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03 Specifications - 01 05 2014 Final
03 Specifications - 01 05 2014 Final
MANUAL OF
SPECIFICATIONS
AND
STANDARDS FOR
EPC CONTRACT 2014
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
GOVERNMENT OF INDIA
R A I L B H A V A N , R A I S I N A R O A D ,0 N E W D E L H I – 1 1 0 0 0 1 ( I N D I A )
Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
INDEX
Item
Item Page No.
No.
1 General 2
2 Standards 6
3 Geotechnical Investigation 17
4 Earthworks 17
5 Road Works 19
8 Piling Work 19
9 Concrete Works 20
10 Pre-stressing 21
14 Miscellaneous Works 27
15 Well Foundation 29
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
1. General
1.1 This Manual is applicable for Planning, Design & Construction of Rail
System (“the Project”) through EPC mode. The scope of the work shall
be as defined in the Agreement. This Manual shall be read harmoniously
with the intent of the Agreement.
1.2 The Project and the project facilities shall conform to the requirements
of design and specifications set out in this Manual, which are the
minimum prescribed. The project report and other information
provided by the Authority shall be used by the Contractor only for its
own reference and for carrying out further investigations. The
Contractor shall be solely responsible for undertaking all the necessary
surveys, investigations and detailed designs in accordance with good
industry practice and due diligence, and shall have no claim against
the Authority for any loss, damage, risk, costs, liabilities or
obligations arising out of or in relation to the project report and other
information provided by the Authority.
1.4 The codes, standards and specifications applicable for design of the
components of the Rail System are listed in Clause 2.
1.5 The latest version of the codes, standards and specifications, which have
been published before the last date of bid submission shall be
considered applicable.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
1.8 All items of building works shall conform to the standards specified in
the National Building Code (NBC) and the relevant codes issued by
BIS. For this purpose, building works shall be deemed to include
station buildings, Depot and workshop, OCC, buildings comprising
Project Facilities, traffic integration works, landscape elements and/or
any other works incidental to the building works.
1.10 The design of a rail system shall be fully integrated and compatible
with all other sub-systems that constitute the Rail System so that the
overall requirements of the Rail System are met. As far as possible,
uniformity of design standards shall be maintained throughout the rail
system.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
(c) Durability
The Project shall not only be safe but also durable. This would mean that
the deteriorating effects of climate and environment (for example
wetting and drying, freezing and thawing, if applicable,
temperature differences, aggressive environment leading to
corrosion, etc) in addition to the traffic shall be duly considered in
design and construction to make the Project durable.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
1.14.2 Before taking up any construction work, the Contractor shall prepare
a Traffic Management Plan for each work zone and furnish it to the
Authority’s Engineer for comments duly incorporating the following:
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
1.15 The Contractor shall set up field laboratory for testing of materials and
finished products as stipulated in QAM. It shall make necessary
arrangements for additional/ conformity testing of any
materials/products at the government accredited laboratory, for which
facilities at site laboratory is not available.
1.17 Utilities
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
2 Standards
2.1 Introduction
The Materials and workmanship specification given herein under is
based on Indian Railway Rules, Standard Codes, Manuals and
Specifications, Indian Standards and International Standards as
scheduled below. Apart from the basic data, specifications etc. all items
of works shall be governed by the Codes & Specifications as detailed
hereunder and as revised / corrected / amended up to the due date of
submission of the Bid Proposal.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
Note:- In case of road related structures, IRC Codal provisions will prevail
over IRS Codal provisions.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
(Second Revision).
17. IS: 887 Animal tallow.
18. IS: 975 (all 5 parts) – Design loads (other than earthquakes) for
buildings and structures.
19. IS: 1024-1999 Use of Welding in Bridges and Structures subject to
Dynamic Loading – code of Practice – Second Revision (Reaffirmed
1998).
20. IS: 1024 Welding in bridges and structures subject to dynamic
loading.
21. IS: 1030 Grade 280-520W- Cast Steel.
22. IS: 1080-1985 Code of practice for design and construction of
shallow foundations in soils (other than raft, ring and shell).
23. IS: 1199 Indian Standard Specifications for Method of Sampling
and analysis of concrete.
24. IS: 1200 (all relevant parts) – Method of measurement of building
and civil Engineering works.
25. IS: 1261 – 1959 – Seam Welding in Mild Steel (Reaffirmed 1998)
26. IS: 1270 Metric steel tape measure.
27. IS: 1323 – 1982-Oxy-acctylene Welding for Structural Work in
Mild Steel (Second Revision).
