GRPH B16.20/B16.47A
C
46-7519-10/IRP4.0-MU1/RS81/2010-11/02
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Page : 9
Piping Class: C
Print Time : 17:14
Rating DN
Gaskets Designation Class from to M a t e r i a l Standard End Connection Note
GA DU 452 SP WD GASKET 300 20 600 SS 316L/FLX GRPH B16.20/B16.5 43
Others
WHC WH 005 RUBBER HOSE (CAUSTIC) 150 80 80 SYNTHETIC RUBBER MFG STD FLGD,RF,B16.5
WHC WH 004 RUBBER HOSE (CAUSTIC) 150 100 100 ELECTRICALLY BONDED MFG STD CON1=FLGD,RF,B16.5/ CONN2=OPEN
WHS WH 003 RUBBER HOSE (STEAM) 150 15 50 SYNTHETIC RUBBER MFG STD FOR QRC WSX361S
WSS WSX361S QRC (STEAM) 3000 15 40 SS304 MFG STD SW ENDS
VA VBF108 HIGH PER.BUTTERFLY VALVE,CS,GO 150 80 600 A216 GR.WCB TRIM NO.8 PTFE API 609 CATG. B DOUBLE FLANGED,B16.5,RF
2
VK VBL801 BALL VALVE,CS,RB,LO 800 20 40 A105 PEEK GRPH API 608 SW ENDS
VC VCK105 SWING CHECK VALVE,CS 150 50 600 A216 GR.WCB TRIM NO.8 BS 1868 FLGD,B16.5,RF 21
2
VY Y X144 Y TYPE STRAINER,CS 800 20 40 A105 MFG STD SW ENDS, B16.11 16
Notes
16 - SS INTERNALS 43 - FOR CL 300 CONNECTION ONLY.
1 - FOR TYPE OF BRANCH REFER PART3 8A - FOR HYDROSTATIC TEST VENTS.
21 - INSTALLED IN HORIZONTAL OR
FLOW
C
46-7519-10/IRP4.0-MU1/RS81/2010-11/02
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Page : 10
Piping Class: D
Print Time : 17:14
Fluid code:
CSA
Basic Material: A106 GR.B Facing: RF Corrosion allowance: 2.00MM
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0
Thk 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27
Sch XS XS XS STD STD STD STD STD STD
Rating DN
P P 130H PIPE,SMLS,CS 50 250 A106 GR.B B36.10M BW ENDS,SCH STD
Fittings
E E 060H ELB,90 DEG,LR, CS 50 250 A234 GR.WPB B16.9 BW ENDS, SCH STD
EF EF 060H ELB,45 DEG,LR, CS 50 250 A234 GR.WPB B16.9 BW ENDS,SCH STD
R EO 060H CON RED, CS 50 250 A234 GR.WPB B16.9 BW ENDS, SCH STD
RE EX 060H ECC RED, CS 50 250 A 234 GR.WPB B16.9 BW ENDS,SCH STD
T ET 060H TEE, CS 50 250 A234 GR.WPB B16.9 BW ENDS, SCH STD 1
D
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Rating DN
Flanges
F F D140MN WN FLANGE, CS 150 20 40 A105N B16.5,RF BW ENDS, SCH XS
F F D140HN WN FLANGE, CS 150 50 250 A105N B16.5,RF BW ENDS, SCH STD
FB FBD140N BLIND FLANGE,CS 150 20 250 A105N B16.5,RF
FM FMD141HN WN ORIFICE FLANGE SET , CS 300 50 250 A105N B16.36 BW ENDS, SCH STD
Bolts
Gaskets
GA D 070 FLAT RING GASKET 300 20 250 CNAF ,BS7531 GR.X B16.21/B16.5 43
Others
VK VBL108 BALL VALVE, CS,FB, GO 150 200 250 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF
VM VDP101 DIAPHRAGM VALVE,DI-PP LIN,HO 150 20 250 DI-PP LIN PTFE BS EN 13397 FLGD,B16.5,RF 10
VC VCK102 SWING CHECK VALVE, CS 150 50 250 A216 GR.WCB TRIM NO.8 BS 1868 FLGD, B16.5, RF 21
D
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Print Time : 17:14
Notes
10 - WEIR TYPE 21 - INSTALLED IN HORIZONTAL OR 43 - FOR CL 300 CONNECTION ONLY.
16 - SS INTERNALS VERTICAL POSITION WITH UPWARD 8A - FOR HYDROSTATIC TEST VENTS.
1 - FOR TYPE OF BRANCH REFER PART3 FLOW
D
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Piping Class: E 2
Print Time : 17:14
Fluid code:
DSA
Basic Material: A 312 TP316L Facing: RF Corrosion allowance: 0.0 MM
Rating: Temperature CEL: -29 38 93
Class 300 Pressure KPag: 4136,5 4136,5 3516,7
Piping Schedule
B36.19M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8
Thk 2,77 2,87 3,38 3,68 2,77 3,05 3,05 3,40 3,76 4,19 4,57
Sch 40S 40S 40S 40S 10S 10S 10S 10S 10S 10S 10S
Rating DN
P PB 440J PIPE,SMLS,SS 15 40 A312 TP316L B36.19M PE,SCH 40S
P P 440C PIPE,SMLS,SS 50 300 A312 TP316L B36.19M BW ENDS,SCH 10S
Fittings
E LE 441 ELB,90 DEG,SS 3000 15 40 A182 Gr.F316L B16.11 SW ENDS
E E 440C ELB,90 DEG,LR,SS 50 300 A403 Gr.WP316L-S B16.9 BW ENDS,SCH 10S
EF LF 441 ELB,45 DEG,SS 3000 15 40 A182 Gr.F316L B16.11 SW ENDS
EF EF 440C ELB,45 DEG,LR,SS 50 300 A403 Gr.WP316L-S B16.9 BW ENDS,SCH 10S
T ED 440C WLET,SS 150 300 A182 GR.F316L MSS-SP-97 BW ENDS,SCH 10S 1
R LO 441 RCPL,SS 3000 20 40 A182 Gr.F316L B16.11 SW ENDS
R EO 440C CON RED,SS 50 300 A403 Gr.WP316L-S B16.9 BW ENDS,SCH 10S
RE EX 440C ECC RED,SS 50 300 A403 Gr.WP316L-S B16.9 BW ENDS,SCH 10S
T LT 441 TEE,SS 3000 15 40 A182 Gr.F316L B16.11 SW ENDS 1
T ET 440C TEE,SS 50 300 A403 Gr.WP316L-S B16.9 BW ENDS,SCH 10S 1
C LK 441 CAP,SS 3000 15 40 A182 Gr.F316L B16.11 SW ENDS
C EK 440C CAP,SS 50 300 A403 Gr.WP316L-S B16.9 BW ENDS,SCH 10S
CX UK 441 CAP,SS 3000 15 40 A182 Gr.F316L B16.11 FNPT, B1.20.1
M LM 441 FCPL,SS 3000 15 40 A182 Gr.F316L B16.11 SW ENDS
T LV 441 HCPL, SS 3000 50 300 A182 GR.F316L B16.11 SW ENDS 1
E
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Print Time : 17:14
Rating DN
F F D441J WN FLG,SS 300 15 40 A182 Gr.F316L B16.5,RF BW ENDS,SCH 40S
F F D441C WN FLG,SS 300 50 300 A182 Gr.F316L B16.5,RF BW END,SCH 10S
FB FBD441 BLIND FLANGE,SS 300 15 300 A182 Gr.F316L B16.5,RF
Bolts
Gaskets
G D 853 FLAT RING GASKET 300 15 300 KLINGER TOP CHEM2003 B16.21/B16.5
Others
WB WBD441 SBLD,SS 300 15 200 A240 Gr.316L B16.48 FOR RF FLGS, B16.5
WB WUD441 PADDLE SPCR & BLANK,SS 300 250 300 A240 Gr.316L B16.48 FOR RF FLGS, B16.5
VG VGA803 GATE VALVE, CS,HO 800 15 40 A182 GR.F316L TRIM NO.8 PTFE API 602 SW ENDS
VG VGA303 GATE VALVE,SS,HO 300 50 200 A351 GR.CF3M TRIM NO.8 PTFE API 600 FLGD, B16.5, RF
VG VGA304 GATE VALVE,SS,GO 300 250 300 A351 GR.CF3M TRIM NO.8 PTFE API 600 FLGD, B16.5, RF
VK VBL804 BALL VALVE,CS,RB,LO 800 15 40 A182 GR.F316L PTFE PTFE API 608 SW ENDS
VM VDP301 DIAPHRAGM VALVE,DI-PP LIN,HO 300 25 200 DI-PP LIN PTFE BS EN 13397 FLGD,B16.5,RF 10
VK VBL305 BALL VALVE,FB,SS, LO 300 50 100 A351 GR.CF3M PTFE PTFE API 608 FLGD, B16.5, RF
VK VBL306 BALL VALVE,FB,SS, GO 300 150 300 A351 GR.CF3M PTFE PTFE API 608 FLGD, B16.5, RF
VC VCK803 BALL CHECK VALVE,SS 800 15 40 A182 GR.F316L TRIM NO.8 BS EN ISO 15761 SW ENDS 47
VC VCK303 SWING CHECK VALVE,SS 300 50 300 A351 GR.CF3M TRIM NO:8 BS 1868 FLGD, B16.5, RF 21
VA VBF304 BUTTERFLY VALVE,LO 300 50 150 A351 GR.CF3M TRIM NO.8 PTFE API 609/CATG. B FOR RF FLGS,B16.5 11
VA VBF305 BUTTERFLY VALVE,GO 300 200 300 A351 GR.CF3M TRIM NO.8 PTFE API 609/CATG. B FOR RF FLGS,B16.5 11
VYA YH 441 START UP STRAINER,SS 300 50 300 A240 Gr.316L PINLES-PIP-6235 FOR RF FLGS, B16.5 16
Notes
10 - WEIR TYPE 1 - FOR TYPE OF BRANCH REFER PART3 47 - TO BE INSTALLED IN HORIZONTAL
11 - LUG TYPE 21 - INSTALLED IN HORIZONTAL OR POSITION ONLY.
16 - SS INTERNALS VERTICAL POSITION WITH UPWARD
FLOW
E
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Piping Class: F
Print Time : 17:14
Fluid code:
AIR1 ALE APS CFL CRS CSR CSS DFS DIS1 DLS1 DSS1 FSS FTS FV FWS HFL HS HTL
MIS1 MPS ODS PDS PFF PFS PGL1 PHS POS PSS SCF SEL1 SFL1 SPL1 TCA TRL WL
Basic Material: A106 GR.B/A53 GR.B/API-5LGR.B Facing: RF Corrosion allowance: 2.00MM
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53 9,53 9,53
Sch XS XS XS STD STD STD STD STD STD STD STD STD STD STD
CONTINUE DN 600,0 750,0 900,0 1050,0 1200,0
OD 609,6 762,0 914,4 1066,8 1219,0
Thk 9,53 9,53 9,53 9,53 12,7
Sch STD STD STD STD XS
Rating DN
Fittings
F
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Rating DN
R EOW060M CON RED, CS 1200 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
RE EXW060M ECC RED, CS 1200 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
RTC EROW130H CONC TAPER, CS 50 600 A515 GR.70 tkIS DRG BW ENDS, SCH STD 20
RTE ERXW130H ECC TAPER, CS 50 600 A515 GR.70 tkIS DRG BW ENDS, SCH STD 20
EQ EQW060H EQUAL CROSS, CS 400 500 A234 GR.WPB-W B16.9 BW ENDS, SCH STD 40
T ETW060M TEE, CS 1200 1200 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 1
Flanges
Bolts
F
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Rating DN
Bolts Designation Class from to M a t e r i a l Standard End Connection Note
Gaskets
Others
WB WUD130A PADDLE SPACER & BLANK, CS 150 750 1200 A515 GR.70 MFG STD FOR RF FLGS B16.47 SR-A 2
WHC WH 006 RUBBER HOSE (CAUSTIC) 150 100 150 RUBBER MFG STD FLGD,RF,B16.5
VB VA3101 ANG. 3-WAY VALVE,CS,HO 150 80 100 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 54
VB VA3102 ANG. 3-WAY VALVE,CS, GO 150 150 600 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 54
VE VAN101 ANGLE SLURRY VALVE, CS, HO 150 50 100 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 47
VE VAN102 ANGLE SLURRY VALVE, CS, GO 150 150 600 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 47
VGX VGA802 GATE VALVE, CS,HO 800 20 20 A105N SS 304 PTFE API 602 SCRD,NPT(F),B1.20.1 8A
VK VBL801 BALL VALVE,CS,RB,LO 800 20 40 A105 PEEK GRPH API 608 SW ENDS 40
VP VAB101 ANG. BAYONET VALVE,CS, HO 150 50 100 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF
VP VAB102 ANG. BAYONET VALVE,CS,GO 150 150 600 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF
VCA VCK101 ANGLE CHECK VALVE,CS 150 50 600 A216 GR.WCB TRIM NO.8 MFG. STD. FLGD, B16.5, RF 53
Notes
16 - SS INTERNALS 40 - TO BE USED WITH LEAD ENGINEERS 54 - FLOW PATTERN AND ORIENTATION
F
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Piping Class: F
Print Time : 17:14
Notes
1 - FOR TYPE OF BRANCH REFER PART3 CONFIRMATION. ON HOLD.
20 - TAPERS SHALL BE INSTALLED 43 - FOR CL 300 CONNECTION ONLY. 8A - FOR HYDROSTATIC TEST VENTS.
ONLY AT PUMP SUCTION & 47 - TO BE INSTALLED IN HORIZONTAL
DISCHARGE FOR SLURRY FLUIDS. POSITION ONLY.
28 - FOR INST. TAP CONN. ONLY 53 - INSTALLED IN VERTICAL POS.
WITH UPWARD FLOW.
F
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Piping Class: G
Print Time : 17:14
Fluid code:
DIS2 DLS2 DSS2 LM MIS2
Basic Material: A106 GR.B/A53 GR.B/API-5LGR.B Facing: RF Corrosion allowance: 3.0-5.0MM
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 3,91 4,55 5,08 5,54 7,62 8,56 10,97 12,7 12,7 12,7 12,7 12,7 12,7 12,7
Sch XS XS XS XS XS XS XS XS XS XS XS XS XS XS
CONTINUE DN 600,0 750,0 900,0 1050,0
OD 609,6 762,0 914,4 1066,8
Thk 12,7 12,7 12,7 12,7
Sch XS XS XS XS
Rating DN
P P W060M PIPE,ERW,CS 50 600 A53 GR.B B36.10M BW ENDS,SCH XS
Fittings
EA EAW130MA 3D BEND, 90DEG, CS 50 500 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 38
EB EAW130M 5D BEND, 90DEG, CS 50 500 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 38
EFA EBW130MA 3D BEND, 45DEG, CS 50 500 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 38
EFB EBW130M 5D BEND, 45DEG, CS 50 500 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 38
T ED 060M WELDOLET, CS 150 1050 A105 MSS SP-97 BW ENDS, SCH XS 1
G
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Rating DN
R EOW060MA CON RED, CS 350 450 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
RE EXW060MA ECC RED, CS 350 450 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
RTC EROW130MC CONC TAPER, CS 50 600 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
2 RTE ERXW130MC ECC TAPER, CS 50 600 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
EQ EQW060M EQUAL CROSS, CS 400 500 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 40
T ETW060MA TEE, CS 350 450 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 1
Flanges
F F D140M WN FLANGE, CS 150 50 600 A105 B16.5,RF BW ENDS, SCH XS
FM FMD141M WN ORIFICE FLANGE SET , CS 300 50 600 A105 B16.36 BW ENDS, SCH XS
G
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Print Time : 17:14
Rating DN
2
Gaskets
Others
2
Notes
16 - SS INTERNALS 28 - FOR INST. TAP CONN. ONLY 53 - INSTALLED IN VERTICAL POS.
G
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Print Time : 17:14
Notes
1 - FOR TYPE OF BRANCH REFER PART3 38 - USE THESE BENDS FOR SAND WITH UPWARD FLOW.
20 - TAPERS SHALL BE INSTALLED SLURRY LINES ONLY. 54 - FLOW PATTERN AND ORIENTATION
ONLY AT PUMP SUCTION & 40 - TO BE USED WITH LEAD ENGINEERS ON HOLD.
DISCHARGE FOR SLURRY FLUIDS. CONFIRMATION. 8A - FOR HYDROSTATIC TEST VENTS.
21 - INSTALLED IN HORIZONTAL OR 43 - FOR CL 300 CONNECTION ONLY.
VERTICAL POSITION WITH UPWARD 47 - TO BE INSTALLED IN HORIZONTAL
FLOW POSITION ONLY.
G
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Piping Class: H
Print Time : 17:14
Fluid code:
CLL CLU
Basic Material: A106 GR.B(STRESS RELIEVED) Facing: RF Corrosion allowance: 2.00MM
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53 9,53 9,53
CONTINUE DN 600,0
OD 609,6
Thk 9,53
Sch STD
Rating DN
Fittings
H
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Rating DN
Flanges
Bolts
2
Gaskets
Others
H
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Print Time : 17:14
VA VBF109 HIGH PER.BUTTERFLY VALVE,CS,LO 150 50 150 A216 GR.WCB 13% Cr PTFE API 609 CATG. B FOR RF FLGS,B16.5 24
VA VBF110 HIGH PER.BUTTERFLY VALVE,CS,GO 150 200 600 A216 GR.WCB 13% Cr PTFE API 609 CATG. B FOR RF FLGS,B16.5 23
VC VCK106 SWING CHECK VALVE,CS 150 50 600 A216 GR.WCB TRIM NO.8 BS 1868 FLGD, B16.5, RF 21
Notes
16 - SS INTERNALS 23 - <DN400 SHAFT INST PREF. HORIZ. 53 - INSTALLED IN VERTICAL POS.
1 - FOR TYPE OF BRANCH REFER PART3 >=DN400 SHAFT INST ALWAYS WITH UPWARD FLOW.
20 - TAPERS SHALL BE INSTALLED HORIZONTAL, WAFER TYPE. 54 - FLOW PATTERN AND ORIENTATION
ONLY AT PUMP SUCTION & 24 - SHAFT INST. PREFERABLY. HORIZ, ON HOLD.
DISCHARGE FOR SLURRY FLUIDS. WAFER TYPE. 8A - FOR HYDROSTATIC TEST VENTS.
21 - INSTALLED IN HORIZONTAL OR 26 - FOR DRAIN PURPOSE ONLY.
VERTICAL POSITION WITH UPWARD 43 - FOR CL 300 CONNECTION ONLY.
FLOW 47 - TO BE INSTALLED IN HORIZONTAL
POSITION ONLY.
H
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Piping Class: J
Print Time : 17:14
Fluid code:
DSS3 MIS3
Basic Material: A106GR.B(STRESS RELIEVED) Facing: RF Corrosion allowance: 3.00MM
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 5,56 4,55 5,08 5,54 5,49 6,02 7,11 8,18 9,27 9,53 12,7 12,7 12,7 15,09
Sch 160 XS XS XS STD STD STD STD STD STD XS XS XS 40
CONTINUE DN 600,0
OD 609,6
Thk 17,48
Sch 40
Rating DN
P PB 130R PIPE,SMLS,CS 20 20 A106 GR.B B36.10M PBE,SCH 160
P P 130M PIPE,SMLS,CS 50 50 A106 GR.B B36.10M BW ENDS,SCH XS
P P 130J PIPE,SMLS,CS 500 600 A106 GR.B B36.10M BW ENDS,SCH 40
Fittings
E E 060M ELB,90 DEG,LR, CS 50 50 A 234 GR.WPB B16.9 BW ENDS,SCH XS
E E 060J ELB,90 DEG,LR, CS 500 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
EA EA 130HA 3D BEND, 90DEG, CS 150 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
EA EA 130MA 3D BEND, 90DEG, CS 350 450 A234 GR.WPB B16.9 BW ENDS, SCH XS
J
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Print Time : 17:14
Rating DN
EA EA 130JA 3D BEND, 90DEG, CS 500 600 A234 GR.WPB B16.9 BW ENDS, SCH 40
EF EF 060M ELB,45 DEG,LR, CS 50 50 A 234 GR.WPB B16.9 BW ENDS,SCH XS
EF EF 060J ELB,45 DEG,LR, CS 500 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
EFA EB 130HA 3D BEND, 45DEG, CS 150 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
EFA EB 130MA 3D BEND, 45DEG, CS 350 450 A234 GR.WPB B16.9 BW ENDS, SCH XS
EFA EB 130JA 3D BEND, 45DEG, CS 500 600 A234 GR.WPB B16.9 BW ENDS, SCH 40
T ED 060M WELDOLET, CS 150 600 A105 MSS SP-97 BW ENDS, SCH XS 1
R EO 130MB CON REDUCING SWAGE, CS 25 40 A106 GR.B MSS SP-95 PBE, SCH XS
R EO 060M CON RED, CS 50 50 A 234 GR.WPB B16.9 BW ENDS,SCH XS
R EO 060HA CON RED, CS 80 100 A234 GR.WPB B16.9 BW ENDS, SCH STD
R EO 060MA CON RED, CS 350 450 A 234 GR.WPB B16.9 BW ENDS,SCH XS
R EO 060JA CON RED, CS 500 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
RE EX 130MB ECC REDUCING SWAGE, CS 25 40 A106 GR.B MSS SP-95 PBE, SCH XS
RE EX 060M ECC RED, CS 50 50 A 234 GR.WPB B16.9 BW ENDS,SCH XS
RE EX 060HA ECC REDUCING SWAGE, CS 80 100 A234 GR.WPB MSS SP-95 BLE X PSE, SCH STD
RE EX 060MA ECC RED, CS 350 450 A 234 GR.WPB B16.9 BW ENDS,SCH XS
RE EX 060JA ECC RED, CS 500 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
RTC EROW130M CONC TAPER, CS 50 50 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
RTC EROW130HA CONC TAPER, CS 80 300 A515 GR.70 tkIS DRG BW ENDS, SCH STD 20
RTC EROW130MB CONC TAPER, CS 350 450 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
2 RTC EROW130JB CONC TAPER, CS 500 600 A515 GR.70 tkIS DRG BW ENDS, SCH 40 20
RTE EROW130M CONC TAPER, CS 50 50 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
RTE ERXW130HA ECC TAPER, CS 80 300 A515 GR.70 tkIS DRG BW ENDS, SCH STD 20
RTE ERXW130MB ECC TAPER, CS 350 450 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
RTE ERXW130JB ECC TAPER, CS 500 600 A515 GR.70 tkIS DRG BW ENDS, SCH 40 20
J
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Print Time : 17:14
Rating DN
T ET 060M TEE, CS 50 50 A234 GR.WPB B16.9 BW ENDS,SCH XS 1
T ET 060HA TEE, CS 80 100 A234 GR.WPB B16.9 BW ENDS, SCH STD 1
T ET 060MA TEE, CS 350 450 A234 GR.WPB B16.9 BW ENDS,SCH XS 1
T ET 060JA TEE, CS 500 600 A234 GR.WPB B16.9 BW ENDS,SCH 40 1
C EK 060J CAP, CS 500 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
CX UK 142 CAP, CS 6000 20 20 A105 B16.11 SCRD ENDS,NPT (F) 8A
Flanges
F FWD141R SW FLG, CS 300 20 20 A105 B16.5, RF SW ENDS,SCH 160
F FWD141M SW FLG, CS 300 25 40 A105 B16.5, RF SW ENDS,SCH XS
F F D141M WN FLG, CS 300 50 50 A105 B16.5, RF BW END,SCH XS
F F D141H WN FLG, CS 300 80 300 A105 B16.5,RF BW END,SCH STD
F F D141J WN FLG, CS 300 500 600 A105 B16.5, RF BW END,SCH 40
FA FSD141 SO FLG, CS 300 50 100 A105 B16.5,RF 40
FB FBD141 BF, CS 300 20 600 A105 B16.5,RF
J
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Piping Class: J
Print Time : 17:14
Rating DN
FM FMD141J WN ORIFICE FLANGE SET , CS 300 500 600 A105 B16.36 BW ENDS, SCH 40
Bolts
Gaskets
Others
WB WBD131 SBLD, CS 300 50 250 A515 GR.70 B16.48,RF FOR RF FLGS,B16.5
WB WUD131 SPACER & BLIND, CS 300 300 600 A515 GR.70 B16.48,RF FOR RF FLGS,B16.5
2
VP VAB302 ANG. BAYONET VALVE,CS, GO 300 150 600 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF
VK VBL301 BALL VALVE,FB,CS, LO 300 50 50 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF 28
Notes
16 - SS INTERNALS 28 - FOR INST. TAP CONN. ONLY 53 - INSTALLED IN VERTICAL POS.
1 - FOR TYPE OF BRANCH REFER PART3 40 - TO BE USED WITH LEAD ENGINEERS WITH UPWARD FLOW.
20 - TAPERS SHALL BE INSTALLED CONFIRMATION. 8A - FOR HYDROSTATIC TEST VENTS.
ONLY AT PUMP SUCTION & 47 - TO BE INSTALLED IN HORIZONTAL
DISCHARGE FOR SLURRY FLUIDS. POSITION ONLY.
J
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Page : 30
Piping Class: K
Print Time : 17:14
Fluid code:
DSS4 PGL2 SEL2 SFL2 SPL2
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53 9,53 9,53
CONTINUE DN 600,0
OD 609,6
Thk 9,53
Sch STD
Rating DN
Fittings
K
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Print Time : 17:14
Rating DN
Flanges
Bolts
2
Gaskets
Others
K
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Piping Class: K
Print Time : 17:14
VP VAB102 ANG. BAYONET VALVE,CS,GO 150 150 600 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 2
Notes
16 - SS INTERNALS 28 - FOR INST. TAP CONN. ONLY 54 - FLOW PATTERN AND ORIENTATION
1 - FOR TYPE OF BRANCH REFER PART3 43 - FOR CL 300 CONNECTION ONLY. ON HOLD.
20 - TAPERS SHALL BE INSTALLED 47 - TO BE INSTALLED IN HORIZONTAL 8A - FOR HYDROSTATIC TEST VENTS.
ONLY AT PUMP SUCTION & POSITION ONLY.
DISCHARGE FOR SLURRY FLUIDS. 53 - INSTALLED IN VERTICAL POS.
WITH UPWARD FLOW.
K
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Piping Class: L
Print Time : 17:14
Fluid code:
SFL3
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 12,7 12,7 12,7
Sch XS XS XS STD STD STD STD STD STD STD STD XS XS XS
CONTINUE DN 600,0
OD 609,6
Thk 17,48
Sch 40
Rating DN
P P 130J PIPE,SMLS,CS 600 600 A106 GR.B B36.10M BW ENDS,SCH 40
Fittings
E E 060J ELB,90 DEG,LR, CS 600 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
EF EF 060J ELB,45 DEG,LR, CS 600 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
L
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Piping Class: L
Print Time : 17:14
Rating DN
R EO 060M CON RED, CS 400 500 A 234 GR.WPB B16.9 BW ENDS,SCH XS
R EO 060J CON RED, CS 600 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
RE EX 060M ECC RED, CS 400 500 A 234 GR.WPB B16.9 BW ENDS,SCH XS
RE EX 060J ECC RED, CS 600 600 A 234 GR.WPB B16.9 BW ENDS,SCH 40
RTC EROW130M CONC TAPER, CS 400 500 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
RTC EROW130J CONC TAPER, CS 600 600 A515 GR.70 tkIS DRG BW ENDS, SCH 40 20
RTE ERXW130M ECC TAPER, CS 400 500 A515 GR.70 tkIS DRG BW ENDS, SCH XS 20
RTE ERXW130J ECC TAPER, CS 600 600 A515 GR.70 tkIS DRG BW ENDS, SCH 40 20
T ET 060M TEE, CS 400 500 A234 GR.WPB B16.9 BW ENDS,SCH XS 1
T ET 060J TEE, CS 600 600 A234 GR.WPB B16.9 BW ENDS,SCH 40 1
Flanges
L
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Piping Class: L
Print Time : 17:14
Rating DN
FA FSD141 SO FLG, CS 300 50 100 A105 B16.5,RF 40
FB FBD141 BF, CS 300 20 600 A105 B16.5,RF
Bolts
Gaskets
Others
WSL WSX361L QRC (LIQUID/WATER) 3000 20 40 SS304 MFG STD SW ENDS 2
VP VAB302 ANG. BAYONET VALVE,CS, GO 300 150 600 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF
Notes
16 - SS INTERNALS 40 - TO BE USED WITH LEAD ENGINEERS 53 - INSTALLED IN VERTICAL POS.
1 - FOR TYPE OF BRANCH REFER PART3 CONFIRMATION. WITH UPWARD FLOW.
L
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Piping Class: L
Print Time : 17:14
Notes
20 - TAPERS SHALL BE INSTALLED 47 - TO BE INSTALLED IN HORIZONTAL 8A - FOR HYDROSTATIC TEST VENTS.
ONLY AT PUMP SUCTION & POSITION ONLY.
DISCHARGE FOR SLURRY FLUIDS.
L
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Page : 37
Piping Class: M
Print Time : 17:14
Fluid code:
DFW FDW FSF OFS OFW OS SNL1 WCL
Basic Material: A106GR.B/A53GR.B/API-5LGR.B Facing: RF Corrosion allowance: 2.00MM
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53 9,53 9,53
CONTINUE DN 600,0 750,0 900,0 1050,0 1200,0
OD 609,6 762,0 914,4 1066,8 1219,0
Thk 9,53 9,53 9,53 9,53 12,7
Sch STD STD STD STD XS
Rating DN
Fittings
M
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Piping Class: M
Print Time : 17:14
Rating DN
EQ EQW060H EQUAL CROSS, CS 400 500 A234 GR.WPB-W B16.9 BW ENDS, SCH STD 40
Flanges
Bolts
M
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Piping Class: M
Print Time : 17:14
2 Rating DN
Gaskets
Others
WSL WSD360L QRC (LIQUID/WATER) 150 50 100 2 SS304 MFG STD FLGD END,B16.5 RF
2
V VGL801 GLOBE VALVE, CS,HO 800 20 40 A105 TRIM NO.8 PTFE BS EN ISO 15761 SW ENDS, B16.11 2
Notes
16 - SS INTERNALS 21 - INSTALLED IN HORIZONTAL OR 43 - FOR CL 300 CONNECTION ONLY.
1 - FOR TYPE OF BRANCH REFER PART3 VERTICAL POSITION WITH UPWARD 47 - TO BE INSTALLED IN HORIZONTAL
20 - TAPERS SHALL BE INSTALLED FLOW POSITION ONLY.
ONLY AT PUMP SUCTION & 40 - TO BE USED WITH LEAD ENGINEERS 8A - FOR HYDROSTATIC TEST VENTS.
DISCHARGE FOR SLURRY FLUIDS. CONFIRMATION.
M
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Page : 40
Piping Class: N
Print Time : 17:14
Fluid code:
DIS4 SFL4
Basic Material: DUPLEX SS (UNS S31803) Facing: RF Corrosion allowance: 0.00MM
Rating: Temperature CEL: -29 38 93 149 204 260
Class 300 Pressure KPag: 5171,2 5171,2 5136,8 4584,7 4240,5 3999,3
Piping Schedule
B36.19M DN 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0 600,0
OD 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0 609,6
Thk 3,91 5,49 6,02 7,11 8,18 9,27 9,53 11,13 12,7 14,27 15,09 17,48
Sch 40S 40S 40S 40S 40S 40S 40S 40 40 40 40 40
Rating DN
P P 540J PIPE,DSS,SMLS 50 300 A790 UNSS31803 B36.19M BW ENDS,SCH 40S
P P 540JA PIPE,DSS,SMLS 350 600 A790 UNSS31803 B36.19M BW ENDS,SCH 40
Fittings
E E 540J ELB,90 DEG LR,DSS 50 300 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40S
E E 540JA ELB,90 DEG LR,DSS 350 600 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40
EF EF 540J ELB,45 DEG LR,DSS 50 300 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40S
EF EF 540JA ELB,45 DEG LR,DSS 350 600 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40
T ED 540J WLET,DSS 150 600 A182 Gr.F51 MSS-SP-97 BW ENDS,SCH 40S 1
T EG 540 STUB IN,DSS 200 300 SAME AS PIPE 1
T EG 540A STUB IN WITH REINFORCEMENT,DSS 350 600 SAME AS PIPE 1
R EO 540J CON RED,DSS 50 300 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40S
R EO 540JA CON RED,DSS 350 600 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40
RE EX 540J ECC RED,DSS 50 300 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40S
RE EX 540JA ECC RED,DSS 350 600 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40
RTC EROW540J CONC TAPER,DSS 50 300 A240 UNSS31803 tkIS DRG BW ENDS, SCH 40S
RTC EROW540JA CONC TAPER,DSS 350 600 A240 UNSS31803 tkIS DRG BW ENDS, SCH 40
RTE ERXW540J ECC TAPER,DSS 50 300 A240 UNSS31803 tkIS DRG BW ENDS, SCH 40S
RTE ERXW540JA ECC TAPER,DSS 350 600 A240 UNSS31803 tkIS DRG BW ENDS, SCH 40
T ET 540J TEE,DSS 50 300 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40S 1
N
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Print Time : 17:14
Rating DN
T ET 540JA TEE,DSS 350 600 A815 UNSS31803 WP-S B16.9 BW ENDS,SCH 40 1
CX UK 541 CAP, DSS 3000 20 20 A182 GR.F51 B16.11 SCRD,NPT(F)B1.20.1 8A
NA PN 540J NIPPLE,100MM LONG, DSS 20 20 A790 UNSS31803 B36.10M PBE, SCH 40S
NB PN 540JA NIPPLE,100MM LONG, DSS 20 20 A790 UNSS31803 B36.10M POE X TOE,XS
NC PN 540JX NIPPLE,100MM LONG, DSS 20 20 A790 UNSS31803 B36.10M TBE, SCH 40S
T LV 541 HCPL, DSS 3000 50 600 A182 GR.F51 B16.11 SW ENDS 1
Flanges
F F D541J WN FLG,DSS 300 50 600 A182 GR.F51 B16.5, RF BW END,SCH 40S,RF
FA FSD541 SO FLG, DSS 300 50 100 A182 GR.F51 B16.5,RF 40
FB FBD541 BF,DSS 300 50 600 A182 GR.F51 B16.5,RF RF
FM FMD541J WN ORIFICE FLANGE SET ,DSS 300 50 300 A182 GR.F51 B16.36 BW ENDS, SCH 40S
FM FMD541JA WN ORIFICE FLANGE SET ,DSS 300 350 600 A182 GR.F51 B16.36 BW ENDS, SCH 40
Bolts
B B 661 SBOLT 50 600 A193GR.B8M/A194GR.8M B18.2.1/B18.2.2
Gaskets
G DU 742 SP WD GASKET 300 20 600 UNS S31803/GRPH B16.20/B16.5
Others
WB WBD541 SPECTACLE BLIND, DSS 300 50 250 A240 UNSSS31803 ASME B16.48 FOR RF FLGS,B16.5
WB WUD541 PADDLE SPACER & BLANK,DSS 300 300 600 A240 UNSSS31803 ASME B16.48 FOR RF FLGS,B16.5
WA WAD541 ADAPTOR,FLGD,DSS 300 50 50 A182 GR.F51 PINLES-PIP-6265 FLGD,B16.5,RF
VE VAN301N ANGLE SLURRY VALVE, CS-NI ,HO 300 50 100 A216 GR.WCB-NI LINED TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 47
VE VAN302N ANGLE SLURRY VALVE, CS-NI, GO 300 150 600 A216 GR.WCB-NI LINED TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 47
VP VAB301N ANG. BAYONET VALVE,CS-NI, HO 300 50 100 A216 GR.WCB-NI LINED TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF
VP VAB302N ANG. BAYONET VALVE,CS-NI, GO 300 150 600 A216 GR.WCB-NI LINED TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF
N
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Piping Class: N
Print Time : 17:14
VK VBL301 BALL VALVE,FB,CS, LO 300 50 50 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF 32
VCA VCK301N ANGLE CHECK VALVE,CS-NI LINED 300 50 500 A216 GR.WCB-LI LINED TRIM NO.8 MFG. STD. FLGD, B16.5, RF 53
Notes
1 - FOR TYPE OF BRANCH REFER PART3 47 - TO BE INSTALLED IN HORIZONTAL 8A - FOR HYDROSTATIC TEST VENTS.
32 - USE THIS BALL VALVE FOR POSITION ONLY.
DRAINING DILUTE ACID ONLY. 53 - INSTALLED IN VERTICAL POS.
40 - TO BE USED WITH LEAD ENGINEERS WITH UPWARD FLOW.
CONFIRMATION.
N
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Page : 43
Piping Class: P
Print Time : 17:14
Fluid code:
FV2 GW2 PC
Basic Material: A106GR.B/A53GR.B Facing: RF Corrosion allowance: 2.00MM
Rating: Temperature CEL: -29 38 93 149 204 260
Class 300 Pressure KPag: 4626,9 4626,9 4626,9 4516,1 4377,8 4171,8
Piping Schedule 2
B36.10M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2
Thk 3,73 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 12,7 12,7 12,7
Sch XS XS XS XS STD STD STD STD STD STD STD XS XS XS
CONTINUE DN 500,0 600,0
OD 508,0 609,6
Thk 15,09 17,48
Sch 40 40
Rating DN
P P W060H PIPE,ERW,CS 2 50 300 A53 GR.B B36.10M BW ENDS,SCH STD
P P W060J PIPE,ERW,CS 500 600 A53 GR.B B36.10M BW ENDS,SCH 40
Fittings
E E W060J ELB,90 DEG,LR, CS 500 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
EF EFW060J ELB,45 DEG,LR, CS 500 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
P
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Piping Class: P
Print Time : 17:14
Rating DN
R EOW060J CON RED, CS 500 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
RE EXW060J ECC RED, CS 500 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
T ETW060J TEE, CS 500 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40 1
Flanges
FB FBD141 BF, CS 300 20 600 A105 B16.5,RF
P
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Page : 45
Piping Class: P
Print Time : 17:14
Rating DN
Gaskets
Others
WA WAX144 ADAPTOR,CS 3000 20 40 A105 PINLES-PIP-6265 FOR SW ENDS VALVES,B16.11
VA VBF308 HIGH PER.BUTTERFLY VALVE,CS,GO 300 80 600 A216 GR.WCB TRIM NO.8 GRPH API 609 CATG. B DOUBLE FLANGED,B16.5,RF
VG VGA801 GATE VALVE, CS,HO 2 800 15 40 A105 TRIM NO.8 GRPH API 602 SW ENDS
VG VGA301 GATE VALVE,CS,HO 300 50 250 A216 GR.WCB TRIM NO.8 GRPH API 600 FLGD, B16.5, RF
VG VGA302 GATE VALVE, CS,GO 300 300 600 A216 GR.WCB TRIM NO.8 GRPH API 600 FLGD, B16.5, RF
VX WKX144 STEAM TRAP, THERMODYNAMIC,CS 800 20 25 A105 MFG STD SW ENDS
V VGL301 GLOBE VALVE,CS,HO 300 50 250 A216 GR.WCB TRIM NO.8 GRPH BS 1873 FLGD, B16.5, RF
VC VCK305 SWING CHECK VALVE,CS 300 50 600 A216 GR.WCB TRIM NO:8 BS 1868 FLGD, B16.5, RF 21
VY Y X144 Y TYPE STRAINER,CS 800 20 40 A105 MFG STD SW ENDS, B16.11 16
Notes
16 - SS INTERNALS 21 - INSTALLED IN HORIZONTAL OR 8A - FOR HYDROSTATIC TEST VENTS.
1 - FOR TYPE OF BRANCH REFER PART3 VERTICAL POSITION WITH UPWARD
FLOW
P
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Page : 46
Piping Class: R
Print Time : 17:14
Fluid code:
HDRM
Basic Material: API-5L GR.X52 Facing: RF Corrosion allowance: 1.50MM
Piping Schedule
B36.10M DN 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0
OD 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4
Thk 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53
Sch STD STD STD STD STD STD STD STD STD
Rating DN
P P W080H PIPE,SAW,CS 50 400 API-5L GR.X52 B36.10M BW ENDS,SCH STD
Fittings
E E W080H ELB,90 DEG,LR,ERW,CS 50 400 A860 GR.WPHY52 B16.9 BW ENDS,SCH STD
EF EFW080H ELB,45 DEG,LR,ERW,CS 50 400 A860 GR.WPHY52 B16.9 BW ENDS,SCH STD
T ED 080H WELDOLET, AS 150 400 A182 GR.F5 MSS SP-97 BW ENDS, SCH STD 1
R EOW080H CON RED,ERW,CS 50 400 A860 GR.WPHY52 B16.9 BW ENDS,SCH STD
RE EXW080H ECC RED,ERW,CS 50 400 A860 GR.WPHY52 B16.9 BW ENDS,SCH STD
T ETW080H TEE,ERW,CS 50 400 A860 GR.WPHY52 B16.9 BW ENDS, SCH STD 1
T UH 142 THREDOLET, CS 6000 50 400 A105N MSS-SP-97 SCRD ENDS, NPT (F) 1
C EK 080H CAP, CS 50 400 A860 GR.WPHY52 B16.9 BW ENDS, SCH STD
US US 142 HEX HEADED PLUG, CS 6000 20 25 A105 B16.11 SCRD,NPT(M)B1.20.1 8A
N PNG130R NIPPLE,100MM LONG,CS 20 20 A106 GR.B B36.10M SCRD NPT(M),SCH 160 8A
Flanges
F F D083H WN FLG, CS 600 50 400 A694 GR.F52 B16.5,RF BW END,SCH STD
FB FBD083 BF, CS 600 50 400 A694 GR.F52 B16.5,RF
Bolts
R
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Page : 47
Piping Class: R
Print Time : 17:14
Rating DN
Gaskets
Others
WA WAD083 ADAPTOR,FLGD, CS 600 50 50 A694 GR.F52 PINLES-PIP-6265 RF, FLG, B16.5
VE VAN601 ANGLE SLURRY VALVE, CS,HO 600 50 100 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 47
VE VAN602 ANGLE SLURRY VALVE, CS,GO 600 150 400 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF 47
VG VGA802 GATE VALVE, CS,HO 800 20 20 A105N SS 304 PTFE API 602 SCRD,NPT(F),B1.20.1 8A
VP VAB601 ANG. BAYONET VALVE,CS,HO 600 50 100 A216 GR.WCB TRIM NO.8 PTFE MFG. STD. FLGD, B16.5, RF
VK VBL601 BALL VALVE,CS,FB,LO 600 50 50 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF 28
VYA YH 133 START-UP STRAINER,CS 600 50 400 A515 GR.70 MFG STD FOR RF FLGS,B16.5 16
Notes
16 - SS INTERNALS 47 - TO BE INSTALLED IN HORIZONTAL 8A - FOR HYDROSTATIC TEST VENTS.
1 - FOR TYPE OF BRANCH REFER PART3 POSITION ONLY.
28 - FOR INST. TAP CONN. ONLY 53 - INSTALLED IN VERTICAL POS.
WITH UPWARD FLOW.
R
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Page : 48
Piping Class: S
Print Time : 17:14
Fluid code:
SNL2
Basic Material: A106GR.B/A53GR.B Facing: RF Corrosion allowance: 2.00MM
Piping Schedule
B36.10M DN 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0 500,0
OD 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2 508,0
Thk 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 12,7 12,7 12,7 14,27 15,09
Sch XS XS XS STD STD STD STD STD STD XS XS XS 40 40
CONTINUE DN 600,0
OD 609,6
Thk 17,48
Sch 40
Rating DN
P P W060J PIPE,ERW,CS 450 600 A53 GR.B B36.10M BW ENDS,SCH 40
Fittings
E E W060J ELB,90 DEG,LR, CS 450 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
EF EFW060J ELB,45 DEG,LR, CS 450 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
S
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Piping Class: S
Print Time : 17:14
Rating DN
R EOW060MB CON RED, CS 300 400 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
R EOW060JB CON RED, CS 450 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
RE EXW060MB ECC RED, CS 300 400 A234 GR.WPB-W B16.9 BW ENDS, SCH XS
RE EXW060JB ECC RED, CS 450 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40
RTC EROW130H CONC TAPER, CS 50 250 A515 GR.70 tkIS DRG BW ENDS, SCH STD
RTC EROW130MA CONC TAPER, CS 300 400 A515 GR.70 tkIS DRG BW ENDS, SCH XS
RTC EROW130JA CONC TAPER, CS 450 600 A515 GR.70 tkIS DRG BW ENDS, SCH 40
2
RTE ERXW130H ECC TAPER, CS 50 250 A515 GR.70 tkIS DRG BW ENDS, SCH STD
RTE ERXW130MA ECC TAPER, CS 300 400 A515 GR.70 tkIS DRG BW ENDS, SCH XS
RTE ERXW130JA ECC TAPER, CS 450 600 A515 GR.70 tkIS DRG BW ENDS, SCH 40
T ETW060MB TEE, CS 300 400 A234 GR.WPB-W B16.9 BW ENDS, SCH XS 1
T ETW060JB TEE, CS 450 600 A234 GR.WPB-W B16.9 BW ENDS, SCH 40 1
Flanges
S
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Page : 50
Piping Class: S
Print Time : 17:14
Rating DN
FB FBD141 BF, CS 300 20 600 A105 B16.5,RF
Bolts
Gaskets
Others
WSL WSX361L QRC (LIQUID/WATER) 3000 20 40 SS304 MFG STD SW ENDS 2
VA VBF307 HIGH PER.BUTTERFLY VALVE,CS,GO 300 80 600 A216 GR.WCB TRIM NO.8 PTFE API 609 CAT.B DOUBLE FLANGED,B16.5,RF 6
VG VGA301 GATE VALVE,CS,HO 300 50 250 A216 GR.WCB TRIM NO.8 GRPH API 600 FLGD, B16.5, RF
VG VGA302 GATE VALVE, CS,GO 300 300 600 A216 GR.WCB TRIM NO.8 GRPH API 600 FLGD, B16.5, RF
V VGL301 GLOBE VALVE,CS,HO 300 50 250 A216 GR.WCB TRIM NO.8 GRPH BS 1873 FLGD, B16.5, RF
VC VCK305 SWING CHECK VALVE,CS 300 50 600 A216 GR.WCB TRIM NO:8 BS 1868 FLGD, B16.5, RF 21
Notes
16 - SS INTERNALS 6 - <DN400 SHAFT INST PREF. HORIZ. 8A - FOR HYDROSTATIC TEST VENTS.
1 - FOR TYPE OF BRANCH REFER PART3 >=DN400 SHAFT INST ALWAYS
21 - INSTALLED IN HORIZONTAL OR HORIZONTAL.
FLOW
S
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Piping Class: X
Print Time : 17:14
Fluid code:
FO LDO
Basic Material: A106GR.B/A672GR.B60 CL32 Facing: RF Corrosion allowance: 2.00MM
Piping Schedule
B36.10M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2
Thk 3,73 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,53 9,53 9,53
CONTINUE DN 500,0 600,0
OD 508,0 609,6
Thk 9,53 9,53
Sch STD STD
Rating DN
P P W180H PIPE,EFW,CS 400 600 A672 GR.B60 CL32 B36.10M BW ENDS,SCH STD
Fittings
X
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Piping Class: X
Print Time : 17:14
Rating DN
Flanges
Bolts
2
Gaskets
Others
X
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Page : 53
Piping Class: X
Print Time : 17:14
Rating DN
WHP WH 007 RUBBER HOSE,PETROLEUM PRODUCTS 80 100 SYNTHETIC RUBBER MFG STD FLGD,RF,B16.5 2
VK VBL803 BALL VALVE,CS,RB,LO 800 15 40 A105 PTFE PTFE API 608 SW ENDS
VK VBL108 BALL VALVE, CS,FB, GO 150 200 450 A216 GR.WCB PTFE PTFE API 608 FLGD, B16.5, RF
V VGL801 GLOBE VALVE, CS,HO 800 15 40 A105 TRIM NO.8 PTFE BS EN ISO 15761 SW ENDS, B16.11
V VGL111 GLOBE VALVE, CS,GO 150 300 300 A216 GR.WCB TRIM NO.8 PTFE BS 1873 FLGD, B16.5, RF
VC VCK111 LIFT CHECK VALVE, CS 150 15 40 A216 GR.WCB TRIM NO.8 BS EN ISO 15761 FLGD, B16.5, RF 47
Notes
16 - SS INTERNALS 43 - FOR CL 300 CONNECTION ONLY. 8A - FOR HYDROSTATIC TEST VENTS.
1 - FOR TYPE OF BRANCH REFER PART3 47 - TO BE INSTALLED IN HORIZONTAL
21 - INSTALLED IN HORIZONTAL OR POSITION ONLY.
FLOW
X
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Page : 54
Piping Class: Y
Print Time : 17:14
Fluid code:
CON1 SLP
Basic Material: A106GR.B/A672GR.B60 CL32 (IBR) Facing: RF Corrosion allowance: 2.00MM
Rating: Temperature CEL: -29 38 93 149 204 260 316
Class 300 Pressure KPag: 3741,35 3741,35 3741,35 3741,35 3741,35 3741,35 3587,38
Piping Schedule
B36.10M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2
Thk 3,73 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 9,0 10,0 11,0
Sch XS XS XS XS STD STD STD STD STD STD STD NON-STD NON-STD NON-STD
CONTINUE DN 500,0 600,0 650,0 700,0 750,0
OD 508,0 609,6 660,0 711,0 762,0
Thk 12,0 14,0 16,0 16,0 16,0
Sch NON-STD NON-STD NON-STD NON-STD NON-STD
Rating DN
P PB Z09M PIPE,SMLS,CS(IBR) 15 40 A106 GR.B B36.10M PE,SCH XS
P P Z09H PIPE,SMLS,CS(IBR) 50 300 A106 GR.B B36.10M BW ENDS, SCH STD
P P WZ09Z PIPE,EFW,CS(IBR) 350 750 A672 GR.B60 CL32 B36.10M BW ENDS,SCH NON-STD
Fittings
E LE Z11 ELB, 90 DEG,LR, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
E E Z06H ELB, 90 DEG,LR, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
E E WZ06Z ELB, 90 DEG,LR, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
EF LF Z11 ELB,45 DEG LR, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
EF EF Z06H ELB,45 DEG,LR, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
EF EFWZ06Z ELB,45 DEG,LR, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
R EO Z09M CON REDUCING SWAGE, CS(IBR) 20 40 A106 GR.B MSS SP-95 PBE, SCH XS
R EO Z06H CON RED, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
R EOWZ06Z CON RED, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
RE EX Z09M ECC REDUCING SWAGE, CS(IBR) 20 40 A106 GR.B MSS SP-95 PBE, SCH XS
RE EX Z06H ECC RED, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
Y
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Piping Class: Y
Print Time : 17:14
Rating DN
RE EXWZ06Z ECC RED, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
T LT Z11 TEE, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS 1
T ET Z06H TEE, CS(IBR) 50 300 A234 Gr.WPB B16.9 BW ENDS, SCH STD 1
T EG Z09A STUB IN WITH PAD 150 750 SAME AS PIPE tkIS DRG 1
T ETWZ06Z TEE, CS(IBR) 750 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD 1
C LK Z11 CAP, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
C EK Z05H CAP, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
C EK Z05Z CAP, CS(IBR) 350 750 A234 GR.WPB B16.9 BW ENDS, SCH NON-STD
CX UK Z11 CAP, CS(IBR) 3000 20 20 A105 B16.11 SCRD,NPT(F)B1.20.1 8A
M LM Z11 FCPL, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
NA PN Z09M NIPPLE,100MM LONG, CS(IBR) 20 40 A106 GR.B B36.10M PBE, SCH XS
NB PN Z09MA NIPPLE,100MM LONG, CS(IBR) 20 40 A106 GR.B B36.10M POE X TOE,XS
NC PN Z09MX NIPPLE,100MM LONG, CS(IBR) 20 40 A106 GR.B B36.10M TBE, SCH XS
T LV Z11 HCPL, CS(IBR) 3000 50 750 A105 B16.11 SW ENDS 1
Flanges
F FWDZ11 SW FLG, CS(IBR) 300 15 40 A105 B16.5,RF SW ENDS, SCH XS
F F DZ11H WN FLANGE, CS(IBR) 300 50 300 A105 B16.5,RF BW ENDS, SCH STD
F F DZ11Z WN FLANGE, CS(IBR) 300 350 600 A105 B16.5,RF BW ENDS, SCH NON-STD
F F DZ11ZA WN FLANGE, CS(IBR) 300 750 750 A105 B16.47 SER-A,RF BW ENDS, SCH NON-STD
FB FBDZ11 BF, CS(IBR) 300 15 600 A105 B16.5,RF
FB FBDZ11A BF, CS(IBR) 300 750 750 A105 B16.47 SER-A,RF
FM FMDZ11H WN ORIFICE FLANGE SET ,CS(IBR) 300 50 300 A105 B16.36 BW ENDS, SCH STD
FM FMDZ11Z WN ORIFICE FLANGE SET ,CS(IBR) 300 350 600 A105 B16.36 BW ENDS, SCH NON-STD
Bolts
Gaskets
Y
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Piping Class: Y
Print Time : 17:14
Rating DN
WB WBDZ21 SBLD, CS (IBR) 300 50 250 A515 GR.70 B16.48,RF FOR RF FLGS, B16.5
WB WUDZ21 PADDLE SPACER & BLANK, CS(IBR) 300 300 600 A515 GR.70 B16.48,RF FOR RF FLGS,B16.5
WA WAXZ14 ADAPTOR,SW, CS(IBR) 3000 15 25 A105 PINLES-PIP-6265 FOR SW ENDS VALVES,B16.11
VA VBF313 HIGH PER.BUTTFLY VA,CS(IBR),GO 300 80 600 A216 GR.WCB TRIM NO.5 GRPH API 609 CAT.B DOUBLE FLANGED,B16.5,RF 2
VA VBF314 HIGH PER.BUTTFLY VA,CS(IBR),GO 300 750 750 A216 GR.WCB TRIM NO.5 GRPH API 609 CAT.B DOUBLE FLANGED,B16.47A 11
VG VGA811 GATE VALVE, CS(IBR),HO 800 15 40 A 105 TRIM NO.5 GRPH API 602 SW ENDS, B16.11
VG VGA312 GATE VALVE, CS(IBR),HO 300 50 200 A216 GR.WCB TRIM NO.5 GRPH API 600 FLGD, B16.5, RF
VG VGA313 GATE VALVE, CS(IBR),GO 300 250 600 A216 GR.WCB TRIM NO.5 GRPH API 600 FLGD, B16.5, RF
VG VGA314 GATE VALVE, CS(IBR),GO 300 750 750 A216 GR.WCB TRIM NO.5 GRPH API 600 FLGD, B16.47SER-A, RF
VX WKXZ14 STEAM TRAP,THERMODYNAMIC,CS 800 20 25 A105 MFG STD SW ENDS
V VGL811 GLOBE VALVE,CS(IBR),HO 800 15 40 A 105 TRIM NO.5 GRPH BS EN ISO 15761 SW ENDS, B16.11
V VGL312 GLOBE VALVE, CS(IBR),HO 300 50 200 A216 GR.WCB TRIM NO.5 GRPH BS 1873 FLGD, B16.5, RF
V VGL313 GLOBE VALVE, CS(IBR),GO 300 250 300 A216 GR.WCB TRIM NO.5 GRPH BS 1873 FLGD, B16.5, RF
VC VCK811 SWING CHECK VALVE, CS(IBR) 800 15 40 A105 TRIM NO.5 BS EN ISO 15761 SW ENDS, B16.11 21
2
VC VCK312 SWING CHECK VALVE,CS(IBR) 300 50 600 A216 GR.WCB TRIM NO:5 BS 1868 FLGD, B16.5, RF 21
VY Y XZ20 Y TYPE STRAINER,CS,(IBR) 800 15 40 A105 MFG STD SW ENDS, B16.11 16
VY Y DZ21 Y TYPE STRAINER, CS(IBR) 300 50 50 A216 GR.WCB MFG STD FLGD, B16.5, RF 16
2
Notes
11 - LUG TYPE 21 - INSTALLED IN HORIZONTAL OR 8A - FOR HYDROSTATIC TEST VENTS.
Y
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Page : 57
Piping Class: Z
Print Time : 17:14
Fluid code:
CON SMP
Basic Material: A106GR.B/A672GR.B60 CL32 (IBR) Facing: RF Corrosion allowance: 2.00MM
Rating: Temperature CEL: -29 38 93 149 204 260 316
Class 600 Pressure KPag: 4511,19 4511,19 4511,19 4511,19 4511,19 4511,19 4417,05
Piping Schedule
B36.10M DN 15,0 20,0 25,0 40,0 50,0 80,0 100,0 150,0 200,0 250,0 300,0 350,0 400,0 450,0
OD 21,3 26,7 33,4 48,3 60,3 88,9 114,3 168,3 219,1 273,0 323,8 355,6 406,4 457,2
Thk 3,73 3,91 4,55 5,08 3,91 5,49 6,02 7,11 8,18 9,27 9,53 10,0 12,0 12,0
Sch XS XS XS XS STD STD STD STD STD STD STD NON-STD NON-STD NON-STD
CONTINUE DN 500,0 600,0 650,0 700,0 750,0
OD 508,0 609,6 660,0 711,0 762,0
Thk 14,0 16,0 17,0 18,0 20,0
Sch NON-STD NON-STD NON-STD NON-STD NON-STD
Rating DN
P PB Z09M PIPE,SMLS,CS(IBR) 15 40 A106 GR.B B36.10M PE,SCH XS
P P Z09H PIPE,SMLS,CS(IBR) 50 300 A106 GR.B B36.10M BW ENDS, SCH STD
P P WZ09ZA PIPE,EFW,CS(IBR) 350 750 A672 GR.B60 CL32 B36.10M BW ENDS,SCH NON-STD
Fittings
E LE Z11 ELB, 90 DEG,LR, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
E E Z06H ELB, 90 DEG,LR, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
E E WZ06ZA ELB, 90 DEG,LR, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
EF LF Z11 ELB,45 DEG LR, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
EF EF Z06H ELB,45 DEG,LR, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
EF EFWZ06ZA ELB,45 DEG,LR, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
R EO Z09M CON REDUCING SWAGE, CS(IBR) 20 40 A106 GR.B MSS SP-95 PBE, SCH XS
R EO Z06H CON RED, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
R EOWZ06ZA CON RED, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
RE EX Z09M ECC REDUCING SWAGE, CS(IBR) 20 40 A106 GR.B MSS SP-95 PBE, SCH XS
RE EX Z06H ECC RED, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
Z
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Piping Class: Z
Print Time : 17:14
Rating DN
RE EXWZ06ZA ECC RED, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD
T LT Z11 TEE, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS 1
T ET Z06H TEE, CS(IBR) 50 300 A234 Gr.WPB B16.9 BW ENDS, SCH STD 1
T EG Z09A STUB IN WITH PAD 80 750 SAME AS PIPE tkIS DRG 1
T ETWZ06ZA TEE, CS(IBR) 350 750 A234 GR.WPB-W B16.9 BW ENDS, SCH NON-STD 1
C LK Z11 CAP, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
C EK Z05H CAP, CS(IBR) 50 300 A234 GR.WPB B16.9 BW ENDS, SCH STD
C EK Z05ZA CAP, CS(IBR) 350 750 A234 GR.WPB B16.9 BW ENDS, SCH NON-STD
CX UK Z11 CAP, CS(IBR) 3000 20 20 A105 B16.11 SCRD,NPT(F)B1.20.1 8A
M LM Z11 FCPL, CS(IBR) 3000 15 40 A105 B16.11 SW ENDS
NA PN Z09M NIPPLE,100MM LONG, CS(IBR) 20 40 A106 GR.B B36.10M PBE, SCH XS
NB PN Z09MA NIPPLE,100MM LONG, CS(IBR) 20 40 A106 GR.B B36.10M POE X TOE,XS
NC PN Z09MX NIPPLE,100MM LONG, CS(IBR) 20 40 A106 GR.B B36.10M TBE, SCH XS
T LV Z11 HCPL, CS(IBR) 3000 50 750 A105 B16.11 SW ENDS 1
Flanges
F FWDZ13 SW FLG, CS(IBR) 600 15 40 A105 B16.5,RF SW ENDS, SCH XS
F F DZ13H WN FLANGE, CS(IBR) 600 50 300 A105 B16.5,RF BW ENDS, SCH STD
F F DZ13Z WN FLANGE, CS(IBR) 600 350 600 A105 B16.5,RF BW ENDS, SCH NON-STD
F F DZ13ZA WN FLANGE, CS(IBR) 600 750 750 A105 B16.47 SER-A,RF BW ENDS, SCH NON-STD
FB FBDZ13 BF, CS(IBR) 600 15 600 A105 B16.5,RF
FB FBDZ13A BF, CS(IBR) 600 750 750 A105 B16.47 SER-A,RF
Bolts
Gaskets
Others
WB WBDZ23 SBLD, CS (IBR) 600 50 250 A515 GR.70 B16.47,RF FOR RF FLGS, B16.5
Z
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Page : 59
Piping Class: Z
Print Time : 17:14
Rating DN
WB WUDZ23 PADDLE SPACER & BLANK, CS(IBR) 600 300 600 A515 GR.70 B16.48,RF FOR RF FLGS,B16.5
WA WAXZ14 ADAPTOR,SW, CS(IBR) 3000 15 25 A105 PINLES-PIP-6265 FOR SW ENDS VALVES,B16.11
Rating DN M a t e r i a l 2
VA VBF611 HIGH PER.BUTTFLY VA,CS(IBR),GO 600 750 750 A216 GR.WCB TRIM NO.5 GRPH API 609 CAT.B DOUBLE FLANGED,B16.47A 11
VG VGA811 GATE VALVE, CS(IBR),HO 800 15 40 A 105 TRIM NO.5 GRPH API 602 SW ENDS, B16.11
VG VGA611 GATE VALVE, CS(IBR),HO 600 50 150 A216 GR.WCB TRIM NO.5 GRPH API 600 FLGD, B16.5, RF
VG VGA612 GATE VALVE, CS(IBR),GO 600 200 600 A216 GR.WCB TRIM NO.5 GRPH API 600 FLGD, B16.5, RF
VX WKXZ14 STEAM TRAP,THERMODYNAMIC,CS 800 20 25 A105 MFG STD SW ENDS
V VGL811 GLOBE VALVE,CS(IBR),HO 800 15 40 A 105 TRIM NO.5 GRPH BS EN ISO 15761 SW ENDS, B16.11
V VGL611 GLOBE VALVE, CS(IBR),HO 600 50 150 A216 GR.WCB TRIM NO.5 GRPH BS 1873 FLGD, B16.5, RF
V VGL612 GLOBE VALVE, CS(IBR),GO 600 200 300 A216 GR.WCB TRIM NO.5 GRPH BS 1873 FLGD, B16.5, RF
VC VCK811 SWING CHECK VALVE, CS(IBR) 800 15 40 A105 TRIM NO.5 BS EN ISO 15761 SW ENDS, B16.11 21
VC VCK611 SWING CHECK VALVE,CS(IBR) 600 50 600 A216 GR.WCB TRIM NO:5 BS 1868 FLGD, B16.5, RF 21
VY Y XZ20 Y TYPE STRAINER,CS,(IBR) 800 15 40 A105 MFG STD SW ENDS, B16.11 16
VY Y DZ23 Y TYPE STRAINER, CS(IBR) 600 50 50 A216 GR.WCB MFG STD FLGD, B16.5, RF 16
2
Notes
11 - LUG TYPE 21 - INSTALLED IN HORIZONTAL OR 8A - FOR HYDROSTATIC TEST VENTS.
Z
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2
Page : 1
Piping Class: XX00
Print Time : 14:45
Basic Material: STANDARD PIPING SPECIALS Facing: Corrosion allowance:

Rating: Temperature :
Class Pressure :
Rating DN
Fittings
XAE SP-335-1101 SCALPING CYCLON OVERFLOW TEE 250 250 A234 GR.WPBW tkIS DRG
XAG SP-334-1103 PRIMARY CYCLON UNDERFLOW TEE 200 200 A234 GR.WPBW tkIS DRG
XAI SP-335-1102 SCALPING CYCLON EMERGENCY OVER 300 300 A234 GR.WPBW tkIS DRG
XAJ SP-335-1109 MILL SLURRY DILUTION MIX. TEE 100 100 A234 GR.WPBW tkIS DRG
XAK SP-335-1105 COURSE SEED FILTRATE TEE 400 400 A234 GR.WPBW tkIS DRG
XAL SP-335-1106 COURSE SEED FILTRATE TEE 400 400 A234 GR.WPBW tkIS DRG
XAM SP-335-1103 FILTER OVERFLOW SLURRY TEE 500 500 A234 GR.WPBW tkIS DRG
XAN SP-335-1104 FILTER OVERFLOW SLURRY TEE 500 500 A234 GR.WPBW tkIS DRG
XAP SP-335-1108 FINE SEED FILTRATE TEE 250 250 A234 GR.WPBW tkIS DRG
XAQ SP-335-1107 PRODUCT DELIQUORING FILT. TEE 200 200 A234 GR.WPBW tkIS DRG
XAS SP-000-0001 SCALE TRAP 150 150 CS tkIS DRG
XAT SP-335-1110 FILTRATE OVERFLOW SLURRY TEE 200 200 A234 GR.WPBW tkIS DRG
XAU SP-000-0001 SCALE TRAP 350 350 CS tkIS DRG
XAV SP-332-1101 FILTER OVERFLOW SLURRY TEE 300 300 A234 GR.WPBW tkIS DRG
XAW SP-000-0001 SCALE TRAP 200 200 CS tkIS DRG
XAX SP-332-1103 SPECIAL TEE 200 200 CS tkIS DRG
XVA SP-332-1101 FILTER OVERFLOW SLURRY TEE 250 250 A234 GR.WPBW tkIS DRG
XVC SP-332-1103 SPECIAL TEE 200 200 CS tkIS DRG
Others
XAA WXSG001 SPLASH GUARD 150 15 FEP MFG STD
XX00
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Piping Class: XX00
Print Time : 14:45
Rating DN
XAB WXSG002 SPLASH GUARD 300 15 FEP MFG STD
XAC ZU0001 FUNNEL 25 CS tkIS DRG BW ENDS, SCH STD
XX00
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Page : 3
Piping Class: XX00
Print Time : 14:45
Rating DN
XAD SP-332-1601 FLEXIBLE HOSE 150 25 SYNTHETIC RUBBER MFG. STD. FLGD,RF,B16.5
XAY SP-332-0001 PP EXTENSION 200 PP tkIS DRG FOE X POE
XAZ SP-335-0001 PP EXTENSION 200 PP tkIS DRG FOE X POE
XCB ZU0006 SQUARE FUNNEL 150 CS tkIS DRG BW ENDS
XCC SP-234-1303 HARD FACE SPOOL 150 400 CS tkIS DRG FLGD ENDS,B16.5,RF
XPO ZU0008 TUNDISH, CS 25 CS tkIS DRG BW ENDS
XX00
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Piping Specification
Miscellaneous Rev. Date
First Issue
:
:
22.01.18
28.09.17
Print Date : 22.01.2018
Print Time : 14:40
PIPING
SPECIFICATION
Nalco
66-6695
Part 5
46-7519-10/IRP4.0-MU1/RS50/1996-12/00
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INSULATION SPECIFICATION
Page : 1
Insulation Type: HC / HEAT CONSERVATION Report Date
Report Rev.
:
:
22.01.18
2
Print Date : 22.01.2018
Print Time : 14:55
DN Insulation Thickness Values