28. IS: 1343 Prestressed concrete.
29. IS: 1493 Design of Bored and Cast in Situ Piles Founded in Rock.-
Guide lines.
30. IS: 1725-1982 Specification for soil based blocks used in general
building construction
31. IS: 1786-1985-High Strength Deformed Steel Bars & Wires for
Concrete Reinforcement (Third Revision).
32. IS: 1791 Batch type concrete mixers.
33. IS: 1893-2002 Criteria for Earthquake Resistance Design of
Structures.
34. IS: 1904-1986 Code of practice for design and construction of
foundations in soils: General Requirements.
35. IS: 1915 Steel bridge code.
36. IS: 2074 Ready mixed paint, air drying, red oxide-zinc chrome.
37. IS: 2339 Aluminum paints for general purposes, in dual container.
38. IS: 2386 (all 8 parts) – Tests for aggregates for concrete
39. IS: 2502 Code of practice for bending and fixing of Bars for
concrete reinforcement.
40. IS: 2722 Indian Standard Specifications for Portable Swing Weight
batches for concrete (Single and Double Bucket type).
41. IS: 2751 Code of Practice for Welding of Mild Steel Bars used for
reinforced concrete construction.
42. IS: 2809-1972 Glossary of Terms and Symbols Relating to Soil
Engineering.
43. IS: 2911 (Part I to IV) - Code of practice for design and
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
(1) IS: 694 PVC insulated Electric cable working voltage up to and
including 11000 volts
(2) IS: 732 Codes of Practice for Electrical Wiring Installations
(3) IS: 1255 Code of Practice for Installation and Maintenance of
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
2.2.7 BS Codes
(1) BS – 3784 Grade “A” Specifications for Polytetra fluroethylene
(2) BS-5350: Standard Method of test of adhesives, Part C9, Floating
roller peel test.
(3) BS-5400: Part – 1 General Statement.
(4) BS-5400: Part – 2 Specifications for loads.
(5) BS-5400: Part – 3 Code of Practice for Steel Bridges.
(6) BS-5400: Part – 5 Code of Practice for composite Bridges.
(7) BS-5400: Part- 9 Bridge Bearings.
(8) BS-5400: Part-10 Code of Practice for Fatigue.
(9) BS-1449, 3484, 1134, 5296.
(10) BS-5400: Part 6 Steel, Concrete and Composite Bridges-
Specifications for Materials and Workmanship-Steel (In case of
Steel Bridges)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
NOTE:
(i) Contractor will procure and keep one copy of these reference codes
and manuals at site office for reference and guidance.
3 Geotechnical Investigation
4 Earthworks
4.1 General
This section deals with the Selection of Materials for Earthwork,
Execution of Earthwork in excavation and formation, Quality Control
of the Earth work, Maintenance of Records and Quality Assurance. In
principle the earth work shall be carried out as per the provisions
of Specifications for Design of Formation No. RDSO / 2007 / GE: 0014
– November 2009 and Earthwork in Railway Projects, GE: G-1 – July
2003 issued by RDSO/ Lucknow except for specific provisions made
herein in these Specifications.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
(ii) Second Step Plate Load Test: This test should be done for
EV2 measurement at top of each formation layers e.g. at sub-
soil, compacted sub-grade, prepared sub-grade, blanket etc.
at the frequency of one test per km length of the section as
per procedure detailed in DIN 18134-2001.
5 Road Works
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
8 Piling Work
8.1 Description
8.1.1 The method of installing the piles, including details of the equipment
shall be submitted by the Contractor and got reviewed from the
Engineer.
8.1.2 The work shall be done as per IS:2911 except as modified herein.
8.2 Materials
9.1 General
This section refers to the construction of concrete structures including
concrete mix design, trial mix, testing and workmanship for concreting.
Prior to the start of construction, the Contractor shall design the mix as
per IS 10262 and submit to the Authority’s Engineer for review, the
proportions of materials, including admixtures to be used. Water-
reducing admixtures (including plasticisers or super-plasticisers) may
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
9.2 Materials
All the materials shall confirm to the relevant IS codes.
All the materials for steel reinforcement shall confirm to the relevant IS
codes.
10 Pre-stressing
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
10.1 Prestressing concrete shall be carried out as per IS 1343 and IS14268.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
(y) All the kitchens / pantry rooms shall be provided with kitchen
shelves with top, fixed type storage cupboards and exhaust fans.