> 65 105 155 200 250 300 350 400
<= 105 155 200 250 300 350 400 450
15 30 40 50 60 70 90 100 120
20 30 40 50 60 80 90 110 120
25 30 40 50 60 80 100 110 130
32 30 40 50 70 80 100 120 140
40 30 40 60 70 90 100 120 140
50 30 40 60 70 90 110 130 150
65 30 40 60 80 90 110 130 150
80 30 50 60 80 100 120 140 160
90 30 50 60 80 100 120 140 160
100 30 50 70 80 100 120 150 170
125 30 50 70 90 110 130 150 180
150 30 50 70 90 110 130 160 180
200 30 50 70 90 120 140 170 190
250 30 50 70 100 120 150 170 200
300 30 50 80 100 120 150 180 210
350 40 60 80 100 130 150 180 210
400 40 60 80 100 130 160 190 220
450 40 60 80 100 130 160 190 220
500 40 60 80 100 130 160 190 230
600 40 60 80 110 140 170 200 230
750 40 60 80 110 140 170 210 240
900 40 60 80 110 140 170 210 250
1050 40 60 80 110 140 180 220 260
1200 40 60 80 110 140 180 220 260
INSULATION MATERIAL: RESIN BONDED ROCKWOOL AS PER IS-8183 FOR MATTRESSES AND IS-9842 FOR
PREFORMED PIPE SECTIONS. ALUMINIUM CLADDING
46-7519-10/IRP4.0-MU1/DS01/1996-12/00
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INSULATION SPECIFICATION
Page : 2
Insulation Type: PP / PERSONNEL PROTECTION Report Date
Report Rev.
:
:
22.01.18
2
Print Date : 22.01.2018
Print Time : 14:55
DN Insulation Thickness Values