(aa) Kitchen sinks in residential buildings / pantry rooms shall be of
stainless steel with drain board and size not less than
460x915mm with bowl depth 178mm.
(bb) Storage Geysers (wherever required) shall be of capacity not less
than 15 liters.
(cc) Ceiling fans shall be of size not less than 1200mm.
(dd) Fire detection & alarm system including fire points shall be
provided as per requirement.
(ee) All the individual residential quarters shall be provided with:
i) Independent overhead water storage tank of capacity as
indicated in the requirement. Overhead water storage tanks
shall be kept at the roof top.
ii) Water supply lines directly from the source as well as from
overhead water storage tank.
(ff) Any other requirements as considered necessary by the Engineer
from safety and operational considerations.
(gg) The work shall be carried out as per CPWD Specifications – 2009
as published by Director General of Works, Central Public Works
Department, Government of India.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
All the land along the track and at Stations shall be provided with pre-
cast RCC Land Boundary pillars. Land Boundary pillars shall be
engraved with the letters as advised by the Authority’s Engineer. The
Land Boundary pillars shall be fixed as per the drawings in such a way
that 750mm of the total pillar height shall be exposed above the existing
ground level. The exposed portion of the pillars shall also be duly
painted.
13 Track Works:
(1) Rails complying Indian Railway Specification for flat bottom rails
i.e. IRS-T-12-2009 shall be used.
The rails in the Main Line tracks shall be Continuous Welded Rails
(CWR) laid on mono- block pre-stressed concrete sleepers at
nominal 600mm spacing (1660/km).
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
13.3 Turnouts:
(2) The design shall be compatible with 1:12 and 1:8.5 turnouts
which incorporate curved thick web switches. The turnouts shall
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
(3) Speed potential of the turnouts shall not be less than the values
as per the design of currently available turnouts (laid on PSC
sleepers) on the Broad Gauge of Indian Railways. These are as
follows:
Fastenings for the turnouts shall be elastic type and compatible with
the main line rail to sleeper fastening system.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
13.4.1 Planning for Construction, Methods and Procedures for Track Work:
14 Miscellaneous Works:
14.1.1 Scope:
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
The work shall consist of covering the slopes of banks with stone,
boulders, cement concrete blocks over a layer of granular material called
filter. Pitching shall be done as per specifications “Indian Railways
Unified Standard Specifications (works and materials) Vol. I and II.
This work shall consist of laying boulders on the bed of rivers for
protection against scour. The stones used in Apron shall be sound,
hard, durable and fairly regular in shape. Stone subject to marked
deterioration by water or weather shall not be used. The size of stone
should conform to clause 5.3.7.2 of IRC: 89. The size of stone shall be as
large as possible. In no case any fragment shall weigh not less than 40
Kg.
The Gabion wall shall be designed with the given specification using
proven system design certified with ISO 9001/2 or equivalent as
reviewed by the Engineer. The designer may adopt system design for
Gabion wall following any proprietary patented technique.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
The diversion work shall be carried out by the Contractor as per the
standard specifications of the concerned public utility company.
The Contractor shall provide precast RCC safety wall of height not less
than 1800mm above ground level and as per the design and drawings
prepared by the Contractor and reviewed by the Engineer. The wall
shall be provided on one side or on both sides of the IR tracks at the
identified locations to isolate from circulating areas of IR / habitation
area for safety considerations.
The pre-cast RCC panels of the safety wall shall be fixed in the grooves of
the pre-cast RCC posts in such a way that the top of the wall shall be at
the same level irrespective of the existing ground profile and there is
always a gap of 150mm above the existing ground level for drainage
purpose.
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
15 Well Foundation:
16.1 General:
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
16.3 Materials:
All the materials for Structural Steel Works shall confirm to the
specifications as specified in Chapter 2. Special requirements are given
below:
All anchor bolts shall be of property class of 8.8 and nuts shall
conform to IS: 1363 (1992), IS: 1364 (1992) and IS: 1367, as
applicable, and unless specified otherwise, shall be hexagonal. All
nuts shall conform to property class compatible with the property
class of the bolt used.
(3) Washers:
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Manual of Standards and Specifications for Indian Railway EPC Contract for New lines / Doubling (2014)
The stud shear connectors shall be high tensile steel and the testing
procedure shall be as per BS: 5400-6-1999. The headed studs for
shear connection shall have minimum properties:
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