> 100 100 150 200 250 300 350 400
<= 100 150 200 250 300 350 400 450
15 30 30 30 30 30 40 40 50
20 30 30 30 30 30 40 40 50
25 30 30 30 30 30 40 40 50
32 30 30 30 30 30 40 50 50
40 30 30 30 30 30 40 50 60
50 30 30 30 30 40 40 50 60
65 30 30 30 30 40 40 50 60
80 30 30 30 30 40 50 50 60
90 30 30 30 30 40 50 50 60
100 30 30 30 30 40 50 60 70
125 30 30 30 30 40 50 60 70
150 30 30 30 30 40 50 60 70
200 30 30 30 30 40 50 60 70
250 30 30 30 30 40 50 60 70
300 30 30 30 30 40 50 60 80
350 30 30 30 30 40 50 60 80
400 30 30 30 30 40 50 70 80
450 30 30 30 30 40 50 70 80
500 30 30 30 30 40 60 70 80
600 30 30 30 30 40 60 70 80
750 30 30 30 30 40 60 70 80
900 30 30 30 30 40 60 70 80
1050 30 30 30 30 40 60 70 80
1200 30 30 30 30 40 60 70 80
INSULATION MATERIAL: RESIN BONDED ROCKWOOL AS PER IS-8183 FOR MATTRESSES AND IS-9842 FOR
PREFORMED PIPE SECTIONS. ALUMINIUM CLADDING
46-7519-10/IRP4.0-MU1/DS01/1996-12/00
669 of 1528
UAN : 66-6695-700
Page : 1
Pressure Testing of Pipeliness Report Date : 22.01.18
Report Rev : 2
Print Date : 22.01.2018
Print Time : 14:58
Test System Test Pressure KPag Test Medium
CN01 1800 WATER
CN02 2040 WATER

CN03 2063 WATER
CN04 2250 WATER
CN05 2259 WATER

CN06 2400 WATER
CN07 6569 WATER
CN08 6750 WATER

CN09 7007 WATER
CN10 7200 WATER

CN11 13800 WATER
CN50 1496 AIR
CN51 1513 AIR
CN52 1650 AIR
CN53 4692 AIR

SN01 3750 WATER
SN02 4047 WATER
SN03 2250 WATER 2
Remark:
46-7519-10/IRP4.0-MU1/ZL11/17-09/00
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NALCO NAL 6695-PIP-G00-TB-0001 66-6695
Dimensional Details of Special Tapers

(Concentric & Eccentric)
Rev 00 Page 1 of 1
00 ISSUED FOR FABRICATION 25.09.17 PTE 25.09.17 SHK 25.09.17 NNG -

Category Code: -3
Barcode
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Dimensional Details of Paddle Spacer and

Blanks for Flanges to ASME B16.47 Series-A
Rev 00 Page 1 of 1
00 ISSUED FOR FABRICATION 25.09.17 PTE 25.09.17 SHK 25.09.17 NNG -

Category Code: -3
Barcode
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--- --- --- PIN-LES-PIP-6235(Contract Specific ---
Document ID if adopted document)
GENERAL ENGINEERING SPECIFICATION Customer Logo

START UP CONICAL STRAINER & SPACER FOR (if applicable for Contract Specific Document)
STEEL PIPING Rev 00 Page 1 of 4
Contents:
1 GENERAL...................................................................................................................................................................................2
2. G.A. OF START UP CONICAL STRAINER & SPACER FOR STEEL PIPING ………………..………...….…………….3
3. DIMENSIONAL DETAILS OF START UP CONICAL STRAINER & SPACER FOR STEEL PIPING …..…..…...….4
PIN-QMC-03-F101 03-2015
Previous Doc.No. GENL-PI-UZ-0035,

Rev.2, is revised and reissued as PIN- 09.07.2015
00 SHK 09.07.2015 NNG 09.07.2015 Sd/-APK -
LES-PIP-6235 due to new document
numbering philosophy.
Based on : PIN-AAA-AAA-NNN
(to be indicated if adopted document)
Category Code: -

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--- --- --- PIN-LES-PIP-6235 (Contract Specific ---

START UP CONICAL STRAINER & SPACER FOR (if applicable for Contract Specific Document)
STEEL PIPING Rev 00 Page 2 of 4
1. GENERAL
This specification covers the GA drawing & dimensional details for Start up Conical Strainer & Spacer
for Steel Piping.
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(if applicable for Contract Specific Document)
DIMENSIONAL DETAILS FOR STEEL ADAPTOR

Rev 00 Page 1 of 6
Contents:
1 GENERAL........................................................................................................................................................................... 2
2. Adaptor for pressure guage & transmitter for valves of flanged ends for NS < 2” …………….….. 3
3. Adaptor for pressure guage & transmitter for valves of flanged ends for NS >= 2” ……….…….…… 4
4. Adaptor for pressure guage & transmitter for valves of welded / screwed ends for NS >= 1” .…….……5
5. Adaptor for pressure guage & transmitter for valves of welded / screwed ends for NS <= ¾”.….…… 6
PIN-QMC-03-F101 03-2015
00 Issued for Reference 15.07.2015 SHK 15.07.2015 NNG 15.07.2015 APK -

Category Code: -

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(if applicable for Contract Specific Document)
DIMENSIONAL DETAILS FOR STEEL ADAPTOR

Rev 00 Page 2 of 6
1. GENERAL
This specification covers the dimensional details for Steel Adaptor.

PIN-QMC-03-F101 03-2015
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STANDARD DRAWINGS FOR METALLIC PIPING (if applicable for Contract Specific Document)
FABRICATION & WELDING Rev 00 Page 1 of 11
Contents:
1 GENERAL ................................................................................................................................................................................ 2
2 TOLERANCES FOR FABRICATION …………………………………………………………………………………….………… 3
3 BRANCH CONNECTION WITHOUT USING STANDARD TEE ............................................................................. 4
4 BRANCH ATTACHMENT WELD DETAILS ................................................................................................................. 5
5 FILLET WELD DETAILS ...................................................................................................................................................... 6
6 BUTT WELDING END PREPARATION ........................................................................................................................... 7
7 WELDING OF PIPING COMPONENTS WITH INTERNAL MISALIGNMENT ........................................................ 8
8 BUTT WELD DETAILS ........................................................................................................................................................ 9
9 DETAILS FOR REINFORCEMENT PAD FOR ELBOW TRUNNION SUPPORTS ................................................. 10
10 DETAILS FOR REINFORCEMENT PAD FOR PIPE TRUNNION SUPPORTS ....................................................... 11

PIN-QMC-03-F101 03-2015
Previous Doc. No. PI-000-TB-00042, Rev.

0, is revised and reissued for reference as
00 22.07.2015 SHK 22.07.2015 NNG 19.08.2015 Sd/-APK -
PIN-LES-PIP-6300 due to New Document
numbering philosophy.
Category Code: -

689 of 1528
690 of 1528

STANDARD DRAWINGS FOR METALLIC PIPING (if applicable for Contract Specific Document)
FABRICATION & WELDING Rev 00 Page 2 of 11
1.0 GENERAL
This specification covers the Standard Drawings for Metallic Piping Fabrication & Welding.
PIN-QMC-03-F101 03-2015
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MASTER ABBREVIATION LIST
Abbreviations Description Remark

+ WITH
13% 13% CHROMIUM
°C DEGREES CENTIGRADE
°F DEGREES FAHRENHEIT
125 Ra Ra=125-250 m. In
16 Ra Ra=16-32 m. In
250 Ra Ra=250-500 m. In
45DEG 45 DEGREE
63 Ra Ra=63-125 m. In
90DEG. 90 DEGREE
A-20 ALLOY 20
AS ALLOY STEEL
ASB ASBESTOS
B18.2.2 THRD. STD (BOLT) ASME B 1.1 CL2A,
Ball valve (LP) BALL VALVE LONG PATTERN
BB BOLTED BONNET
BC BOLTED COVER
BE BEVELED END TO B16.25
BET THREADED BOTH ENDS
BF BLIND FLANGE
BLE BEVELLED LARGE END
BOE BEVELLED ONE END
BS BELLOW SEALED
BW BUTT WELDING
C&W COATED AND WRAPPED
CA CORROSION ALLOWANCE
CAP PIPE CAP
CF COLD FORMED (EX HEX NUTS,MACH.BOLTS ETC.)
CI CAST IRON
CL CLASS
CON RED CONCENTRIC REDUCER
CONC. CONCENTRIC
CORR CORRUGATED
CP CONVENTIONAL PORT
CRS CROSS
CS CARBON STEEL
CTFE CARBON GRAPHITE REINFORCED TEFLON
CVR COVER
DEG DEGREE
DI DUCTILE IRON
Dia. DIAMETER
DIPH DIAPHRAGM
DN NOMINAL DIA
DPR DESIGN PRESSURE
ECC RED ECCENTRIC REDUCER
EFW ELECTRIC FUSION WELDED
ELB ELBOW
ERW ELECTRIC RESISTANCE WELDED
EX: EXAMPLE
FB FULL BORE
FBE FLANGED BOTH ENDS
FBE FLG FIXED FLANGE BOTH ENDS
FBP FABRICATED FROM PIPE
FCPL FULL COUPLING
FF FLAT FACE
FLEXI DISC FLEXIBLE DISC
FLG FLANGE
FLGD FLANGED
FNPT SCREWED TO NPT(F) TO B 1.20.1
FOE FLANGED ONE END
FS FORGED STEEL
FT FEET
Ft/sec FEET PER SECOND
FW FIELD WELD
GALV GALVANIZED
GASK GASKET
GE GROOVCED ENDS
GF GLASS FILLED
GI GALVANIZED IRON
GJ GROUND JOINT
GNLLY GENERALLY
GO GEAR OPERATED
Gr. GRADE
GRF GRAFOIL
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GRPH ASB + INC WIRE GRAPHITED ASBESTOS WITH INCONEL WIRE
HCPL HALF COUPLING
HDPE HIGH DENSITY POLYETHYLENE
HEX HEXAGONAL
HF HARD FACED
HO HAND WHEEL OPERATED
HP HIGH PRESSURE
HPR HYDROSTATIC PRESSURE
HRL HARD RUBBER LINED
Hvy. HEAVY
HYP HYPALON
IBBM IRON BODY BRASS MOUNTING
ID INSIDE DIAMETER
IN INCH OR INCHES
IPS IRON PIPE SIZE
ISNRS INSIDE SCREW NON RISING STEM
ISRS INSIDE SCREW RISING STEM
JG J / U GROOVE ( FOR HIGH THICKNESS PIPE)
LAS LOW ALLOY STEEL
Lb POUND
LBE FLG LOOSE FLANGE BOTH END
LE LAMINATED ENDS, TYPE L
LEB LONG END BUTT WELDED
LEB & SET LONG END BEVELLED & SHORT END B.W. THREADED
LEFLG LARGE END FLANGED
LEL LARGE END LAMINATED, TYPE L
LET LONG END THREADED
LET & SEB LONG END THREADED & SHORT END B.W.
LG LARGE GROOVE
LIN LINED
LJ LAP JOINT FLANGES
LLET LATROLET
LO LEVER OPERATED
LOE LAMINATED OTHER END TO TYPE L5
LOE FLG LOOSE FLANGE ONE END
LP LOW PRESSURE
LR LONG RADIUS(1.5D)
LT LARGE TONGUE
LTCS LOW TEMPERATURE C.S.
LW LONGITUDINALLY WELDED
Mach. MACHINED
MATL MATERIAL
Max. MAXIMUM
MBOLT MACHINE BOLT WITH HEAVY NUT
MFG STD MANUFACTURER’S STANDARD
MI MALLEABLE IRON
MJ MECHANICAL JOINT
MNPT SCREWED TO NPT(M) TO B 1.20.1
MP MEDIUM PRESSURE
MSS MANUFACTURERS STANDARDIZATION SOCIETY
NAT NATURAL
NC NATIONAL COARSE THREAD (BOLTING)
NIP NIPPLE
NLET NIPOLET
NOD NODULAR
Nom NOMINAL
NRL NATURAL RUBBER LINED
OD OUTSIDE DIAMETER
OEB ONE END BUTT WELDED
OEP ONE END PLAIN
OET ONE END THREADED
OQ OIL QUENCHED (E.G. HEX NUTS)
OS&Y OUTSIDE SCREW AND YOKE
PBE PLAIN BOTH END
PE PLAIN END
PLG PLUG
POE PLAIN ONE END
PP POLY PROPYLENE
PSB PRESSURE SEAL BONNET
PSIA POUNDS PER SQUARE INCH ABSOLUTE
PSIG POUNDS PER SQUARE INCH GAUGE
PTFE POLY TETRA FLUORO ETHYELENE
Rad RADIUS
RB REDUCED BORE
RCPL REDUCING COUPLING
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RED REDUCER
RF RAISED FACE
RFSF RAISED FACE SMOOTH
RL RUBBER LINED
RST RAISING STEM
RTJ RING JOINT
RUB RUBBER
SAW SUBMERGED ARC WELDING
SBLD SPECTACLE BLIND
SBOLT STUD BOLT WITH TWO HEAVY NUTS
SC SQUARE CUT
SCH SCHEDULE
Sch. SCHEDULE SCRD SCREWED
SCRB SCREWED BONNET
SCRD SCREWED
SCRD(F), IS554(Rc) SCREWED(F) TO IS554(Rc), Taper Internal Pipe thread
SCRD(F), IS554(Rp) SCREWED(F) TO IS554(T), Parallel Internal Pipe thread
SCRD(M), IS554(R) SCREWED(M) TO IS554(T), Taper External Pipe thread
SEB SHORT END BUTT WELDED
Sec. SECONDS
SEFLG SMALL END FLANGED
SEL SMALL END LAMINATED, TYPE L
SET SHORT END THREADED
SG SMALL GROOVE
SL SEAL
SLET SOCKOLET
SMLS SEAMLESS
SO SLIP-ON
SOL SOCKOLET
SOLWDG SOLID WEDGE SP.
SP WD SS304+GRPH SPIRAL WOUND SS 304 WITH GRAPH. FILLER
SP WD SS304+PTFE SPIRAL WOUND SS 304 WITH PTFE FILLER
Sp.wnd SPIRAL WOUND
SR SHORT RADIUS(1D)
SS STAINLESS STEEL
ST SMALL TONGUE
Std.Wt. STANDARD WEIGHT
Stem(ABP) ANTI BLOW OUT PROOF STEM
STL STEEL
STLD STELLITED/HARD FACED
STND STUB END
SW SOCKET WELDING
SWP STEAM WORKING PRESSURE
TEE TEE
TLET THREADOLET
TOE THREADED ONE END
TPR TEST PRESSURE
UON UNION
WLD WELDED
WLET WELDOLET
WN WELD NECK
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NALCO NAL 6695-PIP-G00-EC-0007 66-6695
REFINERY STREAM-5
TECHNICAL REQUIREMENTS FOR PIPES, FITTINGS,

FLANGES, GASKETS & FASTENERS Rev 01 Page 1 of 6
Finalized after NALCO’s review &

01 IFD 05.01.18 PTE 05.01.18 SHK 05.01.18 NNG -
Issued for Engineering
00 IFR ISSUED FOR REVIEW 04.10.17 PTE 04.10.17 SHK 04.10.17 NNG -
Category Code: -4
Barcode
704 of 1528
1.0 MTPA ALUMINA
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REFINERY STREAM-5

FLANGES, GASKETS & FASTENERS
Rev 01 Page 2 of 6
Contents:
1 GENERAL ................................................................................................................................................ 3
2 INSPECTION AND TEST ........................................................................................................................... 4
3 RADIOGRAPHY ....................................................................................................................................... 6
4 HYDROTEST ........................................................................................................................................... 6
5 MARKINGS ............................................................................................................................................. 6
6 PACKING ................................................................................................................................................ 6
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Rev 01 Page 3 of 6
1 GENERAL
1.1 Unless otherwise specified, pipes shall be supplied in random lengths of minimum 4 meters.
1.2 In case of low temperature carbon steel pipes and fittings, material certificates for impact test as per
relevant codes shall be furnished.
1.3 All socket weld and slip-on flanges shall suit pipe O/D as per ASME B36.10 / ASME B36.19 unless
specifically asked to suit pipe O/D of IS 1239 pipes.
1.4 Slip-on flanges NS 4" & above shall have 1/8" diameter drilled hole through the hub for venting of gases
during welding.
1.5 The surface finish for flanges shall be obtained by cylindrical machining so that no radial tool marks are
created on the finish surface during machining.
1.6 All gasket design shall be such that the gasket factor (m) and minimum gasket design seating stress (y)
shall conform to the requirements of ASME B16.5.
1.7 Unless otherwise specified, all threaded items shall have NPT threads as per ASME B 1.20.1.
1.8 For pipes and fittings required to be galvanised, the zinc coating shall be in accordance with IS 4736 for
IS pipes and fittings and as per ASTM A123 for ASTM pipes and fittings respectively.
1
1.9 For welded tees (longitudinally welded), set-on type branching is not permissible.
1.10 In case of fasteners, the first size specified indicates bolt / stud diameter in mm and second dimension
indicates length in mm.
1.11 Unless otherwise specified, spiral wound gaskets shall have inner & outer ring construction. Inner ring
bore shall be equal to pipe bore.
1.12 All SW flanges & fittings should be as per ASME B16.11.
1.13 All BW ends should be as per ASME B16.25.
1.14 For stud bolts, rolled / formed threads are only allowed (no cut threads).
1.15 For bolts, heat treatment & threading sequence shall be as specified in the applicable codes.
1.16 Fasteners & washers, if required galvanized, the galvanizing shall be as per ASTM A153.
1.17 For Fasteners
1.17.1 Thread std. (bolt) : ASME B1.1 CL.2A / Thread std. (Nut) : ASME B1.1 CL.2B.
1.17.2 UNC thd. for  1" dia & UN8 thd. for > 1" dia.
1.17.3 End machining of Studs shall be to DIN 976 Type B / ISO 4753 (chamfered ends).
1.18 Any conflict between this document and technical specification, the latter shall govern.
1.19 The technical part of the offer must consist of Contractor Technical Specification for the particular item in
which the vendor has to mark clearly 'YES' against each line of the specification sheet under the column
"Bidder's Comments", in case the bidder is taking a deviation from Contractor spec. The bidder should
clearly state the alternative offered. Deviations indicated anywhere else will not be entertained. The sheet
must bear the seal and signature of the bidder in the technical specification sheet.
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Rev 01 Page 4 of 6
1.20 Tolerance for components shall be as per applicable codes.
1.21 All welded pipes & fittings shall have max. longitudinal welding seams as stated below:
Pipes Fittings
< 24” Max. 1 longitudinal welding seam Max. 1 longitudinal welding seam
26” – 48” Max. 2 longitudinal welding seams Max. 2 longitudinal welding seams
50” – 72” Max. 3 longitudinal welding seams Max. 4 longitudinal welding seams
> 72” Max. 4 longitudinal welding seams Max. 4 longitudinal welding seams
Circumferential welding seams are not permitted.
For parts with welding factor E=1.0 the welding seams shall be 100% radiographed.
1.22 Weld penetrations shall be ground flush where possible. If grinding is not possible max. acceptable
weld penetration shall not exceed 1 mm.TIG root runs may be specified.
1.23 The carbon percentage shall be as per individual ASTM material grade.
2 INSPECTION AND TEST
Vendor / manufacturer shall have and maintain a quality control system which will establish that all
specified requirements including raw material control system, manufacturing, heat treatment, NDT and
all other tests will be met. Vendor shall follow standard ITP submitted by Contractor. Vendor shall offer
the products for Contractor inspection at manufacturer’s place with all necessary gauges and measuring
instruments. The following evaluation / inspection shall be carried out by Contractor as per attached
standard ITP.
2.1 All shop test certificates and records as defined in the technical specification shall conform to the
corresponding ASME / ASTM / API / BS / IS / IBR specifications.
2.2 Where corrosion test is specified as a supplementary requirement, it shall be carried out for at least one
sample per size / Heat / heat treatment lot (Lot is as defined in ASTM A960).
2.3 Review of manufacturing / inspection procedure followed by manufacturer.
2.4 Identification / review of raw material test certificate / records.
2.5 Review of heat treatment charts.
2.6 Review of manufacturer’s Test certificates / Reports.
2.7 Verification of marking / stamping on each item.
2.8 100% visual inspection by Contractor– Surface of fittings shall be free from rust, rust preventive coating,
mill scales etc. CS fittings shall be offered in shot blasted condition and SS fittings shall be offered after
pickling and passivation. Flanges shall be offered in machined condition before applying rust preventive.
2.9 Dimensional inspection: - Manufacturer must ensure that 100% pipes, fittings, flanges, gaskets are
dimensionally inspected by them and item wise major dimensions are recorded in an inspection report
before offering to Contractor. Contractor will carryout dimensional inspection. Refer standard ITP for
extent of inspection by Contractor. Fasteners – Inspection with “GO” and “NO GO” gauge -100%
inspection by manufacturer & 10% inspection by Contractor.
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Rev 01 Page 5 of 6
2.10 Review of chemical & witness random Physical / IGC test etc., as per standard ITP.
2.11 Fittings / Flanges shall be subject to hardness test of CS & AS material as per standard ITP.
2.12 Butt weld edge preparation of Fittings / Flanges shall be subject to DP test as per standard ITP.
2.13 Pipes, Fittings and Flanges of Alloy steel, Stainless steel and Non-Ferrous materials (except carbon
steel), shall be subjected to PMI Test as per below listed table.
Sr.No Scope Material of Manufacturer Trader Contractor Remarks

Construction / TPI
1 1) Pipes and Fittings Stainless as per *In the case of

– material and welds Steel 100% - standard ITP imported items,
2) Flanges Alloy Steel scope to be
3) Spectacle blinds Non-Ferrous decided by Client
4) RTJ Gasket / Contractor.
- 100% 100%*
2 Fasteners Stainless Up to 100 lot size : 2% ( min. 2)

Steel
Alloy Steel > 100 up to 500 lot size : 1% ( min 3)
Non-Ferrous
> 500 lot size : 0.5% ( min 5)
Note:-
1) Contractor reserves the right to increase the % of Witness based on vendor past performance.
2) In case of failures noticed during witness by Contractor, additional sampling shall be in accordance with
API 578.
2.14 Radiography - Extent of radiography shall be as per applicable code / Contractor specification. All RT
films shall be reviewed by manufacturer & offered to Contractor for review.
UT - If specified, 100% examination must be performed by manufacturer & Contractor shall review the
UT report.
2.15 Hydro test of Pipes – 100% by manufacturer. For pipes ordered on manufacturer, inspection shall be as
per standard ITP. Post / pre order, the % of witness by Contractor may be increased at discretion of
Contractor.
2.16 No repair is permitted on the base material.
2.17 Steel Insert Rubber Gaskets – 100% shall be spark tested at min 15 kV.
PTFE Enveloped Gaskets – 100% shall be spark tested at 5 kV / mm thickness of gasket.
2.18 Any non-conformity during sampling inspection will lead to rejection of total lot of
material offered for inspection.
2.19 100% Pipes, Fittings, Flanges shall be stamped with “Contractor” control marks after satisfactory
inspection. In case of Gaskets and Fasteners – Tags to be stamped by Contractor.
2.20 Manufacturer’s certificate shall be countersigned by Contractor after satisfactory inspection.
2.21 Above requirements are minimum and any other purchase order / project specific requirements must
also be fulfilled by the Manufacturer / Vendor.
2.22 All measuring gauges and instruments shall have valid calibration certificate.
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Rev 01 Page 6 of 6
2.23 All welded duplex stainless steel components shall be passivated in conformance with ASTM A380 and
ASTM A967 as applicable.
3 RADIOGRAPHY
3.1 For fittings, 10% radiography means 10% of the quantity ordered per tag size, per heat, per lot per visit
& for pipes, 10% radiography means 10% of the running pipe length per heat lot / per size / per visit.
3.2 100% radiography means entire quantity for all sizes has to be radiographed.
3.3 Where extent of radiography is specified as 300mm per pipe length, it shall be distributed at least two
places along the pipe length.
4 HYDROTEST
4.1 Hydrotest for the pipes shall be as defined under Clause 22 of ASTM A530 or Clause 22.2 of ASTM
A999 as applicable. For hydrotest the chloride content in water shall not exceed 25 ppm for SS items
unless otherwise specified.
5 MARKINGS
5.1 Pipes, flanges and fittings shall be furnished with weatherproof marking as per respective technical
specification sheets. However, for NS 1" and below the code no. & size shall be minimum specified and
other details should be furnished with a metal tag in the packing box.
5.2 As far as possible hard stamping shall be avoided for wall thickness less than 3.2mm. Any other
suitable means of identification shall be used instead. Light metals, like Al, Ti, Ni, Monel and Hastelloy
should not be hard stamped.
6 PACKING
6.1 Machined surfaces of flanges and all threaded and welding ends shall be protected against damage
during transit and storage. For flanges the machined surfaces shall be coated with easily removable rust
preventive grease or protective coating and the surface shall then be covered with heavy-duty plastic or
wooden or metallic covers.
6.2 Where wood fiber or metal covers are used, plastic sheet shall be placed between the flange and the
cover for additional protection.
6.3 Varnish or other suitable protective coating to be applied to pipes, fittings and flanges before delivery to
protect during shipment and storage.
6.4 Packing should be sea worthy for items intended to be transported by ship.
6.5 All pipes shall be supplied thoroughly cleaned from inside and with ends plugged properly.
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REFINERY STREAM-5
TECHNICAL REQUIREMENTS FOR VALVES

Rev 02 Page 1 of 16
Revised as per NALCO’s comments

02 IFD 15.02.18 PTE 15.02.18 SHK 15.02.18 NNG -
& Re-Issued for Engineering
Finalized after NALCO’s review &
01 IFD 05.01.18 PTE 05.01.18 SHK 05.01.18 NNG -
Issued for Engineering
00 IFR ISSUED FOR REVIEW 05.10.17 PTE 05.10.17 SHK 05.10.17 NNG -
Category Code: -4
Barcode
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Rev 02 Page 2 of 16
Contents:
1 GENERAL ............................................................................................................................................. 3
2 DOCUMENT SUBMISSION .................................................................................................................... 3
3 DESIGN AND CONSTRUCTION .............................................................................................................. 4
4 OPEARTION........................................................................................................................................ 11
5 INSPECTION AND TESTING ................................................................................................................ 12
6 RADIOGRAPHY OF CAST VALVES........................................................................................................ 14
7 IBR CERTIFICATION............................................................................................................................ 15
8 MARKING ........................................................................................................................................... 15
9 PAINTING AND COATING .................................................................................................................... 15
10 PACKING ............................................................................................................................................ 15
11 GUARANTEE ....................................................................................................................................... 16
12 MAINTENANCE SPARES ..................................................................................................................... 16
13 LINED VALVES.................................................................................................................................... 16
14 SLEEVED BUTTERFLY VALVES ............................................................................................................ 16
15 FOUNDRIES FOR VALVE CASTINGS .................................................................................................. 166
Attachments and Forms
Annxure – I : BODY AND SEAT TEST PRESSURES FOR VALVES ……………………………………….……. 1 of 2
Annxure – II : BY-PASS ARRANGEMENT DETAILS FOR VALVES …………………………….……..…....……. 1 of 1
Annxure – III : SUMMARY OF ENGG. AND FINAL DOCUMENTS ………………………….……………....…… . 1 of 1
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Rev 02 Page 3 of 16
BIDDERS DEVIATION
1 GENERAL
1.1 Vendor shall supply valves in accordance with the Valve Specification
sheets along with auxiliaries, if any, such as Gear Operator, Bypasses,
Locking Arrangement, Drains etc. wherever specified in the specification
sheets, supplementary requirements and other enclosures if any
specified in the technical specification.
1.2.1 Vendor shall quote in strict accordance with the valve technical
specification sheets, supplementary requirements and all other
enclosures to the technical specification. Deviations to the
specification/data sheets, supplementary requirements and other
enclosures of the technical specification, if any, shall be stated as
explained in Clause 2.0.
1.2.2 All codes and standards for manufacture, testing, inspection etc. shall be
of latest editions.
1.2.3 Any conflict between this document and technical specification the later
shall govern.
2 DOCUMENT SUBMISSION
2.1 Bidder shall submit with the offer the following:
2.1.1 The technical part of the offer must consist of Contractor Technical
Specification for the particular item in which the vendor has to mark
clearly 'YES' against each line of the specification sheet under the column
"Confirm to spec " if there is no deviation to Contractor Specification.
2.1.2 In case the bidder is taking a deviation from Contractor spec, the bidder
should clearly state the deviation under column “Deviations”. Deviations
indicated anywhere else will not be entertained. The sheet must bear the
seal and signature of the bidder in the technical specification sheet.
2.1.3 If the bidder is regretting or has no deviation to state for any specific valve
code the bidder shall clearly specify on the applicable valve specification
sheet as "regret" or "no deviation".
2.1.4 Failure to submit documents as specified in Clauses 2.1.1 to 2.1.3 above,

shall lead to rejection of the offer.
2.2 After the placement of order on successful bidder:
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2.2.1 On the issue of Letter/Fax of Intent, Contractor shall issue order

specification along with the list of acceptable agreed deviations . Vendor
to submit the relevant construction feature drawings including all the
technical details like rating , material , overall dimensions etc. within two
weeks of Order placement. Descriptive and illustrative catalogue
information is not acceptable. The construction feature drawing submitted
shall be approved by Contractor and sent to vendor along with the order
technical specification. The order specification forwarded along with the
approved drawings shall form an integral part of the order. No deviation
to specification shall be permitted after placement of order.
Approval of drawings shall be valid for construction features,

dimensions & material specification. In case the drawing is approved
with comments, then the drawing shall not be re-submitted for final
approval. These comments shall be incorporated in final documentation
drawings.
2.2.2 Test reports shall be supplied for all mandatory tests as per the
applicable code. Test reports shall also be furnished for any
supplementary tests as specified in Clause 5.4
2.3 For final documentation:
2.3.1 The final drawing submitted for documentation shall incorporate the
material and dimensional details as per the order specification with the
constructional features remaining unchanged. Refer Annexure – III for
Summary of Engineering and Final Documents.
3 DESIGN AND CONSTRUCTION
3.1 Valves shall be designed, manufactured, tested, inspected and marked

as per the design manufacturing standards (latest editions) indicated in
the respective valve specification sheets. Any conflict between the
technical specification, enclosures and referred standard codes shall be
brought to the notice of Contractor /purchaser for clarifications, but
generally enclosures of the technical specification including
supplementary requirements shall govern.
3.2 Unless otherwise specified in the technical specification the following

standard construction features shall be followed:
3.2.1 Face to face dimension: Face to face dimension of valves shall conform
to following :
- All flanged / BW end CS/SS/AS/LTCS/Exotic material valves shall be to

ASME B16.10 except flanged Butterfly & Diaphragm valves.
- For sizes not listed in ASME B 16.10 the Face-to-Face dimension shall be
to BS EN 558. For ball valves for sizes not listed in ASME B16.10, the
Face-to-Face dimensions shall be as per API 6D.
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- Flanged/sandwich type butterfly valves, diaphragm valves as well as

other sandwich type valves shall be to their respective design
manufacturing standard.
- Lined Y-type globe, diaphragm, ball, plug valves shall have face to face
dimension as per respective design manufacturing standard or ASME B
16.10 as the case may be before lining.
- Socket welded and screwed valves shall have face to face dimension to
manufacturer’s standard.
3.2.2 No repair welding shall be done on valve bodies during manufacturing.
3.2.3 All flanged valves shall have flanges integral (except forged valves) with
the valve body. For forged valves with weld-on flanges, the valve shall be
with BW ends welded with forged WN flanges. The weld joint shall be
100% radiographed. The surface finish for flange shall be obtained by
cylindrical machining so that no radial tool marks are created on the
surface finish during machining.
3.2.4 For all butt weld end valves the bevel end preparation shall be as per
ASME B16.25. For all socket weld end valves, the ends shall be as per
ASME B16.11.
3.2.5 Valve body/bonnet shall be forged/cast as specified.
3.2.6 All sandwich type valves shall have self-centering feature.
3.2.7 Spiral wound bonnet gaskets are to be provided with inner/outer ring
except when encapsulated gasket type body-bonnet joints are employed.
Outer ring may be avoided in case of non-circular spiral wound gasket
used in CL.150 valve provided the outermost layer of spiral touches the
bolts ascertaining the centering.
3.2.8 When specifically stated "Valve to be provided with locking arrangement ”

then the arrangement shall be for both open & closed position.
3.2.9 Valves under "NACE" should follow the requirement of the specification
stated in the technical specification.
3.2.10 Gate/Globe/check valves:
3.2.10.1 The valve design shall be outside screw and yoke type (OS & Y) when
manufactured as per API600, BS1873, API602, BS EN ISO 15761,
BSEN12288 (bronze valves). All Gate and Globe Valves shall be
furnished with back seat arrangement.
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3.2.10.2 The integral and renewable seating for Gate, Globe and Check Valve
shall be as listed below:
Back Seat Disc Seat Body Seat
Forged C.S./LTCS/AS Valves Integral Integral Renewable

Forged SS/Exotic material Integral Integral Integral
Cast C.S/LTCS/AS valve Renewable Integral Renewable
Cast SS/Exotic material Integral Integral Integral
3.2.10.3 The trim material wherever indicated in the specification shall mean the
following:
- Body seating surface

- Disc / Gate seating surface
- Stem
- Bushing or deposited weld for backseat and stem hole guide
- Small internal parts normally in contact with the service fluid
excluding the pin that is used to make a stem to disc connection.
This pin shall be made of minimum austenitic stainless steel
material.
3.2.10.4 Regulating type globe valve shall have parabolic disc with linear flow
character. Regulating type globe valve shall be provided with guided
disc for size 2” and above. Vendor to indicate the same on valve
drawings. Non-regulating type globe valve shall have plug type disc.
3.2.10.5 Gate valve & bellow sealed globe valves shall have rising stem non-
rising handwheel design. Globe valve shall have rising stem and rising
handwheel design. Gate valve shall have solid wedge upto 1½” dia.,
above 1½” dia the wedge shall be flexible.
3.2.10.6 Swing check valve shall have dash pot arrangement for nominal sizes
10” and above.
3.2.10.7 For check valves, where the weight of valve necessitates provisions of
lifting lugs, eyebolts and such standard devices the same shall be
provided.
3.2.10.8 In case of Gate and Globe valves of CL.300 and above rating, the depth
of gland stuffing box shall be sufficient to accommodate lantern rings in
addition to gland packing.
3.2.10.9 Extended Bonnet wherever specified in the valve data sheet to BS:6364
shall be for "Non-cold box application" unless otherwise specified in the
technical specification. Even if not specified in technical specification,
"Cryogenic" service valve shall be supplied with bonnet extension. For
bonnet extension, fillet welds shall be DP tested, BW joints shall be DP
tested & 100% radiographed before valve assembly.
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3.2.10.10 Unless specified otherwise in the data sheet, all check valves 3" &
above (except in CL.900, 1500, & 2500 ratings) shall have a drain boss
at location "G" (Refer Fig. No.1 of ASME B 16.34). A tapped drain hole
with plug shall be provided as per ASME B16.34. Threads shall be
NPT(Taper).
3.2.10.11 Wherever check valve disc assembly is supported from the cover of the
check valves, the following shall be ascertained:
i. Positive location/positioning of cover must be provided to ensure
correct alignment of the valve disc.
ii. Hinge pin design must permit accurate alignment of the disc and valve
seat.
3.2.10.12 Bellow seal feature of bellow sealed valve shall comply with BS EN
ISO 15761. Bellow design shall be such that no torsion is developed on
bellow. The life cycle of bellow shall be minimum 10000 cycles.
3.2.11 BY-PASS
3.2.11.1 By-pass requirement for gate valves is indicated in the respective

data sheets. As a rule following shall be followed:
ASME 150 Class on sizes 26" and above
3.2.11.2 By-pass valve shall be a globe valve. The material specification shall
be same or equivalent as of main valve. The sizes shall be as under:
Main Valve Size Min. by-pass Valve Size
Less than or equal to 4" 1/2"

Greater than 4" & less than 10" 3/4"
Equal to or greater than 10" 1"
3.2.11.3 Vendor shall supply the by-pass valve duly tested and fitted to the main
valve. By-pass piping & fittings shall be of compatible material and
design. Valves with by-pass shall have the direction of flow marked on
the main valve. By-pass attachment to the main valve body shall not
be screwed. All fillet welds for by-pass installation shall be 100%
examined by DP test.
3.2.11.4 The by-pass piping arrangement shall be such that clearance between
main valve body & by-pass assembly shall be the minimum possible for
layout reasons. Vendor shall follow the sketch indicated in Annexure –
II.
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Ball / Plug / Butterfly valves
3.2.12 Ball valves shall be long pattern to ASME B16.10 and shall be
quarter-turn design unless otherwise specified in the technical
specification. Plug Valve to BS5353 shall be short pattern.
3.2.13 Ball valve shall be of two piece design and with blow out proof stem.
The ball design shall be as per the design manufacturing standard
stated in the technical data sheet.
3.2.14 Ball valve specified with Reduced Bore(RB) shall be with single reduce
bore type.
3.2.15 Plug valve shall have top entry body construction with integral stem and
solid taper plug.
3.2.16 Butterfly valves shall have integral disc seat and renewable sleeve body
seat.
3.2.17 Soft-seated ball, plug & butterfly valves shall be supplied with antistatic
devices.
3.2.18 Soft seated BW/SW end ball/plug valves shall have a 80 mm long
seamless pipe nipple (compatible to body material) welded to each end
of the valve. Forged gate / globe valves shall have a 100 mm nipple
welded to each end, if specified on the valve data sheet. Vendor to
indicate the same on valve drawings. Nipples are to be welded prior to
assembling teflon/soft seats/seals. Schedule of nipple shall be
indicated in the valve specification sheet. For BW end valves, the weld
joint between valve body and the pipe nipple shall be full penetration
weld, 100% radiographed and DP tested. For SW end valves, the same
shall be 100% DP tested.
3.2.19 Bidder to ensure while quoting for fire safe design valves that he has
been qualified for supplying these valves by certifying authorities like
Lloyds etc. Bidder's offer will be valid only for those size ranges
approved by the certifying authority as per the guideline laid down in
ISO 10497 : 2004, part II / API 607.
The certificate shall be produced to the Contractor inspector during

inspection of these valves.
3.2.20 Ball valves shall be floating ball type / trunnion mounted type as per
following :
CL.150 6” & below Floating Ball

8” & above Trunnion mounted
CL.300 4” & below Floating Ball
6” & above Trunnion mounted
CL.600 & 1.5” & below Floating Ball
above 2” above Trunnion mounted
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3.2.21 Diaphragm valves:
The valves shall have indicating stem and solid compressor with rising
handwheel upto 6” and non-rising handwheel for 8” and above.
The valves shall be provided with travel stop arrangement to avoid over
compression.
3.3 Basis for material selection:
3.3.1 Following basis shall be considered while selecting material of

construction for Yoke, Yoke bush, Gland Flange, Gland etc.:
Disc : Same as body material for cast valves

and equivalent to trim material for
forged valves.
Bonnet : Same as body material
Thrust collar : Same as plug material
Yoke : Same as body/bonnet material.
Gland Flange : Minimum equivalent to body/bonnet but
only forged. In case of cast iron or
ductile iron the gland flange shall be
ASTM A105.
Yoke Bush : Ni-resist
Gland : Gland material shall be same as trim
material.
Compressor for : Same as body material
diaphragm valve
Hand wheel/lever : Malleable iron/Carbon steel
Locking plate : Locking plate material shall be minimum
SS304. In case of integral design,
locking plate material same as body
material is acceptable.
Bellow material of : Shall be minimum SS321
Bellow seal valve
Note : Stem material for butterfly valves to be specified by vendor in his

offer.
Valves for steam service, rating CL.300 and above requiring IBR
certification shall always be provided with stellited seatings.
Valves for rating CL.900 and above shall be provided with stellited
seating.
3.3.2 Stelliting/ hard facing by deposition, shall be minimum 1.6 mm.
3.3.3 For gate / globe valve of NS 2½” & above the body seat / wedge disc
seat can be provided of 13% Cr overlay over WCB in place of solid 13%
Cr.
3.3.3 Stem shall be forged or machined from forged/rolled bar. No casting is

permitted. However, integral stem of cast stainless steel ball valve is
acceptable.
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3.3.4 Wherever stem material is specified as 13% Cr the valve manufacturer

shall provide minimum hardness of 200 BHN. Wherever 13% Cr is
specified for Body Seat and Disc Seat, the hardness of Body Seat shall
be 300 BHN and that of Disc Seat shall be 250 BHN. Vendor shall
submit certificate to confirm the same for Contractor review.
3.3.5 The alumina refinery environment is aggressive to most non-ferrous

metals.Mechanical components formed from aluminium, zinc, copper
and their alloys are specifically excluded from exposed use in all
outdoor and production areas. Non-metallic materials shall not be used
for pressure parts, with the exception of non-metallic seating
components.
3.3.6 Materials containing asbestos fibres shall not be used.
3.3.7 The carbon percentage shall be as per individual ASTM material grade.
3.4 Cryogenic Service Valves:
3.4.1 As a pre-qualification, low temperature carbon steel (LTCS), 31/2 Ni

steel & austenitic stainless steel valves for cryogenic applications shall
be subjected to cryogenic test as per BS 6364 and test shall be
witnessed and certified by Contractor or Contractor nominated
inspection agency. The vendor has to submit test certificate for
prototype valves along with the offer. Prototype test carried on a
particular size, rating and design will qualify valves of sizes equal to and
below the particular size of the same rating and design.
3.4.2 Cryogenic testing as per BS 6364 shall be carried out at temperature (-

45°C), (-100°C) & (-196°C) for "LTCS", 31/2 Ni steel & austenitic
stainless steel valves respectively.
3.4.3 Wherever impact test of SS studs/nuts is called for in the data sheet,
the impact value shall be 27J at the intended service temperature
specified in the data sheets.
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4 OPERATION
4.1. Gear operators, where specified shall be heavy-duty lubricated type and
shall be completely housed in a weatherproof enclouser.
4.2. For pressure balance plug valves the gear operator shall be as per
manufacturers recommendation. For sizes lower than these ranges,
hand wheel / lever / wrench shall be provided.
4.3 Gear operator shall be as under, with position indicators for open /
close positions, with limit stops. (Limit stops are not applicable for gate
and globe valves).
For Gate / Globe / Diaphragm Valves Totally enclosed bevel gear in

grease case with grease
nipples / plugs.
For Ball / Plug / Butterfly Valves Totally enclosed helical worm

or combination of helical worm
and spur gear in grease case
with grease nipples / plugs.
4.4 Where gear operator is not called for as per Clause 4.1 but vendor
recommends a gear operator, he shall highlight such case(s) and quote
separate prices for the valve and gear operator.
4.5 Gear operator shall be so designed to operate effectively with the

differential pressure across the closed valve equal to the cold non-
shock pressure rating.
4.6 Ball, Plug & Butterfly valves provided with wrench or lever operators
shall have "open" position indicators with limit stops.
4.7 Hand wheel diameter shall not exceed 750 mm and lever length shall
not exceed 500 mm on both sides. Effort to operate shall not exceed
35 kgs. at hand wheel periphery. However, failing to meet the above
requirements, vendor shall offer gear operated valve and quote as per
Clause 4.3.
4.8 Vendor shall indicate dimensions of valve spindle / handwheel position

during both open & closed position in the drawing.
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5 INSPECTION AND TESTING
5.1 Every valve shall be subjected to all the mandatory tests and checks
called in the respective codes / technical specification.
5.2 The following tests are mandatory for all types of valves -
- Hydrotest of body
- Hydrotest of seat.
- Hydrotest of backseat. (for Gate/Globe valves)
- Pneumatic testing of seat
- In addition to above all S.W. and B.W. valves shall be DP tested
at both ends.
- Strip test shall be carried out for minimum 1% of offered quantity
on random basis.
- Spark test shall be carried out for lined valves. PTFE lined valves
shall be tested at 20 KV and rubber lined valves shall be
tested at 6 KV per MM of lining thickness. (not applicable to
valves with loose liners)
- PMI (Positive material identification) of Low Alloy / High Alloy /
Stainless Steel / Non-Ferrous valves shall be carried out if
specified in order specification. PMI by the vendor shall be as per
standard ITP. PMI will be applicable to the body and bonnet only
and not to the valve internals.
- When specification requires that the carbon content of the base
metal be determined so that "L" (Low Carbon) or "H" (High
Carbon) grades may be distinguished, chemical analysis for
carbon shall be conducted in accordance with ASTM E1086.
- For hydrotest the chloride content shall not exceed 25 ppm
for SS valves.
All the test details shall be indicated by vendor on valve GA drawings.
5.3 The testing pressure against each type/rating/material is indicated vide

Annexure-I to this document.
5.4 The testing standard to be followed shall be as follows:

API Standard Valves : API 598
(Eg: API 600, API 602)
British Standard Valves : BS EN 12266-1

(BS EN ISO 15761, ISO 17292, BS 5353 etc)
The leakage rate shall be 'Rate A' as per BS EN 12266-1
except check valves. For check valves the leakage rate shall be "Rate
C".
ASME B16.34 : API 598
Fire Safe Design

For British Standard Valves : ISO 10497
For API Standard Valves : API 607
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All the valves manufactured as per any other International Standard

shall be tested as per guidelines laid in the respective standards.
5.5 Material/Production/Heat Treatment Certificate shall be 100% reviewed.

The completeness of each piece shall be verified.
5.6 Surface, dimension, identification, marking, leakage and functioning

shall be witnessed by inspector. Extent of inspection shall be as per ITP.
5.7 Radiography when specified in the technical specification, 100%

radiography films shall be offered for Contractor / TPIA review along
with reports duly certified by vendors / sub-vendors RT Level-II
personnel. This is applicable for IBR valves also.
5.8 Every valve, its components and auxiliaries be subjected to additional

mandatory tests and checks if any called in the respective codes.
5.9 In addition to the normal seat test, all Check Valves shall undergo low
pressure closure test as per API 598. Also a test should be carried out
to ensure that all Check Valves start opening at 0.2 kg/cm2(g) on the
inlet side.
5.10 Any additional testing required will be listed in the technical

specification sheet and mentioned as separate enclosure to the enquiry
specification shall be carried out as per the laid guidelines.
5.11 Review of Fire safe test certificates furnished against each size by the
approving authority as listed in Clause no 3.2.18.
5.12 In case of motor operated valves, functional/operational checks as per

the requirements of the specifications shall be made on each valve.
5.13 In size range DN 100 & over, for Valve Body & Yoke(Bonnet)
supplementary requirements S4 & S12 of ASTM A703 shall apply.
5.13 IGC TEST
5.13.1 Wherever specified inter-granular corrosion test shall have to be

conducted as per following for valve body / bonnet :
ASTM A 262 practice "B" with acceptance criteria of "60 MILS/year

(max)" - for all materials forged, rolled, wrought and casting.
OR
ASTM A 262 practice "E" with acceptance criteria of "No cracks as
observed from 20X magnification" - for all materials other than
castings. "Microscopic structure to be observed from 250X

magnification" in addition.
5.13.2 When specifically asked for in technical specification for high

temperature application of some grades of austenitic stainless steel
(e.g. SS309, 310, 316, 316H etc.) ASTM A 262 practice "C" with
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acceptance criteria of "15 MILS/year (max.)" shall have to be

conducted.
5.14 Fugitive Emission Testing (FET)
Wherever specified, Fugitive emission test (type test) shall be

conducted for the entire valve ,including the body seals as per ISO
15848. It specifies testing procedures for evaluation of external
leakage of valve stem seals (or shaft) and body joints of isolating valves
intended for application in volatile air pollutants and hazardous
fluids.The ISO type test classifies the complete valve into a pressure,
temperature, endurance and tightness class.
6 RADIOGRAPHY OF CAST VALVES
6.1 Valves under critical, very highly critical, lethal and toxic services shall
be radiographed as specified in respective data sheets. When
specifically not mentioned in individual data sheets, valve castings shall
undergo radiographic examination as specified here under :
MATERIAL RATING SIZE RANGE RADIOGRAPHY

All CL.150 24" and below Nil
CL.150 26" and above 100%
CL.300 16" and below Nil
CL.300 18" and above 100%
CL.600 & above All sizes 100%
6.2 Radiography procedure, areas of casting to be radiographed shall be as

per ASME B16.34 and acceptance criteria shall be as per ASME
B16.34, Mandatory Appendix - I. However, for areas of casting to be
radiographed for types of valve not covered in ASME B16.34, vendor
shall enclose details of areas to be radiographed in line with ASME
B16.34, Mandatory Appendix - I.
6.3 Following inspection procedure shall be applicable where 10%

radiography of casting is specified:
a. 10% radiography means, 10% of the quantity ordered per size per
heat per foundry per tag number. Fraction shall be rounded off to 1
to decide the number of castings to be radiographed.
b. In case of rejection, double the quantity of the casting to be

radiographed as determined by 6.3(a) above shall be offered for
radiography. In the event of further rejection of single casting, the
whole lot shall be radiographed.
c. The extent of radiography shall be restricted only to the critical

areas as defined in ASME B16.34. Acceptance of radiography is
level 3 as defined in ASTM E446.
6.4 Radiography wherever specified in the data sheets or as per Clause

6.1 shall be done by X-ray / GAMMA-ray to get the required sensitivity.
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7 IBR CERTIFICATION
7.1 For valves described "IBR", valves shall be in accordance with the latest
IBR (Indian Boiler Regulation) including the requirements specified in
the specification.
7.2 SW/BW end carbon steel valves under IBR, the chemical composition
shall conform to the following:
Carbon (Max) : 0.25%

Others (S, P, Mn) : As per IBR Regulations
The above composition is not valid for non-IBR valves.
7.3 For IBR valves, manufacturer’s test certificate shall be attached with
IBR certificate – Form IIIC, giving details of testing carried out as per
technical specification with valve tag no., size, order no., serial no. of
PO etc. duly endorsed by Contractor-IN / TPIA / manufacturer as
applicable. IBR original certificate shall be submitted to Contractor.
7.3.1 All "IBR" valves shall be painted red in body bonnet/body cover joint.
8 MARKING
Each valve shall be supplied with a stainless steel tag, attached to the
gland bolting,or hand wheel, with stainless steel wire, bearing the
applicable valve identification,Tag Number and Purchase Order
number.
Each valve shall bear the manufacturer's name or trademark and
reference symbol to indicate the service conditions for which the
manufacturer guarantees the valve. The marking shall be in accordance
with MSS-SP-25.
9 PAINTING AND COATING
Unmachined exterior surfaces of the shell shall be painted as per the

manfacturer’s standard paint with an aluminium or silver color.
Austenitic SS valves shall not be painted. Machined and threaded
surfaces (except those on austenitic SS materials) shall be coated with
an easily removable rust preventive. The stem does not need to be
coated if the stem packing contains a corrosion inhibitor.
10 PACKING
10.1 All valves shall be packed after inspection taking particular care for
protection of the valve yokes and flanges. The flanges shall be closed
with plate covers. Ends of threaded and socket welded valves shall be
closed using plastic caps.
10.2 Valves having pressure grease seal gland packing arrangement for
Stem shall be supplied free of grease. The grease sealing arrangement
shall be well protected to prevent damage during shipping & shall be
indicated by vendor on valve drawings.
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10.3 Packing should be sea worthy for items intended to be transported by

ship.
11 GUARANTEE
All valves and their components shall be guaranteed for trouble-free

operation for a period of 12 months from the date of commissioning
unless otherwise specified in any other document.
12 MAINTENANCE SPARES
2
Bidder should furnish a complete list of maintenance spares required
for one year trouble-free operation along with recommended quantities
and quote the price for the same.
13 LINED VALVES
13.1 Rubber lining:
Rubber lining of valves shall confirm to IS 4682 PART- I or equivalent

DIN / ASME / BS / any other international standard with minimum
thickness of 3mm. Minimum 3 mm thickness of rubber lining shall be
maintained on flange facing.
13.2 PTFE /FEP/PFA/PVDF lining:
Lining thickness shall be minimum 3mm after machine.
14 SLEEVED BUTTERFLY VALVES
Sleeved butterfly valves are valves wherein the entire body of the valve
is lined either by moulded liner or by a loose liner. In either case, for
rubber sleeves the same shall confirm to IS 4682 or equivalent DIN /
ASME / BS / any international standard with minimum thickness of
3mm. Spark testing of sleeve shall be carried out at 6KV / mm of
thickness of rubber lining. For PTFE lined valves the thickness too shall
be 3mm minimum and spark testing shall be carried out at 20KV.
Vendor shall indicate the same on valve drawings. (not applicable to
valves with loose liners.)
15 FOUNDRIES FOR VALVE CASTINGS
In addition to IBR approved foundries, castings / forgings from reputed

foundries who have supplied castings / forgings under reputed TPIA’s
like LRA, EIL, CEIL, PDIL, NPCIL, NTPC, SGS, BVIS, TUV, DNV, ABS,
IRS etc” are acceptable for which documentary proof shall be
produced immediately after placement of order.
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Industrial Solutions (India) Annexure - I Rev.02
TEST PRESSURE FOR VALVES Page 1 of 2
Body & Seat Test Pressures of valves (Except Diaphragm valves)
CL.150 CL.300 CL.600 CL.800 CL.900 CL.1500 CL.2500
Body Body Body Body Body Body Body

Matl. Seat Test Seat Test Seat Test Seat Test Seat Test Seat Test Seat Test
Sr. No. Material Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test
Group Pr. Pr. Pr. Pr. Pr. Pr. Pr.
Pressure Pressure Pressure Pressure Pressure Pressure Pressure
(Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2)
1 1.1 A 105 / A 216 Gr. WCB 285 22 30 740 57 78 1480 114 156 1973 153 208 2220 172 234 3705 287 391 6170 477 651
A 352 Gr. LCB / A 217 Gr.
2 1.3 265 20 28 695 54 73 1395 108 147 1858 144 196 2090 162 220 3480 269 367 5805 449 612
WC1 / A 352 Gr. LC1
3 1.4 A 350 Gr. LF1 235 18 25 615 48 65 1235 96 130 1645 127 173 1850 143 195 3085 239 325 5145 398 543
4 1.5 A 182 Gr. F1 265 20 28 695 54 73 1395 108 147 1858 144 196 2090 162 220 3480 269 367 5805 449 612
A 182 Gr. F2 / A 217 Gr.
5 1.7 290 22 31 750 58 79 1500 116 158 2000 155 211 2250 174 237 3750 290 395 6250 483 659
WC4 / A217 Gr. WC5
A 182 Gr. F11 CL.2 /
6 1.9 290 22 31 750 58 79 1500 116 158 2000 155 211 2250 174 237 3750 290 395 6250 483 659
A 217 Gr. WC6
A 182 Gr. F22 CL.3 /
7 1.10 290 22 31 750 58 79 1500 116 158 2000 155 211 2250 174 237 3750 290 395 6250 483 659
A 217 Gr. WC9
8 1.13 A 182 Gr. F5 / A 217 Gr. C5 290 22 31 750 58 79 1500 116 158 2000 155 211 2250 174 237 3750 290 395 6250 483 659
A 182 Gr. F304 /
9 2.1 275 21 29 720 56 76 1440 111 152 1920 148 202 2160 167 228 3600 278 380 6000 464 633
A 351 Gr. CF8
A 182 Gr. F316 /
10 2.2 275 21 29 720 56 76 1440 111 152 1920 148 202 2160 167 228 3600 278 380 6000 464 633
A 351 Gr. CF8M
A 182 Gr. F304L /
11 2.3 A 182 Gr. F316L / A 351 Gr. 230 18 24 600 46 63 1200 93 127 1600 124 169 1800 139 190 3000 232 316 5000 387 527
CF3 / A 351 Gr. CF3M
12 2.4 A 182 Gr. F321 275 21 29 720 56 76 1440 111 152 1920 148 202 2160 167 228 3600 278 380 6000 464 633
13 3.1 B 462 N08020 290 22 31 750 58 79 1500 116 158 2000 155 211 2250 174 237 3750 290 395 6250 483 659
14 3.4 B 564 N04400 230 18 24 600 46 63 1200 93 127 1600 124 169 1800 139 190 3000 232 316 5000 387 527
15 3.6 B 564 N08800 275 21 29 720 56 76 1440 111 152 1920 148 202 2160 167 228 3600 278 380 6000 464 633
B 564 N10276 / B 425
16 3.8 290 22 31 750 58 79 1500 116 158 2000 155 211 2250 174 237 3750 290 395 6250 483 659
N08825
17 3.15 A 494 Gr. CW-12MW 230 18 24 600 46 63 1200 93 127 1600 124 169 1800 139 190 3000 232 316 5000 387 527
18 3.17 A 351 Gr. CN7M 230 18 24 600 46 63 1200 93 127 1600 124 169 1800 139 190 3000 232 316 5000 387 527
19 ---- Cast Iron IS 14846 PN 1.0 ---- 10 15 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ----
20 ---- Cast Iron IS 14846 PN 1.6 ---- 16 24 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ----
21 ---- Bronze IS 778 PN 1.0 ---- 10 15 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ----
22 ---- Bronze IS 778 PN 1.6 ---- 16 24 ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ----
Cast Iron BS standard,
23 --- ---- 15 20
CL.125
726 of 1528
thyssenkrupp Technical Requirements for Valves Doc. No. 6695-PIP-G00-EC-0008
Industrial Solutions (India) Annexure - I Rev.02
TEST PRESSURE FOR VALVES Page 2 of 2
Body & Seat Test Pressures of valves (Except Diaphragm valves)
CL.150 CL.300 CL.600 CL.800 CL.900 CL.1500 CL.2500
Body Body Body Body Body Body Body

Matl. Seat Test Seat Test Seat Test Seat Test Seat Test Seat Test Seat Test
Sr. No. Material Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test Rated Pr. Test
Group Pr. Pr. Pr. Pr. Pr. Pr. Pr.
Pressure Pressure Pressure Pressure Pressure Pressure Pressure
(Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2) (Psi) (Kg/Cm2) (Kg/Cm2)
24 Cast Iron lined, CL.125 13 18
Body & Seat Test Pressures of Diaphragm valves
The Test pressure for diaphragm valve depends on type and sizes which shall be as listed below
Material Sizes Seat Body

Kg/Cm2 Kg/Cm2
All Material Weir type,

1 upto 2" 11 24
CL.125/150
-"- 21/2" -6", 9 12

-"- 8" 6.6 9
-"- 10" 5.5 7.5
-"- 12" 4.3 6.5
All Material straight through-

2 upto 4" 10 15
type, CL.125/150
-"- 6", 6.6 9

-"- 8" -12" 4 5.2
-"- 14" 1.7 2.6
Pneumatic testing of seat
Pneumatic test wherever specified shall be carried out at the pressure of 6 – 7 Bar(g).
Note : For sleeved (lined) butterfly valves the hydro test pressure for body & seat shall be 1.5 times / 1.1 times the design pressure of the fluid.
However vendor to specify in his offer max. hydro test pressure for body & seat that the offered valves shall with stand.
727 of 1528
728 of 1528
Doc. No.6695-PIP-G00-EC-0008
Rev.02
Page 1 of 1
Plant Customer Code

UAN
TON
ANNEXURE- III : Summary of Engineering & Final Documents Item
VALVES
1 The following engineering and final documents shall be furnished by the manufacturers :
2
3
4 1.0 For engineering and approval Quantity
5 Documents Reproducible Copy Version Delivery Date
6 1 Constructional feature drawing 2 II A
7 2 Technical Specification (Duly stamped in acceptance) 2 II A
8 3 Technical requirement for valves(Duly stamped in acceptance) 2 II A
9 Accessories (If applicable)
10 1 Gear arrangement drawing 2 II A
11 2 Locking arrangement drawing 2 II A
12 3 Parabolic disc arrangement drawing 2 II A
13
14
15
16
17
18
2
19 2.0 SPARE PARTS
20 1 Quotation for one years operation & commissioning spares 2 II A
21
22
23 3.0 FINAL DOCUMENTS :
24 1 Construction feature drawing 1 8 II F
25 2 Accessories drawings(If applicable) 1 8 II F
26 3 Test certificates for all mandatory tests as per code 8 II F
27 4 Test certificates for supplementary tests if any as per technical specifcation 8 II F
28 5 Guarantee certificate 8 II F
29 6 Works compliance certificate
30
31
32
33
34
35
36
37
38 4.0 INSPECTION :
39 1 Shop inspection certificate 8 II E
40 2 Inspection reports to DIN 50 049/3.1A-3.1C 8 II E
41 3 Inspection reports issued by inspection authority such as TUV (if applicable) 8 II E
42 4 Inspection reports, stress-relieving diagrams, etc. 8 II E
43 5
44 5.0 Explanation of figures listed in column version Notes pertaining to column “delivery date””
45 I Lettering or wording in German A To be submitted with quotation
46 B 15 days after order placements
47 II Lettering or wording in English C Two weeks after return of documents
48 D One month after order placement, thereafter monthly
49 III Lettering or wording in German and English E Not later than date of final inspection
50 F Within two weeks after final inspection ; to be submitted with shipping documents if the
51 valve has to be shipped
52 G After final release, but not later than 4 weeks prior to final inspection
53 6.0 REMARKS :
54
55
56
57
58
59
60
© Copyright 2016 : All rights reserved thyssenkrupp Industrial Solutions (India) Private Limited
Signature Not Verified

Digitally signed by ANIL KUMAR PANDA
Date: 2018.09.22 07:25:08 IST
Location: eProcure
729 of 1528

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5TH STREAM ALUMINA PLANT AT DAMANJODI

1.0 MTPA Alumina Refinery Project

NOTICE INVITING TENDER (NIT)

(BIDDING DOCUMENT NO.: 6695-CMG-G00-CA-0011)

AREA GRADING AND ENABLING WORKS FOR 5TH STREAM

3 CONTRACT DETAILS ----- 07

INSTRUCTION TO BIDDERS Annexure-AA 08-33

INSTRUCTIONS TO THE BIDDERS FOR THE E-SUBMISSION

GUIDELINE TO BIDDERS ON REVERSE AUCTION Annexure-C to ITB 39-41

6 TECHNICAL SPECIFICATIONS Annexure-IAA 60-1130

A CIVIL, PAINTING & EQUIPMENT 60-551

I GENERAL ENGINEERING SPECIFICATIONS (CIVIL) 6695-CVC-G00-EC- REV-02

VI TECHNICAL SPECIFICATION FOR WEIGH BRIDGE 6695-PIP-G00-EC- REV-00

I PIPING SPECIFICATION 6695-PIP-G00-EC- REV-02

AREA GRADING AND ENABLING WORKS FOR 5TH STREAM

TECHNICAL SPECIFICATIONS – DISTRIBUTION 6695-ELT-G00-EC-

TECHNICAL SPECIFICATIONS – HIGH VOLTAGE 6695-ELT-G00-EC-

QAP FOR SITE INSTALLATION, TESTING & 6695-ELT-G00-QA- REV-00

INTEGRITY PACT Annexure-IV BB 1172-1181

ANNEXURE FOR ONLINE SUBMISSION OF EARNEST

AREA GRADING AND ENABLING WORKS FOR 5TH STREAM

PROFORMA FOR SUBMISSION OF DETAILS OF SPECIFIC

13 BANK MANDATE FORM Annexure– V 1194-1195

14 ENVIRONMENT, HEALTH & SAFETY POLICY. Annexure– VIII 1196

15 SOCIAL ACCOUNTABILITY 8000 REQUIREMENTS Annexure– IX 1197-1202

PROFORMA FOR BANK GUARANTEE FOR EMD, SD,

17 FORMAT FOR DECLARATION OF BIDDER’S RELATIVES IN Appendix-I & II 1213-1215

19 DETAIL OF PROPOSED ORGANISATION Appendix-IV 1217

20 FORWARDING LETTER AND UNDERTAKING Appendix-V 1218-1219

21 EXCEPTION/DEVIATION STATEMENT Appendix-VI 1220

22 FORMAT OF DECLARATION BY BIDDER Appendix-VII 1221

23 FORMAT OF WAIVER LETTER Appendix-VIII 1222

22 AFFIDAVIT TOWARDS NON-CRIMINAL BACKGROUND Appendix-IX 1223

23 FORMAT FOR PRE-BID QUERIES Appendix-X 1224

25 UNDERTAKING BY THE TENDERER(S) Appendix-XII 1227

26 METHODOLOGY OF EXECUTION Appendix-XIII 1228

27 LITIGATION / ARBITRATION DETAILS Appendix-XIV 1229

28 PAST EXPERIENCE FOR THE LAST 05 YEARS Appendix-XV 1230

29 DEPLOYMENT SCHEDULE OF CONSTRUCTION Appendix-XVI 1231-1232

31 DECLARATION OF BLACK LISTING / HOLDING LISTING Appendix-XVIII 1235-1236

32 LIST OF WORKS TO BE SUB-CONTRACTED Appendix-XIX 1237

33 APPROVAL OF CONSTRUCTION SUB-CONTRACTOR Appendix-XX 1238

34 DETAILS OF SAFETY STATISTIC OF PAST 3 YEARS Appendix-XXI 1239

35 FORMAT FOR CONSORTIUM AGREEMENT Appendix-XXII 1240-1243

AREA GRADING AND ENABLING WORKS FOR 5TH STREAM

37 INSPECTION TEST PLAN Annexure-III 1244-1268

38 tkIS OHS & E MANUAL AND CONSTRUCTION MANUAL Annexure-VII 1269-1407

39 TENDER DRAWINGS 1408-1418

G STANDARD DRAWING FOR HAND RAIL PIN-LEP-CVC-1023 Rev.00

H STANDARD DRAWING FOR FENCING DETAILS PIN-LEP-CVC-1029 Rev.00

CONCEPTUAL PLAN OF CONSTRUCTION WATER & DRINKNIG WATER 6695-LAY-G00-LD-

40 GENERAL CONDITIONS OF CONTRACT “GCC” 1419-1516

AREA GRADING AND ENABLING WORKS FOR 5TH STREAM

TENDER FOR AREA GRADING AND ENABLING

2. TENDER DOCUMENT NO. 6695-CMG-G00-CA-0011

Within 12 (Twelve) months from the date of issue of

4. MODE OF TENDERING Open e-Tender ( Single Stage Two Part Bid)

5. NUMBER OF AGENCY REQUIRED 01

Rs.1,32,00,000 ( Rupees one crore thirty two lakhs only) –

7. VALIDITY OF BG SUBMITTED AGAINST EMD 6 Months after validity of offer

8. PERIOD OF DOWNLOAD From 21/09/2018 to 12/11/2018

TENDER SUBMISSION AT CPP PORTAL DATE &